Refractory bricks and materials for ceramic kilns
2024 Best refractory solutions for high temperature industrial ceramic kilns. Selection of refractory materials and refractory bricks for various parts of different types of ceramic kilns.
What is a ceramic kiln?
Ceramic kiln is a high-temperature kiln equipment used for firing ceramic products. By precisely controlling the parameters of temperature, atmosphere and time, it realizes the transformation of ceramic materials from plasticity to hardness, so as to obtain ceramic products with specific properties and appearance. Ceramic kiln performance is directly related to the quality and yield of ceramic products. Therefore, the design, refractory selection and maintenance of ceramic kilns are of paramount importance.
Types of Ceramic Kilns
There are many types of ceramic kilns, which can be divided into tunnel kilns, shuttle kilns, electric kilns and other types according to different classification standards. The following is a detailed introduction:
Tunnel kiln: Tunnel kiln is a kind of ceramic kiln for continuous production, which has the advantages of high output, low energy consumption and high degree of automation. Its structure usually consists of preheating section, firing section and cooling section, through the conveyor belt or push plate will be sent to the ceramic products sequentially into each section for firing.
Shuttle kiln: Shuttle kiln is a kind of intermittent production of ceramic kiln, its structure is similar to the drawer, can be moved back and forth. During the firing process, the ceramic products are placed in the kiln car, and the operation of entering and leaving the kiln is realized by pushing the kiln car. Shuttle kiln has the advantages of simple structure, flexible operation, suitable for small batch, multi-species production.
Electric Kiln: Electric kiln is a kind of ceramic kiln using electricity as the heat source, which has the advantages of fast heating speed and precise temperature control. Electric kilns are usually used to fire high-precision, high-quality ceramic products, such as arts and crafts.
In addition, there are other types of ceramic kilns such as roller kilns and push plate kilns, each of which has its own unique advantages and scope of application.
Ceramic kiln parts and refractory selection
Refractories for kiln walls
Kiln wall: The kiln wall is the main structure of the ceramic kiln, bearing high temperatures and mechanical force.
Aluminum silicate refractory bricks: made of alumina, silica clay, and other raw materials with good resistance to high temperatures, erosion, and abrasion. They are commonly used in ceramic kiln walls under the material plate and other parts.
High alumina bricks: made of kaolin as the main raw material, have high abrasion resistance, erosion resistance, and high temperature resistance and are commonly used in ceramic kiln walls, support beams, and other parts.
Refractories for ceramic kiln roofs
Kiln roof: The kiln roof is the upper structure of the ceramic kiln, which needs to withstand the dual role of high temperature and gravity. Therefore, the design and selection of materials for the kiln roof are equally critical, and it is usually constructed using lightweight refractory materials or reinforced refractory bricks.
Lightweight clay bricks: Because of the simple manufacturing process and low price, they are used in large quantities in the kiln lining, which helps to reduce the heat dissipation of the kiln body.
Lightweight high alumina bricks: refractoriness and load softening temperature are higher than those of lightweight clay bricks, which is suitable for parts requiring higher refractory performance.
Calcium silicate board: has excellent heat insulation properties, commonly used in the kiln roof insulation layer.
Refractories for ceramic kiln combustion systems
Combustion system: The combustion system is a key part of the ceramic kiln, responsible for providing the heat required for firing ceramic products. The combustion system usually includes the burner, fuel delivery piping, smoke exhaust equipment, etc. Its performance directly affects the quality of ceramic products and energy consumption.
Synthetic alumina bricks: With excellent high-temperature resistance, erosion resistance, and compressive strength, they are commonly used in high-temperature areas such as near burners.
Directly bonded magnesium-chromium bricks: with excellent high-temperature thermal shock performance and erosion resistance, they are suitable for critical parts of the combustion system.
Refractory materials for ceramic kiln temperature control system
Temperature control system: The temperature control system is the core part in a ceramic kiln, which realizes the uniform sintering of ceramic materials by precisely controlling the temperature changes in the kiln. The temperature control system usually includes temperature sensors, controllers, actuators, etc. Its accuracy and stability are crucial to ensuring product quality.
Silicon carbide bricks: with excellent thermal stability and erosion resistance, they are commonly used in parts near temperature sensors and controllers.
Silicon refractory bricks: high temperature resistance and good thermal shock resistance, can be used in the temperature control system needs to withstand temperature changes in the part.
