Insulation Refractory Bricks

Insulating refractory brick (IRB) is the term used for heat insulating bricks
and covers those heat insulating materials which are applied up to 1000 deg C.
IRBs are often mistakenly referred to as rear insulation materials. These bricks are
assigned to the group of lightweight refractory bricks and are manufactured on the
basis of naturally occurring lightweight raw materials.

IRB is a class of brick, which consists of highly porous fireclay or kaolin. IRBs are
lightweight, low in thermal conductivity, and yet sufficiently resistant to temperature
to be used successfully on the hot side of the furnace wall, thus permitting thin walls
of low thermal conductivity and low heat content. The low heat content is particularly
important in saving fuel and time on heating up, allows rapid changes in temperature
to be made, and permits rapid cooling. IRB is characterized by the presence of large
amount of porosity in it. The pores are mostly closed pores. The presence of porosity
decreases the thermal conductivity of the insulating bricks.

IRBs were developed in the 1930s, and they were the predominant form of
insulation until the development of insulating castable and fiber refractories. There
are two types of bricks namely (i) bricks based on clay and gypsum using the
burnout of sawdust to create high porosity (and thereby provide better insulating
value), and (ii) bricks based on lightweight aggregate and clays. Like all alumina-
silica brick, IRBs have a duty rating (service limit).

Over the years, IRBs have been made in a variety of ways, such as mixing of
organic matter with clay and later burning it out to form pores; or a bubble structure
incorporated in the clay-water mixture which is later preserved in the fired brick.

IRBs are characterized by the presence of large amount of porosity (45 % -90 %) in
it. The pores are mostly closed pores. These bricks due to a highly porous structure
exhibit low thermal conductivity values. The thermal conductivity not only depends
on the total porosity, but also on the size and shape of the pores as well as chemical
and mineralogical composition. The bricks also have low heat capacity. Due to the
presence of high porosity in these bricks, the bulk density and the strength of the
bricks are low. The application temperature of these bricks depends on the
constituents. For example, kyanite based insulation bricks can be used at a
temperature greater than 1250 deg C. Whereas fireclay based insulation refractories
are usually used at low temperatures.

IRBs are shaped light weight refractory products with a total porosity of greater than
45 % and an application temperature of 800 deg C minimum. ASTM C 155-70 and
DIN- EN-1094, part 2 define the temperatures at which shrinkage of the material
should not exceed 2 %. The maximum bulk density is also defined. Both norms
specify typical grades of IRBs. The classification of IRBs as per ASTM C155 and
DIN-EN-1094, part 2 is given in Tab 1.

Tab 1 Classification of shaped heat insulation refractory products

ASTM C155 DIN-EN-1094, part 2

Max.
Test Bulk
Group* Test temp.** bulk Group
temp.** density#
density

Deg F Deg C kg/cum Deg C kg/cum

16 (875) 1550 845 540 75 750 400

20 (1100) 1950 1070 640 80 800 500

23 (1260) 2250 1230 770 85 850 550

26 (1430) 2550 1400 870 90 900 600

28 (1540) 2750 150 960 95 950 650

30 (1650) 2950 1620 1090 100 1000 650

32 (1760) 3150 1730 1520 105 1050 650

33 (1820) 3250 1790 1520 110 1100 700

115 1150 700

120 1200 700

125 1250 750

130 1300 800

135 1350 850

140 1400 900

 150 1500 950

160 1600 1150

170 1700 1350

180 1800 1600

* abbreviated deg F, example 16 = 1600 deg F = 875 deg C

** test temperature at which no more than 2 % permanent linear change may occur after 24
hours.

# upper limit of median bulk density of group L. In each group of the L class the bulk density is a
property used only for differentiation and is indicated with two digits after the decimal point.

Important properties of insulation refractories are given in Fig 1.

 Fig 1 Important properties of insulation refractories

Different types of IRBs are mainly manufactured by using the raw materials such as
diatomite, perlite, expanded vermiculite, calcium silicate, fireclay, kaolin, quartz,
alumina and light weight refractory aggregates by conventional method. Different
types of pore formers such as sawdust, foam polystyrene, fine coke, binders and
organic foams or granular materials such as hollow microspheres and bubble
alumina are commonly used to obtain decreased density or to produce porous
bodies in the IRBs.

The raw material of diatomaceous earth products are microscopically small shells
derived from diatoms. The heat insulation results from the large number of small
pores within the shells of various shapes with sizes from 5 to 500 micro meters.
Diatomaceous bricks are produced by extrusion presses. Bonding clay, burning out
materials and fibres can be added. The fine pore structure of these bricks has a
better heat insulation than vermiculite products with the same bulk density.

Vermiculite is a 3-layer mineral which expands like an accordion when heated

quickly above 700 deg C. Through the pressure of the evaporating water in the
intermediate layer, the original volume enlarges by 20 to 30 times. This so-called
exfoliated vermiculite (density 60 to 200 kg/cum) serves as raw material for the
production of vermiculite bricks, boards and shaped parts. Concrete, water glass and
phosphates are used as binder .
Perlite is water containing volcanic rock, solidified to a glass shape. Water was
absorbed by the magma under high pressure during litho genesis and can evaporate
when heated quickly. Expanded perlite is formed with a settled density of 35-150
kg/cum. The production process of bricks, boards and shaped parts is almost the
same as that for vermiculite. The application limit of this product range is from 750
deg C to 1000 deg C due to intensive shrinkage at higher temperatures.

Rice husk/ sawdust straw or low cost biomaterial are used as combustibles or pore
former in manufacturing of insulation brick. However naphthalene, starch are also
used for pore former in high duty insulation brick. These combustibles either
evaporate or burnout during initial stage of firing and creates pores in the brick. The
size and shape of pore former controls the pore morphology in insulation brick.
Polystyrene foam each particle, which is dissipated during firing process and leaves
behind a cavity that can improve thermal insulation properties of the brick.
Polystyrene foam is, therefore, used as a pore forming material in the brick body .To
that correspondence should be addressed for reducing thermal conductivity.
Sawdust is combustible material, which produce channel and porosity at high
temperature.

Normally plastic clay based binders are used in manufacturing of insulation brick.
Other binders are ethyl cellulose, starch and molasses. Calcium oxide based binder
lime or sometime gypsum is used during manufacturing of insulation brick via casting
and setting process.

IRBs are produced predominantly in rectangular dimensions or arch shapes. End

arches and side arches for round shapes can be cut from the rectangular sizes and
adapted to the radius.

The maximum size of IRBs bricks is limited by the manufacturing process, because
uniform properties can only be realized up to certain sizes. Larger dimensions (e.g.
hanging blocks and roller bushings) are produced by gluing smaller sizes with high
temperature refractory mortars. In general, the strength of the bonding joint is higher
compared to the strength of the IRB itself. It is important to pay attention to the
usage instructions of the mortar adhesive, as mortars are sensitive to extreme
weather and climate conditions.
If the chemical structure is considered, IRBs are classified in aluminum silicate
lightweight refractory bricks, silica lightweight refractory bricks, zircon lightweight
refractory bricks and corundum lightweight bricks. The group of aluminum silicate
IRBs (fireclay and mullite bricks) is the most important and common group. Raw
materials based on Al2O3, SiO2 and in some cases CaO are used for the production
of these bricks. Raw materials such as clay, kaolin, fireclay, sillimanite, andalusite,
kyanite, mullite, alumina, alumina hydrate and corundum are used as alumina
carriers. In addition to the fine grained raw materials, coarse grained and porous raw
materials are also applied. These include lightweight fireclay and hollow spheres
(balls) consisting of corundum or mullite.

The thermal decomposition process is best known and most applied technique to
produce pores in the insulating firebricks. Fine saw dust, petroleum coke, lignite
abrasion, styropor balls, fine waste products of the cellulose and paperboard (carton)
industry are used as burning out materials. Decomposition materials with low ash
content are required in order to prevent negative effects on the hot properties (e.g.
alkalines). The so called foaming process is another further method for the
production of pores in insulating fire bricks. Special soaps, saponins and sulfonates
are used to produce stable foams. The slurry for the ceramic body is often made
separately from a foam emulsion. Foam and slurry are homogenized in an intensive
mixer. The required bulk density is adjusted by controlled mixing of foam and slurry.

In practice the gas impellent process is used less frequently. Gas producing
substances are mixed into the compound.

Lightweight refractory bricks which are produced by mixing in evaporating

substances (naphthalene) have distinctive differences in their properties compared
to other brick qualities. It is possible to produce bricks with low density and high
strength. Very fine pores guarantee low thermal conductivity values.

Shaping of the lightweight refractory bricks is done by casting, slinger method or

pressing. During casting, the perforated metal moulds (forms) are lined with filter
paper before being filled. Sulphite liquor, gypsum or concrete can be added to
improve the mixing of the raw material and to speed the setting.
The slinger method is very efficient due to the continuous shaping of large blocks.

Plastic, semi-dry and dry mixes are shaped with the corresponding presses
(extrusion presses, hydraulic presses or mechanical presses).

Bricks, unfinished cylindrical pieces or blocks are fired in chamber furnaces, bogie
hearth furnaces or tunnel kilns. The firing temperature corresponds approximately to
the classification temperature indicated by the producers. Cutting or grinding is
necessary for most brick qualities in order to obtain the standard shapes due to high
drying and firing shrinkage.

IRBs with complicated shapes are produced by hand forming, vibration or moulding
processes.

For long term exposures near the rated service temperature, shrinkage may occur
sufficiently to allow joint opening. For this reason, it can be important to use IRBs
with a higher duty rating than seems required by the process temperature alone.

IRBs are susceptible to alkali attack. The products made using gypsum and sawdust
burnout material (indicated by high CaO contents) may undergo an expansion
reaction in a service environment containing alkali. In some cases, this reaction has
been deleterious and reduces service life. By contrast, the IRB made with lightweight
aggregate may experience surface glazing in an alkali environment.

The uses of IRBs ranges from laboratory furnaces to foundry furnaces and large
tunnel kilns. The requirements on IRBs are diverse and in some cases even
contradictory. On the one hand, high thermal insulating capability and low bulk
density are the desirable properties of IRBs, on the other hand the bricks need to
have sufficient mechanical strength but also good machining. Additionally the
properties needed in these bricks are high thermal resistance under a multitude of
atmospheric conditions as well as resistance to temperature shocks and changes.

The operation time of the industrial furnace is a decisive criterion for the IRBs. For
furnaces operated on a continuous basis the mass of the constructed refractory
lining is less important concerning energy efficiency. The thermal conductivity (l) is
significant for efficient operation, therefore bricks with low l-values are
preferred. The basic rule is ‘The lower the bulk density, the lower the thermal
conductivity’. The bulk density needs to be adapted to the service temperature of the
kiln. The reason is the existence of a minimum thermal conductivity which is shifted
to higher bulk densities at higher operating temperatures.

The cold compressive strength is less important compared to the hot properties of
the brick. In general the mechanical loads are not high. The strength of insulating fire
bricks is fully sufficient. Approximately 0.5 N/sq mm is required as a minimum
strength. That value ensures safe transport, handling and installation work. Often a
compromise between strength, bulk density and thermal conductivity has to be
found.

Constructions with higher mechanical loads require bricks with higher cold crushing
strength. It is important that the higher cold compressive strength is not the result of
a higher fluxing agent content in the brick, otherwise the creep under compression
increases at high temperatures.

Thermal shock resistance is an important property for periodically operated furnaces.

Depending on the heating up and cooling down conditions of the furnace, it is

important to know the stress limits of the material. The material will crack, if
temperature differences between cold and hot side are higher than 130 to 250 deg
K. Such temperature differences are often exceeded repeatedly in wall linings. Each
temperature change affects the structure of the brick.

The critical heating up speed for lightweight fireclay bricks (depending on the shape)
is 5-10 deg K/min. according to the literature.

The different IRBs vary in their thermal shock behaviour due to their specific
composition and porosity. High cristobalite contents (more than 10 %) have a
negative effect on thermal shock resistance. In case of less than 10 % other criteria
are more essential.

Micro cracks in the structure are an advantage since they absorb stresses without
further crack development
IRBs remain a choice for construction and repair when castable or fiber products
may not be preferred. IRBs constitute the working lining of many furnace structures.
Construction is usually convenient since most IRBs can be cut with a hacksaw.
Caution should be used in selecting IRBs when abrasion resistance or impact
resistance is required.

Mortar joints and adhesive joints are the weak points in the brickwork. Due to high
porosity and therefore fast removal of water, there are the following two important
factors that are to be considered.

 The mortar must be ‘plastic’ and must have a high capability to bond water. If
not, the bricks cannot be laid precisely according to measures and the bond of
the individual bricks is lost when corrected later.
 The mortar should have low alkali content. The insulation firebricks are
infiltrated with the binder liquid resulting in a higher alkaline concentration in
the border areas. This causes lower melting points/increased sintering of the
material and increased creep at high temperatures. Also thermal shock
resistance is lowered by alkaline impurities. Hence mortars without water
glass are preferred for high temperature applications.