ALUMINA BASED REFRACTORY BRICKS

(Brief Overview of Raw Materials)

 Types of Alumina Refractories

TYPE RANGE OF ALUMINA %

Fire clay-based bricks 30 – 45
Dense bricks 40 – 60
Sillimanite based bricks 50 – 65
Mullite based bricks 70 – 75
Bauxite based bricks 50 – 80
Corundum based bricks 85 – 99
 Major Raw Materials
o Fire Clay:
Grog (High purity calcined clay)

o Sillimanite Based:
 Andalusite
 Sillimanite
 Kyanite

o Mullite Based:
 Sintered Mullite
 Fused Mullite

o Bauxite based
 Calcined Bauxite

o Corundum Based:
 Fused Alumina – WFA, BFA
 Tabular Alumina - WTA
PHYSIOCHEMICAL PROPERTIES OF SILLIMANITE GROUP OF RM

Chemical Properties Physical

Properties
Raw Material
Al2O3 SiO2 Fe2O3 Na2O + K2O TiO2 A.P (%) B.D
(g/cc)

Sillimanite 58.56 38.24 0.83 0.29 0.87 - -

Kyanite 53.85 41.9 1.00 1.7 0.85 - -

Andalusite 58.1 39.04 0.84 0.57 0.25 0.57 3.14

 PHYSIOCHEMICAL PROPERTIES OF MULLITE BASED RM

Chemical Properties Physical

Properties

Raw Material
Al2O3 SiO2 Fe2O3 Na2O + K2O TiO2 A.P (%) B.D
(g/cc)

Sintered 57.9 39.26 1.50 0.35 - 7.33 2.69

Mullite

Fused Mullite 74.5 23.80 0.45 0.30 - 1.48 3.05

PHYSIOCHEMICAL PROPERTIES OF BAUXITE BASED RM

Chemical Properties Physical Properties

(Typical Values)
Raw Material
Al2O3 SiO2 Fe2O3 CaO TiO2 A.P (%) B.D
(g/cc)

Grade – 1 90 6 1.8 0.6 3.5 6 3.20

Grade – 2 85 6 2.8 1.8 4 8 3.15

Grade – 3 80 12 2 1.8 5 10 3.05

Grade – 4 80 6 4 1.8 7 12 3.05

PHYSIOCHEMICAL PROPERTIES OF CORUNDUM BASED RM

Chemical Properties Physical

Properties

Raw Material
Al2O3 SiO2 Fe2O3 Na2O + K2O TiO2 A.P (%) B.D
(g/cc)

WFA 99.0 0.1 0.20 0.40 - 7.78 3.62

BFA 94.5 0.9 0.42 0.17 2.8 1.22 3.9

WTA 99.5 0.04 0.10 0.30 - 2.07 3.548

 Principal Raw Materials used for Fireclay & HA Products
Sillimanite Bauxite
Fireclay 40-60% Mullite Corundum
Raw Materials Products (50 - Based
Products Products Products Based
65%) Products
Sillimanite √ √ √

High Purity Ball Clay √ √ √ √ √

Andalusite √ √ √ √

40-60% Grog √ √ √

60 – 80% Grog √

80 % Bauxite √

85 % Bauxite √

89 – 90 % Bauxite √ √

WTA √ √

WFA √

BFA √ √ √

Calcined Alumina √ √ √

Fused Mullite √

Synthetic Mullite √ √

* This table shows the variety of raw materials that can used in the said category. It doesn’t necessarily mean that all
are to be used together. Selection of raw materials is strictly based on the quality of the bricks and area of application.
 PRODUCT KEY PROPERTIES AND APPLICATION

Categories Key Properties Application Area

30 – 45% fire clay-based bricks • Moderate gas permeability Back up lining, Steel ladle, Blast
•Excellent CO resistance furnace stack area
•Volume stability at high temp

50 – 65% Sillimanite based
Bricks
• High Spalling resistance Anode Baking Furnace, Glass Tank
• High RUL Furnace, BF hot blast stove, BF
• High Creep Resistance checkers
• Cost effective compared to fused alumina-based bricks
• High volume stability

50 – 80% Bauxite Based Bricks • Good refractoriness Roof of electric arc furnace, Cement
• High Spalling resistance rotary Kiln, Transfer Ladle
• High abrasion resistance
• High STrength
 PRODUCT KEY PROPERTIES AND APPLICATION (CONT.)
Categories Key Properties
70 – 75% mullite based bricks • Low Iron and TiO2 content
• High RUL
• Excellent creep resistance
85% - 99% Corundum • High thermo mechanical strength
Bricks • Good alkali and resistance
• Resistance towards molten aluminum attack
•Excellent abrasion resistance
•Excellent wear resistance
• Super dense quality
Application Area
Glass tank regenerator, BF stove,
Carbon black reactors
Aluminum Melting holding
furnace, Reheating furnace bottom,
Carbon black reactor,
Petrochemical and fertilizer
application, Secondary steel
making vessel
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