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For the production of the fireclay bricks, the particles of ground clay must include a range of graded sizes, each in proper proportion.
The clays are typically ground in a dry pan, which is a rotating pan shaped grinding mill, having slotted opening in the bottom. The
batches are screened to the desired sizes and thoroughly mixed with a small but closely controlled amount of water. The moistened
batch is then fed to a mechanically or hydraulically operated press in which the brick is formed under pressure.
For many applications , the plastically pressed fireclay bricks no longer meet the technical requirements. Improved properties
requirement of the fireclay bricks is achieved through semi dry and dry pressing. Generally super duty and high duty bricks are pressed
by semi dry and dry pressing, since clay mix for these bricks contain lower percentage of bond clay.
In a modification of the power press process, certain physical properties are enhanced by the application of a high vacuum during the
forming of the brick. Bricks made with the application of vacuum, typically have a more homogeneous textures and are harder, stronger,
less porous and more dense than the bricks which are made without vacuum. Hence these bricks are more resistant to impregnation
and corrosion by slags and to penetration by gases.
The extrusion process is sometimes used for making special shapes. In making extruded bricks, clays are ground in a dry pan, mixed
wet or dry in a mixer, and brought to proper consistency in a pug mill, and extruded through the die of an augur machine in the form of a
stiff column. The air is removed from the clay before extrusion by a deairing system within the auger machine chamber. The column is
cut into brick by means of wires. The bricks are then typically re-pressed to give them sharp corners and edges and smooth surfaces.
Many intricate and special shapes are formed in vertical piercing and forming presses, in which blanks from the extrusion machine are
completely reshaped.
Bricks formed by any process are dried in tunnel or humidity driers. A high moisture content and a high clay amount lead to
considerable shrinkage. The dimensions of the fired bricks vary considerably and other irregularities such as warping or bloating can
happen if the bricks are not dried carefully and very slowly.
The temperature of firing depends upon the maturing temperatures of the clays, and often upon the service for which the bricks are
intended. In firing the brick, several necessary ends are accomplished. These include, driving off the free and combined water, oxidizing
of iron and sulphur compounds and organic matters, transformation of the minerals, and changes in volume. Finally the particles of clay
are ceramically bonded together into mechanically strong bricks.
After firing, the fireclay bricks consist of mullite, cristobalite, residual quartz and glass. In fired bricks, the mineral components are not
present in equilibrium condition. Only after the fireclay bricks have been installed in the furnace, then only the bricks approach
equilibrium at the brick hot phase. With rising temperature and a longer holding period at high temperature, the mullite content changes
little, where as the content of cristobalite and quartz declines and disappears totally at 1400 deg C to 1500 deg C. The fireclay bricks
then consist only of mullite and a viscous glass which, in addition to silica and some alumina, may contain alkalis and other fluxing
agents.
Important characteristics of fireclay refractory bricks
The softening behaviour of fireclay refractory bricks is determined by the amount and the composition of the glassy phase. Due to the
alkali content and the presence of other impurities, this phase starts to soften at 1000 deg C and it imparts a high softening interval to
the fireclay bricks because of its high viscosity. The softening behaviour of fireclay bricks are determined by testing the bricks for
refractoriness under load (RUL), thermal expansion under load (creep), and hot crushing strength.
Types of fireclay refractory bricks
As defined by the American Society of Testing Materials (ASTM), there are five standard classes of fireclay bricks (Fig 1). These
classes are (i) super duty, (ii) high duty, (iii) medium duty, (iv) low duty, and (v) semi silica.
volume and mineral composition, increases their resistance to fluxing, and renders them practically inert to disintegration by carbon
deposition in atmospheres containing carbon monoxide gas.
High duty fireclay bricks High duty fireclay bricks are used in large quantities and for a wide range of applications. Because
of their greater resistance to thermal shock, high duty fireclay bricks can often be used with better economy than medium duty
bricks for lining of furnaces operated at moderate temperatures over long periods of time but subject to frequent shutdowns. The
PCE value of the high duty brick may not be less than 31.5, and usually varies from 31.5 to 33.
Medium duty fireclay bricks Medium duty fireclay bricks are appropriate in applications where they are exposed to
conditions of moderate severity. These bricks, within their serviceable temperature ranges, can withstand abrasion better than
many bricks of the high duty class. Medium duty fireclay bricks have PCE values in the range of 29 to 31.
Low duty fireclay bricks These bricks find application as back up bricks for bricks with higher refractoriness. They are used
for services where relatively moderate temperature prevails. The PCE values of low duty fireclay bricks cover the range 15 to 27-29.
Semi silica fireclay bricks These bricks contain 18 % to 25 % alumina and 72 % to 80 % silica, with a low content of alkalis
and other impurities. With notable resistance to shrinkage, these refractories also have excellent load bearing strength and volume
stability at relatively high temperatures.
Application of fireclay bricks
The application of fireclay bricks is influenced by several other properties in addition to the refractoriness. These properties are
dimensional accuracy, crushing strength, porosity, and refractoriness under load. Machine pressed, fired fireclay refractories are used
for many applications. The stress on the materials differs widely. For special applications, It is customary to manufacture bricks which
are tailored to meet specific requirements. Fireclay refractory bricks are used in steel industry in coke oven batteries, blast furnace, hot
blast stoves, and various other furnaces used in the steel industry.