REFRACTORY BRICKS

Presented By :
NUTHAN M

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 FLOW OF PRESENTATION

 Introduction
 Classification
 Properties
 Manufacturing process
 Other special refractory bricks
 Applications

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 INTRODUCTION

The word refractory implies resistant to

melting or fusion. Refractory refers to those
materials which are used to withstand the effect
of thermal, chemical and physical effects that
are not met within furnace procedures.
Whenever very high temperature are
involved, the refractories provide the linings,
supports and other filaments.

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  Refractory Brick -

A refractory brick or fire brick is a block of

refractory ceramic material used in lining
furnaces, kilns, fire boxes and fire places.
Thus refractories are those materials which
are used for the construction of furnaces, kilns,
ovens, crucibles and retorts etc on account of
their resistance to heat , when they are
subjected to the action of flue gases, sudden
changes in temperature and to influence of
slags.
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 FIRE CLAY BRICKS -

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 DIFFERENT SHAPES OF FIRE CLAY BRICKS -

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 CLASSIFICATION OF REFRACTORIES

1. CHEMICAL CLASSIFICATION:

 Acidic Refractories

 Basic Refractories

 Neutral Refractories

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  ACIDIC REFRACTORIES -
 CEMENT SAND BRICKS-

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  BASIC REFRACTORIES -
 MAGNESITE BRICKS -

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  NEUTRAL REFRACTORIES -
 SILICON CARBIDE BRICKS -

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 GRAPHITE BRICKS -

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 2. CLASSIFICATION BASED ON REFRACTORINESS:

Specially fire clay bricks are also classified

according to their alumina content and
refractoriness. It should be noted that
refractories include all materials of PYROMETRIC
CONE EQUIVALENT (PCE) greater than cone-26.

 NOTE :- PCE is a measure of refractoriness

of raw ceramic materials, mixtures or products.
It is usually calculated by comparisons with
mixture of known properties, i.e, pyrometric
cones, which are heat work recorders.

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  On the basis of refractoriness -

No PCE No. Classes of Refractories

1. Cones of PCE 26-28 Moderate heat duty

2. Cones of PCE 28-31 Intermediate heat duty

3. Cones of PCE 31-33 High duty

4. Cones of PCE 33-34 Super duty

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3. CLASSIFICATION BASED ON RESISTANCE TO
TEMPERATURE

 Low quality refractory materials :-

These are used in the manufacture of bricks,
as lining material for furnaces etc. Melting point of
such materials is more than 1580 C.

 High quality refractory materials :-

These are stable even at high temperature.
These materials are composed of either pure clay
or metals or combination of clay and metals.

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 PROPERTIES OF ACIDIC REFRACTORY MATERIALS

No NAME PROPERTIES

Its important
1. Fire- Clay constituents are
alumina and silica.
It is a
2. Quartzite metamorphic stone.
It is hard, crystalline
and compact.
It is available in
3. Silica the form of sand with
some impurities from
river bed.
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 PROPERTIES OF BASIC REFRACTORY MATERIALS

No NAME PROPERTIES

It is a
1. Dolomite carbonate of lime
and magnesium.

It is available
2. Magnesia in crystalline form.

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 PROPERTIES OF NEUTRAL REFRACTORY MATERIALS

No NAME PROPERTIES

It is an amorphous
1. Bauxite substance with dry
white, brown or reddish-
brown colour.
It is available in 3
2. Carbon forms- amorphous
carbon, graphite and
diamond.
It is the oxide of iron
3. Chromite and chromium.

It does not spall

4. Forsterite easily and maintains its
volume at high
temperature.
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  OTHER PROPERTIES

 Fusion Point
 Chemical Properties
 Porosity
 Spalling
 Strength
 Resistance to sudden changes in temperature

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  MANUFACTURING PROCESS
1. Crushing
2. Grinding
3. Screening
4. Mineral Dressing
5. Storage
6. Mixing
7. Moulding
8. Drying
9. Burning or Firing

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  SPECIAL REFRACTORY BRICKS:

 FIRE CLAY BRICKS –

Fire clays are the most widely used

refractory materials since they are suitable for a
variety of applications. Fire clay form acidic
refractories and may be of three different types.
These are flint or hard clay, plastic soft clays and
clays of intermediate character between hard
clay and soft clay.

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 HIGH ALUMINA OR BAUXITE BRICKS -

These are made from clay rich in bauxite and

diaspore and usually embrace those which contain more
than 45% alumina. Alumina content increases
refractoriness. These are practically inert to carbon-
monoxide and are not disintegrated by natural gas
atmosphere upto 1000 C.

 USES - It is used in very high temperature or where

resistance to basic slag is required. These are employed
in cement industries, paper mill factories and in the
lining of glass furnaces.

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 HIGH ALUMINA BRICKS -

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  SILICA BRICKS -

These contain about 95-96% SiO2 and about 2%

of lime is added during grinding to furnish the bond.
They do not contain clay but physical strength when
heated is much higher than those made of clay.

 USES – Open hearth furnaces have silica bricks in their

main arch side walls. It can be used where no shrinkage
in refractory and high resistance to heat is required,
because silica bricks have a tendency to expand on
heating.

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 SILICA BRICKS -

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  FORSTERITE BRICKS -

It is used as a base for high temperature

refractories. Here, dead burned magnesite is usually
added to convert some accessory minerals also to
forsterite, which is the most stable silicate at higher
temperatures. These have high melting point and
unsurpassed volume stability at higher temperatures and
no calcination is necessary in preparation.

 USES - It is used in glass tank super-structures, open

hearth end walls and copper refining furnaces.

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 FOSTERITE BRICKS -

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  DOLOMITE BRICKS -

These are made by mixing calcined dolomite

mixture in equimolecular proportions with silica as
binding material. Other binding materials used for the
purpose are tar, magnesium silicate, basic slags, quick
lime, iron ore or iron oxide, clays etc.

 USES - It is used for basic electric furnace linings,

Bessemer converters, open hearth furnaces, ladle linings
etc.

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 DOLOMITE BRICKS -

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  CHROMITE BRICKS -

Chromite is a neutral refractory and hence

very valuable as a contact material for basic
materials.

 USES - These are used in steel furnaces,

copper works and lead furnaces. It is also used
in making hearths of industrial reheating
furnaces, inner lining of acid converters used in
the extraction of Cu from low grade ores and in
the bottom of soaking pits.

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  APPLICATIONS OF REFRACTORY
MATERIALS:

 It is used for the manufacture of fire-bricks,

crucibles, lining material for furnaces, hollow
tiles, etc.

 It is used in high pressure oil stills and in

generator checkers of blast furnaces.

 It is used in glass tank super-structures,

open hearth end walls and copper refining
furnaces.

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  CONCLUSION -
A refractory brick is primarily built to
withstand high heat. It usually has low thermal
conductivity and hence saves energy.
A refractory brick will not spall under rapid
temperature changes and hence will be more
stronger. Either dense or porous firebricks can
be used depending upon the situation. These
bricks have been in use, in industries, where
high temperature has to be encountered.

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