Products
Products
Fireclay Products
The predominant chemical components of fireclay products are SiO2 and Al2O3. Fireclay products are categorized by their Al2O3 content which lies between 10 % and 45 %, by the choice of shaping (plastically, half dry, dry or slip casting), and also by specified parameters according to their use. The main raw materials are heat resistant bonding clays and fired clays.
High-Alumina Products
P-D Refractories manufactures aluminium rich products with an Al2O3 content range of 45 % to about 99 % and based on natural raw material sources and synthetic raw materials such as:
- Fused alumina and sintered corundum
- Fused mullite and sintered mullite
- Andalusite and kyanite
- Bauxite
- Calcinated fireclay
These products are also offered in combination with raw materials rich in aluminium with either ceramic binding or aluminium phospate binding. Special characteristics of the aluminium rich products, such as thermal shock resistance and corrosion resistance, are achieved by additives having zirconium, chromium and carbon content and which are tuned to the relevant usage conditions.
Zirconium Containing Products
Materials with a zirconium content are categorized in pure zirconium silicate materials and
compounds of zirconium, mullite and corundum (aluminum-zirconium-silica material). Of note is that partly or fully stabalized zirconium oxide materials are also manufactured.
Materials with zirconium content have a very high corrosion resistance against numerous agressive media, and are mainly used in the glass industry and the steel industry.
Chromium Containing Products
Chrome oxide bricks and chromium corundum bricks are part of chrome containing products. Chromium oxide is extracted through the elaborate processing of chromium ores, in contrary to all natural raw material. Therefore chromium is classified as technical raw material.
Technically high purified chromium oxides (mineral name eskolait), or pre-sintered and later granulated and ground raw materials, serve as basic material for all of our company’s chromium oxide products. Shaping takes place by isostastic pressing or uniaxial pressing, manual shaping or vibration compaction.
Isostatically Pressed Products
Isostatic pressing provides a very good homogeneous and solid, i.e. strongly densified, brick structure due to the even compression during the manufacturing process. The shaping technologies normally used in the refractory industry, such as hydraulic pressing,, hand ramming, slip casting and vibration casting do not achieve this even distribution or the densification of each raw material component.
Isostatically pressed products are characterized by their outstanding material properties, e.g. a very high corrosion resistance against glass-type melts. The main areas of use are the glass contact areas in the glass fiber industry (textile glass, glasswool and mineral wool industries). In these industries isostatically pressed products with contents of zirconium, chromiumoxide and chromium corundum are used.
Isostatically pressed products with contents of zirconium mullite, chromiumoxide and chromium corundum were developed many years ago and successfully introduced for use in soda-lime glass and silica melting plants. Certain high stress zones in glass melters often show premature wear, together with an increase in the number of glass faults and a diminished melting capacity when these areas are lined with AZS material. Extremely longer life times and considerably improved glass qualities are achieved by the use of isostatically pressed products at these weak spots. These products are almost in standard use these days for the lining of glass melting plants, and contribute considerably to diminishing production costs and improved glass quality, and overall, the profitability of the plant.
Fused Silica Products
The basic raw materials for these products are silica glass (also called quartz), and glassy set SiO2, which is manufactured by electric melting of high quality quartz sands (> 99,5 SiO2).
Shaping of the fused silica products is achieved by pressing or slip casting in the presence of chemical binders. The moldings are tempered in a defined way. These products typically have an extremely low thermal expansion coefficient which makes them ideal for use as a hot repair material. When used at temperatures above 1150°C, the product is irriversably converted into Cristobalit.
Fused silica products are used in the glass industry, as an acid-resistant lining in the chemical industry, and as a hot repair material (for glass melters and coke oven plants).
SiC Products
SiC products are based on synthetically manufactured silicon carbide grains with selected bonding components and metal oxide additives tuned to the use. The excellent characteristics of SiC products, such as high thermal conductivity and high corrosion resistance against numerous process media make it particularly ideal for use in high temperature furnaces and in waste incineration plants.
Heat Insulation Products
Basic raw materials for insulating and lightweight refractory bricks with an overall porosity of > 45% are porous materials, such as diatomite, vermiculite, hollow sphere corundum or -ash with different alumina contents, as well as volatile, flammable or foam-forming additives and burning substances.
Modern hydraulic presses enable the manufacture of large scale bottom blocks for the insulation of the bottom of glass melters. Another area of application is heat insulation in thermal industrial plants.
To characterize heat-insulating products the application limit temperature is used at which the material will not show any after-contraction of not more than 2% within 12 or 24 hours (DIN EN 1094-2 and ASTM C 155). Another distinction can be made according to the used raw materials, such as vermiculite brick, diatomite brick, perlite brick, silica light brick, sillimanite brick or hollow sphere corundum brick. Also possible is the classification according to the application limit temperatures into insulating bricks used in temperatures below 1,000 ° C and into refractory lightweight bricks at temperatures above 1,000 ° C.
Cordierite Products
The basic raw materals for cordierite products are cordierite fireclay and special MgO-substrates which contribute to the cordierite formation at the point of an Al2O3 and SiO2 surplus, in particular in the bonding matrix. Usually shaping is done by hydraulic dry pressing, in particular for the manufacture of large shaped kiln furnace covers.
Cordierte rich products are characterized by their excellent thermal shock resistance due to their very low reversible heat expansion. Their main area of use in kiln cars and as kiln furniture for ceramic firing furnaces relies on the latter.
