Refractory materials for non-ferrous metallurgy

• Growth of corundum
• Mechanical damages
• Metal penetration
• Thermal shock
• Erosion
• Chemical exposure

Insulation Fiber Products (Superwool, Cerablanket, Kaowool, Pyrobloc)

Advantages and available forms

• Protective coatings (features: excellent heat resistance, soft fiber coating, flexible, easy to cut and give any forms, no degassing during firing)
• Modules
• Bulk fiber (features: long loose fiber supplied with and without lubrication, means for sealing, does not contain binders or corrosive substances)
• Papers (features: made from fiber with a low percentage of organic binder, tear resistant, very elastic, exceptional properties for ease of handling)
• Vacuum molded
• Low biological stability insulating fibers (biological stability means the ability of fiber to resist removal from the lungs through natural mechanisms, dissolution and destruction)
• Superwool panels (rigid panel of refractory filler and binder, light weight, excellent resistance to temperature shock, uniform thickness)

Fused Cast Refractories

• Insulating refractories
• Dense refractories
• Special use
• Low cement, ultra low cement, cement-free refractories
• Plastic monoliths
• Microporous insulation BTU-Block (extremely low thermal conductivity, good compressive strength, minimal required area, available in many forms)

Non-wetting refractories for high temperature applications

• Performance Requirement
• Rising melting rates
• Rise in oven temperature
• Enhanced corundum growth
• Improved varieties developed with high temperature corundum resistance

Special testing of refractories

• Slag resistance
• Resistance to liquid metals
• Alkali resistance

Composition and raw materials

• Fillers (calcined clay, lamellar alumina, fused alumina, broken refractory bricks of all types, perlite, expanded clay, vermiculite)
• Cements (high alumina cement of all types of purity)
• Modifiers (silica for the formation of mullite, for strength in the intermediate roasting, the addition of clay for additional plasticity, the use of high-grinding alumina gives increased strength and refractoriness)
• Chemical additives to control the time of hardening, plasticity, rate of increase of strength, fluidity for pumping

Application methods

• Casting
• Torkret process
• Concrete mix rodding
• Hand stowage
• Wet gunning

Main applications in the aluminum industry

• Refractory kilns
• Anode furnace with carbon anodes
• Electrolytic crucible cells
• Melting furnaces
• Metal transportation

Examples of refractories use in non-ferrous industry

Anode furnace with carbon anodes - areas of application of refractories

• Orange color (tubular wall) - K® / JM tm insulating refractory bricks, Kaolite® / Firelite® cast refractories, TR-19® Block;
• Blok 607®, BTU-BLOCK™
• Brown color – furnace hearth:
• Red color (chimney distributors) - cast refractories with low cement content;
• Yellow color (distributor cap) - fiber / cast refractory.

Electrolyzer

• Red (bottom insulation) — TR-19® / блок Blok 607®
• Green (upper side wall) — SIC blocks;
• Yellow (heating cap) — SW Bikt Seal – Kaofil® mastic.