The production of refractory materials mainly revolves around core processes such as raw material processing, forming, drying, and firing, and modern production lines are upgrading towards automation and intelligence. The mixing process is important by high technology refractory intensive mixer.
How to turn raw materials into finished products
1. Raw material pretreatment: Firstly, crush, screen, and remove iron from raw materials such as alumina, magnesia, and silica. Then, store them in a closed warehouse for 7-15 days for aging and homogenization to balance the moisture content of the raw materials and improve their plasticity.
2. Mixing ingredients: Mix the raw materials and binders in the intensive mixer according to the formula for 30-50 minutes to ensure even distribution of ingredients.
3. High pressure forming: Use a friction brick press or isostatic pressing equipment weighing over 630 tons to form the billet with a density of 2.8g/cm ³ or higher.
4. Drying control: The temperature of the tunnel dryer gradually increases from 80 ℃ to 160 ℃, and the moisture content needs to be reduced to below 1% before entering the firing process.
5. High temperature firing: For shuttle kiln or tunnel kiln firing, magnesium materials need to be sintered at 1750 ℃ or above, and the insulation time should not be less than 8 hours.
Which stages are the most critical
1. The firing temperature should be sufficient: the fire resistance of ordinary clay bricks is usually higher than 1580 ° C, while high alumina bricks, corundum bricks, etc. can reach above 1770 ° C. Insufficient temperature will affect the final performance.
2. Porosity should be controlled: Materials with high bulk density and low apparent porosity have better density, strong resistance to erosion and permeability, but may have slightly weaker insulation performance.
3. Quality inspection is essential: After firing, ultrasonic flaw detectors and X-rays should be used to screen for micro crack products to ensure that each brick is qualified.
4. Mixing the refractory raw materials is the most important in the whole process by suitable intensive mixer.
How to do it
1. High degree of automation: Modern intelligent workshops adopt fully automated production lines, unmanned equipment to complete packaging and palletizing, and there is no noise or dust like traditional factories in the large factory building.
2. Strict environmental requirements: The production line is equipped with bag filters with a dust removal efficiency of 99%, and the equipment is monitored in real time according to the electronic control system.
3. Product traceability: Using a QR code management system, each refractory material can be traced back to specific production batches and process parameters.
