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The process of shaping clay into a body or product of a certain size, shape, and strength with the help of external forces and models is called shaping. There are many methods for forming refractory materials, which are generally divided into three types according to the moisture content of the billet. Semi-dry method: the moisture content of the blank is about 5% Plastic method: the moisture content of the blank is about 15% Grouting method: The moisture content of the steel billet is about 40% In addition, there are vibration molding, 500~1500℃ hot pressing, and isostatic pressing molding. 1. Grouting method The grouting molding method injects a slurry with a moisture content of about 40% into a water-absorbing model (usually a gypsum type). The plaster mold absorbs the slurry moisture and forms a mud film on the surface. When the mud film reaches a certain thickness requirement over time, pour out the excess mud and leave it for some time. When the green body reaches a certain strength, it is demoulded, dried, damaged, and then sent to the next process. This method is mainly used to produce thin-walled hollow high-end products and special products, such as thermowell, high-temperature furnace tubes,...
At present, clay products in my country generally use semi-dry pressing. Therefore, the moisture content of the billet is low. If the kiln has a drying section, it can be fired directly into the kiln without pre-drying. Drying medium inlet temperature: 150~200℃ (standard bricks and ordinary bricks), 120~160℃ (special-shaped bricks) Exhaust temperature: 70~80℃ The residual moisture of the brick is less than 2% Drying time: 16~24 hours It should be pointed out that although the moisture content of semi-dry pressed bricks is low, for special types of large hand-made plastic-shaped bricks, due to difficulty in drainage, to prevent cracking due to excessive drying, the bricks should generally be dried in the air first. After drying for about a week, it is sent to the dryer or directly into the kiln to fire single bricks according to the complexity of the shape. During the firing process of clay products, under high temperatures and a suitable atmosphere, the brick body undergoes a series of physical and chemical changes. The heating characteristics of clay directly affect the determination of the firing system of clay products. Physical and chemical reactions occur when the bonded clay is heated, which promotes the destruction and sintering of...
The process of producing semi-silica bricks by Xinhongji Refractory can be divided into two types: fired and unfired. Unfired bricks are mainly made of sodium silicate as a binder. The production processes of fired bricks and clay products are roughly the same, but they also have their characteristics, mainly reflected in the following points. 1. Whether to add clinker is determined based on the raw materials’ characteristics and the product’s usage requirements. Siliceous clay has a small sintering shrinkage and no clinker is used. To improve the thermal shock resistance of semi-silica bricks, 10 to 20% clinker should be added. 2. If there are few fusible materials in the raw material and the quartz particles are coarse, the semi-silica brick will have low density and poor strength, but it will have good thermal shock performance and high load softening temperature; otherwise, the product will have poor fire resistance and thermal shock resistance. Therefore, the addition of quartz sand or siliceous clinker should be determined according to the use conditions of the product. Determine whether to add granular material or fine particle material. 3. When the temperature is lower than 1250°C, the volume shrinkage of semi-silica bricks is not obvious, and...
Under the premise of continuous improvement of production technology, today, refractory bricks with a good reputation and good quality are becoming more and more perfect in terms of variety and characteristics. Through a more comprehensive inspection and combined with the introduction during use, Xinhongji Refractory, which specializes in the production of refractory bricks, believes that modern high-end refractory bricks have the following characteristics. 1. Stronger chemical stability Cheap and environmentally friendly Xinhongji Refractory pays great attention to the chemical composition of refractory bricks during the production process, especially in optimizing the composition, and tries to start from the perspective of high-temperature resistance. Therefore, at present, the chemical stability of refractory bricks produced by Xinhongji Refractory has been qualitatively improved, and they can play a better role in more chemical production. 2. More resistant to external pressure Xinhongji Refractory found through relevant instrument testing that by optimizing production and constantly combining new processes to complete refractory bricks, their ability to resist external interference is also constantly improving, especially the compressive strength, flexural strength, linear change rate, and wear resistance. Better improvement, so that external influencing factors are continuously reduced. Refractory bricks with relatively stable quality have also given Xinhongji Refractory a...
Xinhongji Refractory describes two production methods of molten refractory materials: cast refractory products and sintered electric fusion products. Cast refractory products refer to products in which the batch of refractory materials is melted at high temperatures and then cast into a certain shape using the melting method. There are two methods of batch smelting, electrofusion and thermite. At present, the electrofusion method is the main method for producing cast refractory materials. Refractory product pouring process: raw material preparation → processing → batching → mixing processing → smelting → casting → heat treatment → mechanical processing. There are many types of fused-cast refractory products, among which fused-cast zirconium corundum bricks are the most widely used. Other foundry products include mullite bricks, zirconium mullite bricks, corundum bricks, quartz, magnesia, spinel and olivine. Compared with sintered products, fused-cast products have the following characteristics: in most cases, the products are dense, with fewer pores and high density; high mechanical strength (several times greater than sintered products); high-temperature structural strength; high thermal conductivity and good slag resistance. Al-Si-Zr melt-cast products are mainly used in the molten pool of glass melting furnaces, especially in the areas near the upper pool wall and feed inlet where corrosion...
This article introduces the characteristics of magnesia bricks and magnesia-silicate bricks, the alkaline refractory products of Henan refractory brick manufacturers. From the perspective of organic chemical properties, they are alkaline raw materials and have strong corrosion resistance to alkali residues. Therefore, this product is generally used in many basic steelmaking charges. Nonferrous metal plate smelting, industrial copper smelting, urban, lead smelting blast furnace, backlight furnace, and other products. With the development of the steel industry and the improvement of smelting standards, basic refractory insulation materials will gradually increase. Magnesia bricks are the most important product among alkaline refractory insulation materials. They have high flame retardancy and good resistance to iron oxide, alkali slag, and high calcium flux. Magnesia bricks are divided into calcined magnesia bricks and non-calcined magnesia bricks. The firing process of magnesia bricks is the same as that of other insulation bricks, but the firing temperature of magnesia bricks is higher than other bricks, generally 1550-1600℃, and the firing temperature of high-purity products is above 1750℃. The CaO content in magnesite is high, and sealing bricks are needed to eliminate the hazards of CaO and improve its formation characteristics. The processing technology of non-calcined magnesia bricks is similar...
Sintered high alumina bricks are the main member of the aluminosilicate refractory family. Aluminosilicate materials are divided into the following four categories based on their alumina content. 1. Semi-siliceous refractory material: alumina content 15% to 30%. 2. Clay refractory materials: alumina content 30% to 48%. 3. High-aluminum refractory materials: alumina content 48% to 89%. 4. Corundum refractory material: alumina content ≥90%. The physical and chemical properties of high-aluminum refractory materials generally depend on the ratio of Al2O3/SiO2, the content of impurities, the density of raw materials, the particle size distribution of bricks, the type and amount of binders, and the conditions of mixing, molding, and sintering. For special high alumina bricks, the type, grade, particle size, and content of special refractory raw materials determine the mineral composition, microstructure, and destruction mechanism of the refractory materials, affecting the physical and chemical properties and application effects of the refractory materials. Ordinary high alumina bricks have good high-temperature resistance, but poor thermal shock resistance. In the 1970s, the China Building Materials Research Institute developed phosphate-bonded high-alumina bricks (hereinafter referred to as phosphate bricks), which solved the problem of poor thermal shock resistance of high-alumina bricks. However, phosphate bricks have poor high-temperature resistance. In...
According to solid-state physics, refractory products can be regarded as solid materials that do not react with flux (or essentially do not react with flux). Therefore, high-temperature calcination is necessary in the production of refractory products. Even for the increasingly developed amorphous refractory materials and unfired products, although there is no sintering process during the production process, its use process can be regarded as a calcination process, that is to say, the sintering process is realized during use. Firing is the last process in the production of refractory products. A series of physical and chemical changes will occur during the sintering process. With these changes, the porosity decreases, the bulk density increases, and the undesirable body becomes a product with a certain size, shape, and structural strength. At the same time, through a series of physical and chemical changes during the sintering process, stable microstructure and mineral phases are formed to provide the required performance for products under different usage conditions. Xinhongji Refractory tells everyone that many factors affect sintering, mainly including the following aspects: 1. Liquid phase recrystallization: Under the action of high temperature, an appropriate amount of liquid phase is generated inside the product to promote the combustion...
High alumina bricks are of important strategic significance to the development of the steel industry. High-temperature industrial production is inseparable from high-temperature-resistant materials, and high-alumina bricks are also indispensable materials for the iron-making industry. Large-scale wear-resistant materials are often overlooked because they are known as auxiliary materials in the metallurgical industry. This is closely related to the development of the steel industry. Under certain conditions, the quality and type of human resistance materials can even play a key role in the advancement of new steel-making technologies. Therefore, to realize the modernization of the gold industry, we must pay attention to and vigorously develop high-alumina brick technology. High alumina bricks are the basic material of dry high-temperature technology and are closely related to the development of the steel industry. The development history of steel freezing and refining technology for more than a century proves that every major process change relies on the development of new varieties of high alumina bricks. Without high-quality and new varieties of high-alumina bricks, many new smelting technologies cannot be realized. The development of dolomite-high alumina bricks guarantees the success of alkaline air converters. The emergence of high-softening point silica bricks is an important factor in the...
Special refractory bricks among amorphous refractory materials are a mixture of aggregates, powders, binders, or other additives in a certain proportion, which can be used directly or mixed with appropriate liquids. In other words, the refractory material is a new type of refractory material that does not undergo calcination, and its refractory resistance is not less than 1580°C. There are many types of unshaped refractory materials, which can be divided into concrete, castables, plastics, ramming materials, gunning materials, projection materials, smear materials, dry ramming materials, and refractory clay materials according to their production methods and usage methods. Various furnace repair materials (asphalt and large surface repair materials, Martin sand, etc.) are also unshaped. Although there are many types of uncertain product names, their typical production methods mainly include the following three forms: 1. Concrete: Concrete technology appeared earlier and is a final product among undefined products. Some parts of the heating kiln, such as the soaking furnace, heating furnace roof and walls, front and rear mouth rings of the rotary kiln, lower material slope, discharge chamber wall, etc., are designed as large masonry (the heating furnace top block weighs 3-4 tons ) to make concrete. The specific production method is...
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