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(ISSN
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2750-1396)
VOLUME
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OCLC
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1368736135
A
BSTRACT
The article explores the primary types of ceramic refractory materials, focusing on their properties and
applications in high-temperature industrial processes. Key technological advancements in refractory
manufacturing are discussed, with an emphasis on enhancing material strength, chemical resistance, and
durability. The analysis highlights the specific characteristics of each refractory type, including fireclay,
magnesite, corundum, and silicon carbide, and their utilization across various industries such as
metallurgy, energy, and glass production. Modern production and modification methods for refractories
are presented, aimed at improving thermal resistance and reducing the operational costs of equipment.
K
EYWORDS
Dolomite, chromium, quartz or dinas, corundum, magnesia, exothermic synthesis, binder, fire resistance,
heat resistance, mullite, fireclay brick.
I
NTRODUCTION
Modern science knows many outstanding
scientists, physical chemists, metal physicists,
and ceramists, whose fundamental works laid the
foundation of modern materials science in the
20th century. These researchers include P.P.
Budnikov, S.G. Tresvyatsky, A.S. Berezhnoy - the
Journal
Website:
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Copyright:
Original
content from this work
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terms of the creative
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attributes
4.0 licence.
Research Article
EXPLORING CERAMIC REFRACTORY MATERIALS:
CLASSIFICATION AND TECHNOLOGICAL INNOVATIONS
Submission Date:
November 02,
2024,
Accepted Date:
November 07, 2024,
Published Date:
November 12, 2024
Crossref doi:
https://doi.org/10.37547/ijasr-04-11-04
M.M. Ergashev
Associate Professor, Fergana Polytechnic Institute, Fergana, Uzbekistan
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founders of the scientific school in the field of
physical chemistry of oxide ceramics and silicate
materials; Grozin, V.I. Trefilov, who developed the
foundations of physical mechanics and physics of
strength of materials; B.Ya. Pines, S.D.
Hertzricken, Ya.E. Yaguzin, M.A. Krivoglaz, L.N.
Larikov - the creators of modern concepts of
defects and diffusion processes in solids. This is
far from a complete list of outstanding scientists,
whose contribution to modern materials science
is invaluable [1-7].
The theoretical foundations of the production of
refractory materials were first outlined by
Academician A. A. Baikov, who considered the
process of converting a powder mass into a solid
crystalline aggregate as a process of
recrystallization of refractory material in the
liquid phase at a certain temperature [8,9].
In its basic features, this process is similar to the
process of hardening cement mixed with water.
Therefore, refractory materials can be called
"high-temperature cements", and finished
refractory products made from them - "high-
temperature concretes" [10].
In the production of refractory products, a mass
consisting of a refractory of a certain chemical
composition and a binder is subjected to
moulding, drying and firing [11].
During the moulding process, the product is given
a given shape using special moulding presses.
During drying, excess moisture is removed and
the product acquires some initial strength [12].
The firing process can be divided into three
periods:
−
During the first period, the temperature
gradually rises to a certain fairly high level,
determined by the chemical and mineralogical
composition of the mass;
−
in the second period, which is quite long,
the temperature is maintained at a given level;
−
In the third period, the temperature drops
to normal, and the fired products cool.
The second period is of the greatest importance
for the quality of the product. At the beginning,
the fired product is a mass consisting of individual
grains or granules of refractory material,
impregnated and moistened with a small amount
of melt. This liquid phase was formed by the
interaction of the main oxide, which is a
refractory material, with all the impurities
present in the mass. The amount of melt formed
depends on the temperature and the amount of
impurities, and the higher the firing temperature
in the second period and the more impurities, the
more melt is formed. As a result of
recrystallization in the melt at the end of the
second period, solid particles form a dense
crystalline intergrowth. In this case, the mass
loses its friability and acquires mechanical
strength. This transformation occurs at a constant
temperature (which is lower than the melting
point of the refractory) by recrystallization of the
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refractory material in a small amount of liquid
phase [13, 14].
The degree of dissolution of the main oxide in the
melt, and consequently the completeness of its
recrystallization, depends on the degree of
crushing of the original material, since with a
decrease in grain size their solubility increases.
A solid with a regular crystal lattice has a lower
solubility than a solid with a deformed lattice.
Deformation of the crystal lattice can occur
during firing either as a result of a polymorphic
transformation accompanied by a significant
change in volume or as a result of the
decomposition of a chemical compound included
in the composition of the original material [15].
The conditions that must be met to obtain high-
quality refractory products are as follows:
−
the presence in the batch of such
impurities with which the refractory material can
produce a melt and can dissolve in it;
−
firing at a temperature that ensures the
formation of the required amount of melt;
−
holding at the firing temperature for a time
sufficient to complete the recrystallization
process.
The raw materials for the production of
refractory types of brick products are mainly
rocks with a fire resistance of at least 1580 °C, as
well as finely ground defective products,
unshaped materials, and waste returned to the
technological process.
Various technologies and processes are used to
manufacture refractories. The predominant
technology includes preliminary, heat treatment
and grinding of components, preparation of
batches with the addition of plasticized
components, moulding of products from them by
pressing on mechanical and hydraulic presses or
extrusion with subsequent additional pressing or
casting, firing in the tunnel, less often in periodic
and gas chamber furnaces to obtain the specified
properties of the material [16].
The operational properties of refractory
materials are determined by a complex of
chemical, physicochemical and mechanical
properties.
The main property of refractory products is fire
resistance, i.e. the ability of the product to
withstand high temperatures without melting.
Fire resistance is characterized by the
temperature at which a standard sample of the
material in the form of a triangular truncated
pyramid 30 mm high and with base sides of 8 and
2 mm (Zeiger cone) softens and deforms so that
its apex touches the base [17]. The temperature
determined in this way is usually higher than the
maximum permissible operating temperature of
refractory materials.
A distinction is made between:
−
refractory materials proper (refractory
1580-1770 °C);
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−
highly refractory (1770-2000 °C);
−
materials with high fire resistance (above
2000 °C).
Refractories can be of general purpose and for the
determination of thermal units and devices, for
example, blast furnaces, high-temperature
furnaces, etc., which is indicated in the regulatory
and technical documentation.
Classification by shape:
- straight.
- trapezoidal, wedge-shaped, arched
–
used for
laying out arched openings and vaults).
- shaped
–
found application in finishing works.
- suspended
–
also go to internal vaults, but
already in powerful industrial furnaces.
Fig. 1.
Average operating temperature is an important
characteristic when choosing a brick for devices
with a long operating cycle.
Thermal inertia is the ability to heat up quickly
and cool down slowly.
Heat capacity is the ability to accumulate thermal
energy for subsequent transfer.
Their main technical characteristics include:
Heat resistance, heat resistance, as this important
parameter determines the range of application of
a particular type of firebrick. For example, for
laying a domestic heating stove or constructing a
steel-making unit with oxygen blasting, different
types of bricks will be required.
Low thermal conductivity coefficient, which
prevents the outer surfaces of heating equipment
from heating up to critical temperatures.
Resistance to sudden strong heating, low
coefficient of linear, volumetric expansion, which
ensures the strength and integrity of the masonry
made of fireproof bricks.
Resistance to aggressive environments - from
acids to alkalis, as well as to radiation, which
allows the use of brick refractories not only in the
construction of furnaces - from household to
thermal power plant boilers, but also in the
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creation of apparatus, chemical industry
installations, and nuclear power plant reactors.
Refractories for glass furnaces. Glass furnaces
operate at critical temperatures, according to
technical standards, special grades of refractory
materials are used for laying instead of bricks,
and the glass industry also uses ceramic products.
Such materials withstand critical heating and
retain strength, providing the frame with the
necessary rigidity. The lining is used as a facing,
which protects the walls from mechanical and
chemical damage.
Features of refractories for glass furnaces. The
following types of refractories are used for glass
melting:
−
Dinas - suitable for constructing furnace
vaults and decorating upper segments;
−
magnesite;
−
aluminosilicate;
−
baddeleyite-corundum.
To produce quality glass, reliable furnaces are
required, in which a constant melting
temperature can be maintained. Under such
conditions, the mass will completely melt and
form a homogeneous substance without
inclusions. Such furnaces must be hermetically
sealed, reliable and made of heat-resistant
materials. The choice of refractories is the most
important factor in creating a glass furnace since
the service life of the furnace directly depends on
the quality of the refractory. While refractory
selection, important factors should be taken into
account:
- heat resistance;
- stability at high temperatures;
- thermal resistance;
- thermal expansion;
- thermal conductivity;
- mechanical strength;
- corrosion resistance.
Aluminium oxide, zirconium dioxide, and silicon
dioxide are the main structural refractory
materials for glass furnaces primarily because it
is not so easily wetted by molten glass, and
because of their low reaction with them. Fused
alumina jargal, zirconium oxide, zirconium oxide-
mullite, silicon dioxide, magnesium oxide,
sillimanite, fireclay refractory brick, refractory
mortar, rammed refractory mixtures and many
other refractory products are used for glass
furnaces. Zirconium-containing products are also
used, which are used to separate dissimilar
materials to eliminate the reaction between them.
A furnace designed on this principle will work for
a long time without breakdowns and provide the
plant with high-quality products.
Refractory materials
–
products based on
mineral raw materials, distinguished by their
ability to retain their properties under operating
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conditions at high temperatures, and which serve
as structural materials and protective coatings.
Raw materials for refractory materials are simple
and complex oxides (e.g. SiO2, Al2O3, MgO, ZrO2,
MgO-SiO2),
oxygen-free
compounds
(e.g.
graphite, nitrides, carbides, borides, silicides), as
well as oxynitrides, oxycarbides, sialons.
Dinas, operating at maximum operating
temperatures of up to 1730 °C.Dinas is a
refractory material made from quartzite or
quartz rocks and containing at least 93% SiO2.
They are used for lining industrial heating units.
Fig. 2. Dinas refractory brick
Corundum (silicon carbide - obtained by calcining
in an electric furnace a mixture of pure quartz
sand with petroleum coke or anthracite and table
salt, fire resistance up to 2000°C) - used in
installations designed to produce sulfuric acid,
furnaces with an oxidizing environment.
Fig. 3. Corundum-zirconium-mullite
Magnesite, (The raw material for the production
of magnesite refractories is the mineral
magnesite MgCO3, which contains 90% or more
MgO)withstands long-term heating up to 1900
℃
,
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has high mechanical strength, including abrasion
resistance, therefore it is widely used in
metallurgy.
Fig. 4. Magnesite refractory brick
Zirconium - made from the mineral baddeleyite
(containing 80-99% ZrO2 and up to 20% other
impurities), with fire resistance up to 2500 °C.
Fig. 5. Zirconium refractory brick
Carbon or graphite, is created based on free
carbon. The fire resistance of such individual
products, obtained by firing up to 2000 °C of a
charge of coal tar with graphite, is simply
enormous - up to 3500 °C, so it is not surprising
that they are in demand for lining smelting
furnaces in metallurgy, at energy enterprises,
including nuclear power plants.
Dolomite refractories are made from the mineral
dolomite, which in its pure form is a double
carbonate of magnesium and calcium (MgCO3 •
CaCO3). They have a fairly high fire resistance up
to 1780-1800 °C.
Chromium is made from chromite rock. It is inert
to acidic and alkaline environments, including the
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effects of slags formed during the welding of
metal
alloys.
The
maximum
operating
temperature is 1850
℃
.
The main, as alumina fireclay brick is often called,
as it is the longest-produced, proven type of
individual refractory product. An important
factor is also the cost of its acquisition, which
costs customers less than other types of this
refractory. Fireclay brick is the main furnace
material in civil engineering, and municipal
infrastructure of populated areas, including
boiler houses, and thermal power plants.
The purpose of fireclay bricks is determined by
their markings:
SHA, SHB, SHAK - universal material, used most
often for laying fireplaces and stoves. Products of
this type are characterized by an optimal price-
quality ratio.
ШКУ
- kosher brick, used for lining cast iron
ladles. The most famous brands are ШКУ
-32, 37,
39.
SHUS, SHV - has the highest heat capacity, due to
which it is used mainly for lining the walls of
convection shafts and steam generator flues.
SHAV - purpose: the lining of cupola furnaces.
ShPD - necessary for laying blast furnaces and
kilns.
ШК
- used mainly in coke production.
ШЛ is a lightweight material for lining furnaces
operating at temperatures not exceeding 1300 °C.
ШЦУ
- end double-sided products intended for
laying rotary kilns.
PV and PB are intended mainly for the
construction of chimneys, barbecues and grills.
The values following the letter are necessary for
dividing the products by size. For example, the
straig
ht product Ш
-5 has dimensions of
230х114х65, the end product Ш
-22 -
230х114х55, and the ribbed product Ш
-45 -
220х114х45 mm.
Brand
Dimensions, mm
Brand
Dimensions, mm
SHA-5
230x114x65
ШБ
-22
230x114x65/55
SHA-6
230x114x40
ШБ
-23
230x114x65/45
SHA-8
250x124x65
ШБ
-25
250x114x65/55
ШБ
-5
230x114x65
SB-29, 30
300x150x65/55
(65/45)
ШБ
-8
250x124x65
SHA-22
230x114x65/55
SL-5
230x114x65
SHA-23
230x114x65/45
ШЛ
-8
250x124x65
SHA-25
230x114x65/45
PB-5
230x114x65
SHA-29. SHA-30
300x150x65/55
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