Production Process for Shaped Refractories Feb03

Production Process for Shaped Refractories...

Production Process for Shaped Refractories Refractory products can be shaped (formed) or shapeless (monolithics/castables).  They can be made of acidic, neutral, basic or composite materials. The materials used for the production of refractories may or may not contain additives. Further shaped refractories can be made in several shapes and are usually called refractory bricks. Typical production flow used in the process of the production of refractories is given in Fig 1. Fig 1 Typical flow in the production process for refractories  Shapeless refractories are normally dispatched from the refractory manufacturing plant not as a refractory but as refractory materials which become refractory only after it undergoes mixing, forming, aging, drying, and preheating etc. at the site of use. This means that in case of shapeless refractories, a part of the process in the manufacture of shaped refractories shifts to site of use. The fundamentals of refractory bricks manufacturing have not changed over time. However, technological advancements have made contemporary brick plants substantially more efficient and have improved the overall quality of the products. The manufacture of these refractories is based on knowing which combination of chemical compounds and minerals will give the produced refractories its needed properties such as refractoriness, thermal stability, corrosion resistance, thermal expansion, and other important qualities. A more complete knowledge of raw materials and their properties, better control of firing, improved kiln designs used for firing of green refractories and more advanced mechanization have all contributed to the advancement of the refractory brick industry. The technical objectives of manufacture of a given refractory are to obtain its properties and performance for an intended application. For fulfilling these objectives, the basic components of the refractory manufacture consist of proper selection of raw materials, processing methods, and maintenance of technological parameters during...