refractories definition & classification tina stendal svendsen product manager
Post on 09-Feb-2016
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RefractoriesDefinition & Classification
Tina Stendal SvendsenProduct Manager
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Definition of Refractory
“non-metallic ceramic material or product whose chemical and physical properties allow it to be
used in a high temperature environment”
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Application of Refractory
Lining of plants for thermal processing (melting, firing and heat-treatment furnaces) e.g.:
• Iron and steel• Cement and lime• Glass and ceramics• Chemical and petrochemical• Heat- and power (waste and biomass)
Heat-insulation Functional products: shaped products with an additional function during service
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Classification due to product type
Refractory
Monolithics
(unshaped)
Castables
Dense Insulating
Mortars
Heat-insulating
Bricks(shaped)
Functional products
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Classification due to bond typeand cement content
Dense castable
Hydraulicbond
Conventional
Traditional castables Gunning
‘high technology’
Low cement1.0-2,5%
CaO
Ultra low cement
< 1.0% CaO
No cement< 0.2% CaO
Chemicalbond
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Classification according to type of chemical composition
Focus on Alumina-Silicate refractory products based on:• Al2O3 (alumina) • SiO2 (sillica)
The variants of alumina-silica castables are formulated by:
• Different amounts of Al2O3 and SiO2 in raw materials
• Different crystal structures of raw materials
• Different properties of raw materials
• Grain size distribution and matrix products
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Composition of dense refractory castables
Aggregates (> 45 μm) 65-75%• Croase; build the foundation of the castable • Fine; fill the voids between the croase aggregates
Matrix products (< 45 μm) 25-35%• Fill the micron size voids, affects workability and strength• Binders; hold castable together until thermal sintering occurs• Additives; reduces water or control setting time
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Raw materials characterization
• Chamotte (calcined fireclay): 30-45% Al2O3 Alkali resistance
• Andalusite: 50-60% Al2O3 Shock resistance
• Bauxite: 80-90% Al2O3 Abrasion resistance
• Corrundum (alumina): 99% Al2O3 High refractoriness
• Syntetic mullite (calcined bauxitic clay): 60-80% Al2O3 Strength
• Silicon carbide: SiC High thermal conductivity
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High quality refractory raw materials:
Are subjected to Calcination (minerals fired at 1400-2000°C)• Reduces the amount of impurities• Low porosity• High density• Chemically stable• Increased refractoriness
Low iron (Fe2O3) content (minimize the risk of CO-attack)Low alkali content (minimize the formation of low-melting-temp. glasses)
Be aware of recycled materials!
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Summary• Refractory materials can be classified according to e.g. type, cement
content, application/installation technique and the main raw material• We will focus on Alumina-Silicate castables• Dense castables contains approx. 70% aggregates and 30% matrix
products• The variants of alumina-silicate castables are achieved by a diversity
of different raw materials with different properties• Both natural minerals and calcined minerals are used• Fractions (and optimal particle distribution) are obtained by crushing,
sieving and grinding/milling • High quality raw materials performs better!
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