Refractories

 Refractories - A group of ceramic materials capable of withstanding

high temperatures for prolonged periods of time.
 Acid Refractories - Common acidic refractories include silica, alumina,
and fireclay (an impure kaolinite).
 Basic Refractories - A number of refractories are based on MgO
(magnesia, or periclase).
 Neutral Refractories - These refractories, which include chromite and
chromite-magnesite, might be used to separate acid and basic
refractories, preventing them from attacking one another.
 Special Refractories - Other refractory materials include zirconia (ZrO2),
zircon (ZrO2 · SiO2), and a variety of nitrides, carbides, and borides.
Acid Refractory

1. Silica Bricks
90-95 % SiO2 + 2 % Lime added during grinding for bonding

(870°C) (1470°C)
Quartzite  Trydymite  Crystobalite

Method:
Temp slowly raised to 1500°C in 24 hrs. Maintained at this
temp for 12 hrs and then cooled slowly for 1-2 weeks.
A mixture of Trydymite and Crystobalite results in the final
bricks.
Porosity: 25 %
PCE: 1700°C
RUL at 3.5 kg/cm2: 1600°C
Resistance to abrasion
Uses: Roofs of open hearth furnances, by product coke
ovens
2. Fire Clay
Al2O3.2 SiO2.2H2O and powdered calcined fireclay ’Grog’
Increase in % Grog= Less Spalling
SiO2= 40-55 %
Al2O3= 35-55 %
Acidic nature depends upon silicon content.
PCE: 1400°C
RUL (2 kg/cm2)= 1350°C
Resistance to thermal shocks is high
Porosity: 20 %
Uses:
Lining of blast furnances, regenerators, Charging doors.
3. High Alumina Bricks
Containing more than 50 % Al2O3 & SiO2
Calcined Bauxite (Al2O3) and clay
Low Coefficient of expansion
Resistance to thermal spalling
High Porosity, Great resistance to slag
Acidic and Non conducting (high porosity)
Medium Duty: 50 –60 % alumina
Heavy Duty: 75 % alumina (used in hottest zone)
Appreciable RUL and Abrasion resistance
Uses
Lining of cement rotary kilns, Soaking pits, Hearth
furnace
Aluminum and Brass melting furnaces
Basic Refractory

4. Magnesite bricks

Calcined Powdered Magnesite + Caustic Magnesia or sulphite lye or

Iron Oxide as binder. Water is added to form slurry which is moulded
into bricks.
Heated slowly to 1500°C and kept for 8 hrs at this temperature. Cooled
slowly.

Basic refractory showing resistance to basic slag.

PCE: 2000°C
RUL at 3.5 kg/cm2= 1500°C
Poor abrasion resistance, extremely sensitive to temperaturę change.
Absorbs CO2 & water.
Uses:
Lining in open hearth furnances.
Lining in furnances for refining Au, Ag & Pt.
Hot zones of cement rotary kilns.
5. Dolomite Bricks
Mixed calcined dolomite (CaO + MgO) with silicate binder. Fired at 1500°C
for 24 hrs.
Less strength, more softness and porosity greater shrinkage than magnesite
bricks.
RUL at 3.5 kg/cm2 = 1650°C.
Not resistant to thermal shocks. Absorbs water & Carbondioxide.

Dolomite mixed with Serpentine (MgO.SiO2) calcined & fired at 1500°C for
a day gives a stablized bricks which doesnot absorb water & Carbondioxide

Uses
Rarely used as a refractory material more as repair material.

Stablized dolomite used in basic electric linings, open hearth furnace as a

cheap subsitute for magnesite bricks.
Neutral Refractory

Carbon

Crushed coke + tar(binding material) or graphite mixed

with clay 1300-1400°C
Infusible
Insensitive to spalling
Highly thermal conductive
Close textured
Withstand temperature fluctuations & chemical attack
of alkalis
Uses
Lining of atomic reactors and electric furnaces
Chromite Bricks
Crushed Chromite Ore (FeO.Cr2O3) and clay as a binding material
1500-1700°C
PCE 1800°C
RUL 3.5 kg/cm21430°C
Resistant to acid and basic slag, non resistant to thermal shocks.

Uses
Useful in separting acid & basic refractories

Carborundum (SiC) bricks

Sand + coke + sawdust heat at 1500°C then add binder
PCE 2000°C
Binder
‘Clay bonded’ 1750°C
Silicon nitride –high strength, superior thermal shock
resistance
Self bonded (glue)- high refractoriness, superior strength
Uses: As heating elements in electric furnaces, partion wall
of chamber kiln
Zirconia brick

ZrO2, CaO or MgO (stablizer), alumina (binding agent). Heat

to 1700°C.
1.Neutrał refractory material but not resistant to acid slag.
2.PCE 2000°C
3. RUL 1900°C at 3.5 kg/cm2
4. Good thermal shock resistance
5. Good resistance to thermal spalling.

Uses: Expensive brick used in High frequency electric

furnaces (high temp is attained)
Beryllia bricks
Powdered Beryllia metal at 1900°C-2000°C.
PCE 2500°C
Low electrical conductivity
High thermal conductivity
Good resistance to thermal shock
Uses: in jet propulsion studies, nuclear engineering

Chrome Magnesite Refractory

Chrome ore + magnesite

During firing
3MgO.SiO2.H2O  2MgO.SiO2 + MgSiO3 + H2O
Serpentine Forsterite
MgSiO3 + MgO  2MgO.SiO2
1. Magnesite Chrome 60 % MgO, 8-18 % Cr2O3: High refractoriness, high
thermal spalling, high conductivity, high resistance to corrosion & erosion.
2. Chrome Magnesite 40-50 % MgO, 15-35 % Cr2O3
Properties same as 1 but undergoes thermal spalling