Installation of Refractory in glass furnace. By shahzaman mehar

Refractories performance affects glass manufacture in the production cost and the quality of the glass. Refractories in different areas of a glass furnace suffer different operating environment. So different types of refractory are used in the different parts of the glass furnaces.
Crown Refractories
Crown of glass furnaces are subjected to long-term thermal attack and chemical corrosion due to alkali vapor. It also need to be heavily insulated to reduce the energy loss. So it requires volume stability, low permeability, low conductivity, and high refractoriness of refractories in this area.
Silica refractories are the preferred material for crown construction due to its affordability, low stoning potential, insulating capability, resistance to creep, low thermal expansion after 600°C and compatibility with the batch material. They have been used for the construction of glass melting furnace for over a century. Although today the use of silica bricks is restricted to crown and superstructure, the steady improvement in production of silica bricks has led to greater chemical purity and stricter dimensional tolerances over a wide range of shape and sizes. To meet the demanding requirement of oxygen-fuel furnaces, fused cast alumina block is used due to its excellent resistance against acid slag, chemical corrosion and alkali vapor.
Superstructure Refractories
The superstructure of the furnace will suffer from high temperature and chemical attacks by volatile products and dust which settle on the walls and attack refractory products characterized by a progressive wear of refractory in contact with the glass. Refractories in this part are required to have a high thermal shock resistance and corrosion and erosion resistance.Fused cast block, Zirconia-Mullite brick and Mullite brick with high density, low porosity, good hot strength and good sag resistance are used in this area.
Bottom and Lower Side wall Refractories
In contact with melt glass, refractories in those areas suffer high Temperature, and glass corrosion. Chemical reactions also take place between refractories and molten glass, fluxing agents, and/or volatile components. Erosion can follow; washing away refractory grains after the original bond has dissolved. With a high refractoriness, high thermal resistance, a low reaction with melt glass, a very strong glass corrosion and vapour resistance, Zirconia-Mullite bricks and Fused Casts are installed on the bottom or in direct contact with sidewalls.
Regenerator Refractories
These areas of the furnaces are subject to special intense aggression in the long campaigns because of the chemical reactions between refractory material and hot gas. A higher performance of the refractory and insulating material is required in these cases in order to attain better heat efficiency. A regenerator consists of a regenerator chamber in which a checker work (or just checkers) of refractory bricks has been stacked. Due to high stability, high thermal shock resistance, low thermal expansion, high refractoriness and the high resistance to basic slags, Magnesia bricks are normally used in the regenerator including area above checker work and crown. With a high alkali resistance and creep resistance, fireclay bricks are particularly suitable for the lower parts of regenerator.
Besides refractories mentioned above, insulating refractories with low conductivity and good mechanical strength are used to reduce heat loss in areas where abrasion and wear by aggressive slag and molten metal are not severe. The insulating materials can lead to savings in fuel cost and a more rapid heat-up. After the furnaces are installed, unshaped refractories such as special ramming &patching masses are used to repair some parts of the furnaces to extend the furnace’s life until the end of the campaign. The main products of include fused cast  block, fused cast alumina block, mullite brick, zircon brick, alumina bubble brick, sillimanite brick, corundum brick, low porosity fireclay brick, high alumina brick, all kinds of glass furnace ramming masses, etc.. mehranceramics.com

Heat resistant binders.

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Refractory Bricks Grades..

http://mehranceramics.tumblr.com/post/119017805898/refractory Refractory Bricks Grades..

Grades:

Alumina Silicate, High Alumina, Silicate, Mag-Chrome, Magenesite, Mag-Carbon, Silicon Carbide, Carbon, Graphite, Mag-Spinell.

We stocks of a wide range of refractory bricks which include normal duty (ND), regular duty (RD), super duty (SD), 60% to 90% Alumina. For details check out the website: mehranceramics.com

Low Cement Castable refractories.

http://mehranceramics.tumblr.com/..... Low cement cast-able refractory:   

  We are engaged in manufacturing, exporting, importing and supplying of Low Cement Castables. The Low Cement Castables are fabricated using high grade raw material. The Low Cement Castables offered by us are ideal for places where abrasion and temperature are very high. Further, these castables are largely used in various furnaces like sintering furnace roof, ladle back up lining & soaking pit cover.

Applications
Sintering furnace roof
Ladle back up lining
Soaking pit cover

Features
Low sintering temperature
The CCS does not fall at 1000o C - but increase progressively
Micro Silica free
The SiO2 is restricted to maximum 1%
The material flows by its weight
The flow ability is maintained for longer time

Variety
49% Alumina Low Cement Castables Rockzytte 49
69% Alumina Low Cement Castables Rockzytte 69
79% Alumina Low Iron Low Cement Rockzytte 79
89% Alumina Low Iron Low Cement Castables Rockzytte 89. For more details check out the website: mehranceramics.com

Insulations.

Insulation bricks. - http://pinterest.com/pin/A1SOewAQwM4H7RiIcnkAAAA/?s=3&m=blogger

Mehran Ceramics's hot face lining works.

Mehran Ceramics refractory furnace linings.

Metal casting is done by many different furnaces within the mining industry of which electric arc furnaces, blast furnaces, cornwall furnaces and iron furnaces are only a few examples.  Every one of these different types of furnaces are manufactured for different purposes but they each have one thing in common which is that, during the manufacturing process refractory lining material is vital.  
 
Electric arc furnace that makes use of refractory lining material:

This type of burner melts charged metal by making use of electricity (an electric arc).  Depending on the size of the furnace, it is able to either melt from 1 ton all the way up to 400 tons.  The smaller electric arc furnaces are used in metal foundries to produce cast iron and the larger ones are preferred during steel making. These electric arc furnaces burn with temperature reaching up to 1800 degrees Celsius.
 
The blast furnace that makes use of refractory lining material:

It is commonly referred to as a metallurgical furnace as it melts metal through the process of smelting.  It differs from and electric furnace in the way that it does not have a special operation technique – one would simply load the metal into the furnace until it reaches melting temperatures and is used during cast iron melting.
 
 
The blast furnace is preferred to the electric arc furnace many times due to its easy manageability.  Where the blast furnace is simply loaded and operates until the iron is melted, the electric arc furnace has to be under constant supervision to make sure that the furnace reaches the correct temperature and also preventing overheating which will cause the metals to become unusable.

This blast furnace contains different sections called the refractory-lined vessel, retractable roof and the furnace itself.  The furnace is divided into three sections called the shell, the hearth and the roof.  These all have to be pre-prepared with refractory lining material for optimum efficiency.

As mentioned, any type of furnace is designed and manufactured with extremely high temperature levels in mind.  This is due to metals not being able to melt at standard temperatures and have, in the past only been shaped by extremely hot temperatures as within a volcano.  

As one can imagine, it takes extreme engineering for any item itself to be able to withstand these temperature levels which explains why any industrial furnace should include refractory lining material into its design.  Refractory lining material greatly lengthens the lifespan of any furnace which thereby keeps it functioning without wearing out.  It is such and important aspect therefore as it could directly relate to more hours of function and less expensive running costs.

 
Our consolidated and integrated solution covers all disciplines and services in furnace-rebuild projects:
Project and construction management;
Salamander tapping and controlled furnace decommissioning and cool down;
Mechanical, structural, steel and piping dismantling, fabrication and erection;
Refractory materials’ management, including selection, procurement, and testing;
Quality assurance and control systems;
Demolition of furnaces, removal of refractory linings, and waste management;
Design, manufacture and installation of anchor systems for all types of monolithic, ceramic fibre, and brick refractory linings;
Manufacture of customised, refractory precast shapes;
Installation of all types of refractory linings’ materials, including bricklaying, pneumatic gunning, ramming, pumping, vibrocast and placement of castables, and ceramic fibre products – across all furnace designs;

Hot and cold furnace repairs; Hot sealing and insulation;
Drilling and installation of thermocouples; Drying and curing of refractory linings; and Furnace start-ups and commissioning.
 
All our customers gain the advantages of our rapid response times, integrated project implementation, project quality and completion guarantees, safe project implementation, reduced downtime, and significant production-cost savings.
 
Refractory Installation Specialists
 
Our company has more than 26 years’ experience with refractories – having pioneered the refractory business in Karachi, Pakistan.
 
The Mehran Ceramics is Pakistan's most high-profile refractory installation company.

We employ some of the most experienced refractory engineers, project managers, supervisors, refractory tradesmen and assistants in allover the country, Mehran Ceramics has installed refractory materials to numerous initial construction and furnace rebuild projects throughout the world.
 
Our extensive experience allows to service all refractory-consuming industries, including: cement and lime, ceramic, glass, ferrous and non-ferrous, chemical and petrochemical, paper and pulp, and power generation.

Mehran Ceramics is committed to superior standards of workmanship and strives to continually improve its refractory installation services. Our ability to provide timely and comprehensive service to all our customers for initial construction project rebuilds, and scheduled maintenance and emergency repairs – sets the Mehran Ceramics apart from all its competitors.

Mehran Ceramics strive to make use of only the best quality refractory lining material.For more check out the website: mehranceramics.com

Mehran Ceramics material applications. Refractories – Applications

Mehran Ceramics material applications.
Refractories – Applications
Copper
Linings and parts for both shaft and holding furnaces in a range of materials.

Electrical Ceramics
A wide range of saggars, batts, sandwich tiles and kiln and furniture, in high purity materials designed and manufactured to meet specific customer requirements.

Energy from Waste (EfW)
Boiler wall tiles and grate shapes manufactured from the highest quality materials, to perform in aggressive environments.

Furnaces & Kilns
Wide range of linings, dependent on the application and operating atmosphere, including high purity alumina to 99.5% with low silica.

Mineral Processing
Numerous applications for wear resistant components, including high temperature and aggressive environments.

Petro-chemical
Domes, catalyst supports and linings for various aggressive environments in a range of materials.

Powder Metallurgy
Crucibles and nozzles in a range of materials including zirconia.

Power Generation
Burner quarls and pipe lining systems for high erosion and temperature zones.

Primary Aluminium
Reduction cell wall linings in silicon carbide, produced to meet specific pot requirements.

Secondary Aluminium
Molten metal movement components in a range of materials.

Steel
Annealing furnace linings flow control and high temperature wear components, including high purity alumina to 99.5% with low silica.

Technical Ceramics
High purity batts, saggars, tiles designed and manufactured to meet specific customer requirements.