SELECT THE PERFECT BINDER FOR SHAPED REFRACTORY BRICKS MANUFACTURING

Generally, refractories are classified as basic, high alumina/silica, fireclay and insulating. There are also classes of “special refractories” which include Silicon Carbide, Silicon Nitride, Graphite, Zircon, Zirconia, fused cast and several others. Most refractory materials are supplied as preformed shapes. However, they also are manufactured in the form of special purpose clays, bonding mortars and monolithic such as castable, plastic refractories, ramming mixes and gunning mixes. In fact, many  refractories materials have been developed specifically to meet the service conditions of a particular process. The characteristic properties of each refractory class are a function of both their raw material base and the methods used to manufacture the refractory products (rsrefractoryfirebrick.com).

Shaped Refractory manufacturing involves five processes: raw material processing, raw material mixing, forming, drying and firing. Another types of refractory processes also warrant discussion - the first is production of fused products and the second is ceramic fiber production.

For the shaped refractory, forming consists of mixing the raw materials and forming them into the desired shapes. The forming process is a big challenge for shape refractories producer because refractory raw materials are almost non plastic materials and  they are not bonded with each other at low temperature even if this process frequently occurs under wet or moist conditions. Therefore  most  refractory producers have to press with very high pressing pressure, control the packing curve of all raw material to obtain the  highest density and have to use binder in their forming process to avoid breakage and chipping before achieving the  ceramic bond after firing.

There are many kinds of binders for shaped refractory to improve compressive strength for pressing, handling and drying processes to avoid breakage and chipping such as Phenolic Resin, Polyvinyl Alcohol (PVA), Dextrin, Starch, Lignosulfonate, Molasses, Carboxyl Methyl Cellulose (CMC) etc. So, binder selection  can be very challenging and producers have to consider  many parameters to ensure  what kind of binder is suitable for their product and process.

Some of the parameters to consider are as below:

1. Rsrefractoryfirebrick.com/refractory-brick-for-sale
2. Type of refractory
3. Mixing technology
4. Pressing process
5. Size and shape of brick
6. Drying process
7. Handling process
8. Firing process

The best binder must have several characteristics:

1. It must be easy to add and mix with a refractory aggregate
2. It does not react with refractory mixes at low and high temperature
3. It must leave a minimal amount of residue after firing
4. It must easily burn out at during the firing process
5. It does not affect the  Bulk Density and Apparent Porosity after pressing, drying and firing
6. It must improve the mechanical strength of green and dry bricks
7. It must improve flow ability of mixes during pressing to get consistent density in whole bricks
8. It does not affect the permanent linear change of bricks
9. It does not cause the mixes to stick to the moulds
10. It cannot be toxic and cause of air pollution
11. It does not affect the refractoriness of the bricks
12. It must be as inexpensive as possible
13. There are no all-in-one binders. The selection of a suitable binder is key to increase a production yield and saving operation cost for refractory producers.

Rongsheng refractory binders offer a unique range of solutions for process and quality improvement. We have developed additives specific  to the manufacturing of hydraulic pressed bricks, plastic shaped bricks and other unshaped refractory products. Our natural products have a neutral CO2 footprint, are environmentally friendly and non-hazardous.

Possible benefits during Process:

1. Improved workability and handling of refractory mixes
2. Reduction of pressing friction for dry pressed bricks
3. Improved mechanical strength of green and dry bricks
4. Increased plasticity for extruded bricks
5. Lubrication during forming process
6. Energy saving
7. Reduced losses during handling and drying process
8. Process and quality improvement
9. Lastly,  it is very important to have the opinion of experts in the field and test thoroughly the results obtained in order to select the best binder possible for your specific production process.

Article comes from: blog.biokeram.com/how-to-select-the-perfect-binder-for-shaped-refractory-bricks-manufacturing

Just What Are Alumina Bubble Bricks?

With the advancements in technology and science, new forms of hollow materials that were crafted from carbon, ceramic and glass are now used widely in different science industries. The refractory products that were constructed out of a hollow sphere represent better high-temperature resistance, high strength, great thermal-shock resistance, and outstanding insulation properties.

Since these material types have lower thermal capacities and a lower bulk density they can increase thermal efficiencies in the high-temperature furnaces, drastically lessen the overall weight of your furnace and also decrease production cycles. This product is used within the lining of the high-temperature furnaces.

The Alumina bubble bricks for sale from Rsrefractoryfirebrick.com are usable at the temperature of 1800℃ for long periods of time. At these higher temperatures they maintain good corrosion resistance and chemical stability. Also, they are able to remain stable in hydrogen atmospheres.

The Alumina raw materials will first be melted inside a power-arc furnace at the temperature of 2200℃. When the melted material is poured out they may be blown using high-pressure air that causes the melted substance to disperse into tiny droplets. During the cooling stages, these droplets form into hollow alumina balls brought on by negative effects of surface tension.

These hollow balls undergo a screening so that you can remove particles, big fragments and fine powder. Any iron will be removed utilizing a magnetic iron. Any broken balls may also be removed by using a “ball selecting” machine. These hollow alumina spheres are then packed in the form of a completed product.

RSrefractoryfirebrick.com/alumina-bubble-bricks are created using a mixture of 30% sintered Alumina powder, 70% Alumina hollow spheres that happen to be bonded using aluminium sulphate. The bricks are molded by using vibration molding inside wooden molds with the use of pressure. Once dried, the green-body is then either light burned or sintered using a high temperature into bricks.

Where to locate The Best Refractory Stone Company

When you plan to built a heater, kiln or boiler or even a fireplace, you need to buy refractory bricks. Then you definitely first need to find a best refractory brick manufacturer. My spouse and i will tell you where to find the best refractory brick manufacturer.

Rsrefractoryfirebrick.com/refractory-brick-for-sale are a kind of shaped refractory materials for application in all types of business hot temperature equipments such as blast furnace, rotary kiln, hot blast range, fireplace and so forth. Refractory voilier can perform most properties in these high heat equipments such as physical wear resistance, high temperatures resistance, chemical erosion amount of resistance, thermal shock resistance and so on. There are also a number of refractory stones being used for different position in these tools according to their different chemical and physical properties.

High quality refractory stones are produced with high quality raw materials. And China is a great place with amount of high quality natural refractory raw materials. There are many refractory brick manufacturers in China. RS Kiln Refractory Company is one of the leading refractory brick manufacturers in China.

When you plan a project, you maybe not only need one kind of refractory bricks. A big project, like a kiln, you may need many types of refractory bricks to together build the quality kiln that different refractory bricks can be used for the suitable position in the kiln. And RS Organization is a professional refractory bricks manufacturer, manufacturing all sorts of high quality refractory stones such as fireclay stones, high alumina bricks, silica refractory bricks, carbon voilier, mullite bricks, magnesia voilier, magnesia chrome bricks and insulating fire bricks for sale and so on. Regardless of what kind of refractory bricks you want to buy, you can have a great chance to do your best choice from RS Company.

If you need to find out more on high quality refractory bricks and the best refractory brick manufacturers, you can search the professional kiln refractory materials website: www.rsrefractoryfirebrick.com.

Use Fire Clay Bricks

Fire clay bricks are a perfect purchase, and lots of people are relying on them since they go through the options.

You may realize they already have numerous advantages to offer and are going to yield quality results. You need to understand the best way to optimize them so you will get real value from the investment and might make best use of them for years. Listed here is a deeper explore what you can do with clay bricks as long as you are selective and careful.

Insulate Steel-Making Furnaces

These are typically their primary uses as well as something you will notice in a variety of factories.

Steel-making furnaces must be protected, and that is only going to happen if you are watching the lining. What exactly is the lining will be made from? It is going to be crafted from robust fire clay bricks that will line in one end on the other.

This is basically the value you will maximize when you are by using these bricks.

Placed Near Expansion Joints

You are also going to appreciate having these as expansion joints due to results they're bringing on the table. You might adore how good they work as well as the value they give in adding durability towards the overall setup.

These represent the options you will have in terms of rsrefractoryfirebrick.com/fireclay-bricks, and you might adore the outcome which come with them in your favor. These represent the ultimate bricks and they are a tremendous option for those who are picky and need an issue that is in addition to the world.

You happen to be not going to use any other type of brick if you get your hands on one of these brilliant fire clay bricks. See more bricks at: RSrefractoryfirebrick.com.

The Application Of Silica Brick

When you are working around high heat furnaces, incinerators or any other equipment which is open to high temperatures you need to be knowledgeable about silica refractory brick. This type of brick can handle contact with very high temperatures plus it won't break or come apart. You will discover this brick in kilns, furnaces, incinerators and other applications and then there is quite high heat.

Silica refractory brick is quite strong also it can handle being open to high temperatures and corrosive conditions. The bricks resist thermal shock which is important when they are being heated and cooled rapidly. Thermal shock causes bricks to breaks while they are cooled and heated up too rapidly. As soon as your bricks break, you will need to buy brand new ones from Comapny rsrefractoryfirebrick.com which can start to consume into the profit and expense you additional money.

Buying bricks that resist thermal shock is going to help you save money and ensure that you don't waste too much money on constantly buying new bricks. Rsrefractoryfirebrick.com/silica-refractory-brick is a little more expensive, but they are strong and will give you more use. They are utilized over and over again without needing to be worried about them breaking.

Silica refractory bricks are really strong and they are generally going to provide years of service. Make certain you get the right form of bricks for your application and always order a few extra. The bricks can be found in sizes and strengths, so it is crucial that you just purchase the right ones.

Silica refractory bricks are a great investment and will give you better service than plain bricks. If you would like be sure that your kilns and furnaces will probably be strong, create the investment in silica bricks and enjoy better service and fewer cracking and spalling. Contact Rongsheng for more details.