Monolithic Refractories...

Monolithic Refractories  Monolithic refractory is the name normally given to all unshaped refractory products, the word monolithic coming from the word monolith meaning ‘big stone’. Monolithic refractories are special mixes or blends of dry granular or cohesive plastic materials used to form virtually joint free linings. They are unshaped refractory products which are installed as some form of suspension that ultimately harden to form a solid mass. Most monolithic formulations consist of large refractory particulates (an aggregate), fine filler materials (which fill the inter particle voids) and a binder phase (that gels the particulates together in the green state). Monolithic refractories represent a wide range of mineral compositions and vary greatly in their physical and chemical properties. Some are low in refractoriness while others approach high purity brick compositions in their ability to withstand severe environments. Monolithic refractories are replacing the conventional type fired refractories at a much faster rate in many applications including those of industrial furnaces. Monolithic refractories are used to advantage over brick construction in different type of furnaces. Their use promotes quick installation, avoid delays for the manufacture of special brick shapes. Use of monolithics frequently eliminates difficult brick laying tasks, which may be accompanied with weakness in construction. They are of major importance in the maintenance of furnaces because substantial repairs can be made with a minimum loss of time and, in some cases, even during operations. Under certain conditions, monolithic linings of the same composition as firebrick provide better insulation, lower permeability and improved resistance to the spalling effects of thermal shock. With little or no preparation, monolithic refractories can be applied to form monolithic or joint free furnace linings in new constructions or to repair existing refractory lining. Other major advantages of monolithic refractory linings are as follows. It...