Refractorymaterials 150313053315 Conversion Gate01

Refractory Materials
What are Refractory

Materials
Refractories are inorganic non-

metallic material which can
withstand high temperature without
undergoing physico chemical
changes while remaining in contact
with molten slag, metal and gases.
They are exposed to environments
above 1,000 F (811K; 538C)".
Classification of Refractory Materials
Refractories can be classified on the

basis of:-
(I) Chemical composition(their
chemical behaviour, i.e. their
reaction to the type of slags.)
(II)The methods of manufacture
(III)Physical form(shaped and
unshaped Refractories)
Classification Based on Chemical
Composition
(I) Acid Refractories: Acid refractories are
those which are attacked by alkalis (basic
slags). These are used in areas where slag
and atmosphere are acidic. Examples of acid
refractories are: Silica (SiO2), Zirconia (ZrO2).
(II) Basic Refractories:- Basic refractories are
those which are attacked by acid slags but
stable to alkaline slags, dusts and fumes at
elevated temperatures. Since they do not
react with alkaline slags, these refractories
are of
considerable importance for furnace
linings where the environment is alkaline.
for e.g. Dolomite (CaO*MgO)
(III) Neutral Refractories: Neutral Refractories
are chemically stable to both acids and
bases and are used in areas where slag and
atmosphere are either acidic or basic. The
common examples of these materials are:
Carbon graphite, Chromites
(Cr2O3),Alumina. Out of these, graphite is
the least reactive and is extensively used in
metallurgical furnaces where the process of
oxidation can be controlled.
Classification Based on Physical
Form
Shaped Refractories: Shaped refractories are
those which have fixed shaped when delivered
to the user. These are what we call bricks. Brick
shapes maybe divided into two: standard
shapes and special shapes. Standards shapes
have dimension that are conformed to by most
refractory manufacturers and are generally
applicable to kilns and furnaces of the same
type. Special shapes are specifically made for
particular kilns and furnaces. This may not be
applicable to another furnaces or kiln of the
same type.
Shaped refractories are almost always
machine pressed, thus, high uniformity in
properties are expected. Special shapes
are most often hand-molded and are
expected to exhibit slight variations in
properties.
Unshaped Refractories: Unshaped
refractories are without definite form and
are only given shape upon application. It
forms joint less lining and are better known
as monolithic refractories. These are
categorized as Plastic refractories,
ramming mixes, gunning mixes.
TYPES OF REFRACTORIES
Refractories are classified as dense or insulating
types. The most high-temperature refractories,
such as firebricks, are high-density (>120 lb/ft3).
They offer excellent resistance in challenging
operating environments, such as slags with
different chemical compositions, fumes, dust,
and gases.
Insulating refractories have lower densities (4 to
70 lb/ft3) and provide insulating properties, while
offering resistance to corrosion and chemical
reactions with the operating environment.
Fire-clay brick Refractories
Fire-clay brick comprise about 75% of the
production of refractories on a volume basis
and are essentially hydrated aluminum
silicates with minor proportions of other
minerals. Typical composition consists of:-
(I) SiO2 <78% and
(II)Al2O3 < 44%.
They are extremely versatile; least costly
of all refractory bricks and are extensively
used in the iron and steel industry, non
ferrous metallurgy, glass industry, cement
industry etc.
These are further divide into 4
catagories
Brick %age %age Othe PCE F
SiO2 Al2O3 rs
Super Duty 49-53 40-44 5-7 3175-3200
High duty 50-80 35-40 5-9 3017-3175
Medium 60-70 26-36 5-9 2975-3075
Duty
Low duty 60-70
Characteristically,23-33
fire-clay 6-10begin
brick 2770-2900
to
soften far below their fusion temperature
and under load actual deformation takes
place. The amount of deformation depends
upon the load, and, once started, this
deformation is a slow but continuous
process unless either the load or the
High Alumina Refractories
Alumina refractory which consists of aluminum
oxide and traces of other materials is the most
mature of the engineering ceramics. Alumina is
one of the most chemically stable oxides
known, which offers excellent hardness,
strength and spalling resistance. It is insoluble
in water and super heated steam, and in most
inorganic acids and alkalis. Alumina refractories
carry the all purpose characteristics of fire-clay
brick into higher temperature ranges that
makes it suitable for lining furnace operating up
to 3350F. It has a high resistance in oxidizing
and reducing atmosphere and is extensively
used in heat processing industries.
Mullite refractory: Mullite brick is
about 72% alumina with 28% silica.
These have excellent volume stability
and strength at high temperatures.
Corundum refractories- The 99%
alumina class of refractories is called
corundum. These refractories
comprise single phase,
polycrystalline, and alpha-alumina.
High alumina bricks are most
commonly used in cement, lime and
ceramic kilns, glass tanks, crucibles
for melting a wide range of metals,
hearth & shaft of blast furnaces and
in lead drossing furnaces.
Silica Brick
Silica Brick is a refractory material
containing at least 93% SiO2. They have
one major drawback too. Their weakness
lies in their susceptibility to spalling at
temperatures below 1200F.
Magnesite
Magnesite refractories are chemically
basic materials, containing at least 85%
magnesium oxide. These are made from
naturally occurring magnesite (MgCO 3)
and Silica (SiO2).
Monolithic Refractories
Monolithic refractory, the name
generally given to all unshaped
refractory products, are materials
installed as some form of suspension
that ultimately harden to form a solid
mass.
Various means are employed in the
placement of monolithic refractories
like ramming casting, spraying, sand
slinging etc.
The main advantages of this are:
1) It eliminates joints which is an inherent
weakness
2) Method of application is faster and skilled
measures in large number are not required
3) Properties can be better than pressed bricks
4) Transportation and handling are simple
5) Offers considerable scope to reduce
inventory and eliminate special shapes
6) Has better spalling resistance and volume
stability
INSULATING
REFRACTORIES
To optimize the energy use and to
prevent its escape into the
ambience, special materials called
insulating refractories are necessary.
The function of insulating refractory
is to reduce the rate of heat flow
(heat loss) through the walls of
furnaces. Insulation is effected by
providing a layer of material having
low heat conductivity, which means
Characteristics of Good Insulating
Refractory
Low thermal conductivity
High degree of porosity(air holes)
The high porosity of the brick is
created during manufacturing by
adding a fine organic material to the
mix, such as sawdust. During firing,
the organic addition burns out,
creating internal pores. Other ways
to accomplish high porosity involves:
a) by using materials which expand and
open up on heating;
b) by using volatile compounds like
naphthalene;
c) By aeration
d) by using substances which by
themselves have open texture e.g.
insulating brick grog, vermiculite, ex-
foliated mica, raw diatomite etc;
e) by using foaming agents to slip;

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Refractory Materials

What are Refractory

Refractories are inorganic non-

Refractories can be classified on the

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