Refractory materials are essential for many high-temperature equipment. They are used to strengthen the inner structure of furnaces and boilers. The materials are characterized by good volume stability and chemical resistance to decomposition.
There are several raw materials that are processed to produce refractory materials. These include sand, clay, limestone, zirconia, magnesium oxide, alum, mullite, fireclay, magnesia, corundum, and glass. When they are processed, the raw materials are mixed and fired in special ovens, reaching temperatures up to 1,800 degrees. After the firing, the raw materials are transported to customer facilities. In some cases, bitumen impregnation is included in the processing.
During the process, the material is shaped or molded into the desired form. It is formed using chemical bonding. The chemical bonding process provides significant energy savings. Chemically bonded refractory bricks are manufactured by selecting and adding appropriate additives and chemicals. They are then fired at high temperatures to create a ceramic bond.
The physical properties of the refractory material are based on ASTM standards. They include cold crushing strength, hot/cold MOR, and abrasion resistance. Alumina refractories, for example, are composed of at least 50% alumina. Fireclay refractories contain between 25% and 45% Al2O3. Magnesia-chrome refractories are manufactured from magnesium oxide, while chrome-magnesia refractories are made from chrome and magnesia.
Refractory materials are available in many different shapes and sizes. They can be supplied in preformed shapes or non-formed. Unformed refractories are often used for patching and maintenance purposes. These can be purchased as a spray mixture or as a granular material.
Refractory materials are used in a variety of industrial applications, including cement, glass, metals, and ceramics. The materials are also used in industrial and commercial boilers, which are exposed to heat and pressure.
One type of refractory material is the refractory brick, which is made from a wide range of materials. Refractory bricks are usually produced in the shape of circular apertures. The bricks are commonly made of a variety of alumina and glass products, with an AL3 content of more than 48 percent. Another type is dry vibrating cement. Other common types are monolithic refractories, plastic masses, and gunning masses.
Another common type of refractory is the fireclay refractory, which is primarily composed of hydrated aluminum silicates. Fireclays are often marketed at a low price, as they combine high plasticity with serviceable refractory character. Typically, fireclays are coarsely ground to ensure adequate support for addition of grog.
Fireclays are widely used in many furnaces and regenerators. Fireclays can be combined with grog to produce a higher performance refractory product. Some of these refractories are manufactured by chemical bonding, which allows for high quality refractories without the need for sintering. Depending on the application, the refractory material may be supplied in the form of bricks, shapes, or preformed compositions.
In the global refractory material market, the market is segmented into five key regions, namely North America, Asia-Pacific, Europe, Latin America, and the Middle East and Africa. These segments are analyzed based on their chemical composition, form, and end use.
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