Refractory Bricks With High-Temperature Resistance&High-quality And Durability&Lower Energy Costs

Brictec Successfully Completes Thermal Shock Resistance Test for Refractory Bricks, Demonstrating Expertise in Brick Plant Construction

With 15 years of experience in complete plant process design and project construction for clay-fired brick production, Brictec has recently completed thermal shock resistance tests for tunnel kiln refractory bricks and kiln car refractory bricks. These tests not only verified the performance of refractory materials under extreme temperature variations but also demonstrated Brictec's professional approach to material selection and quality control in brick plant construction.

Importance of Thermal Stability Testing
In sintered brick production, tunnel kiln refractory bricks and kiln car refractory bricks are directly exposed to high-temperature impacts and frequent thermal cycling. Tunnel kiln bricks must withstand continuous operating temperatures above 1000°C, while kiln car bricks endure severe thermal shocks during the loading/unloading of red brick green bodies. Inadequate thermal stability can lead to cracking and spalling, significantly affecting kiln service life and production safety.

Brictec's Rigorous Testing Protocol
To ensure refractory bricks meet operational requirements, Brictec has established strict "Refractory Brick Thermal Shock Resistance Testing Standards":

Sample Preparation: Specimens cut from production batches according to GB/T 3997.1

Equipment: Program-controlled electric furnace with water quenching system

Procedure:

Heat specimens to 1100°C for 30 minutes

Rapidly quench in 20°C water

Repeat cycles until failure occurs

Evaluation: Strength retention rate after 20 cycles (≥80% qualified)

Quality Assurance for Construction Projects
During testing, Brictec utilized temperature monitoring systems integrated with (clay brick making machines) for accurate data collection. Our engineering team paid special attention to refractory performance in actual (red brick making machine) production lines, using test results to select optimal materials for ongoing projects.

The Importance of Refractory Bricks to the Quality of Kiln Cars:
Refractory bricks play a crucial role in the quality of kiln cars. Here are the specific aspects of their importance:
1. High-Temperature Resistance
Kiln cars are exposed to extremely high temperatures during the firing process, often above 1000ºC. Refractory bricks, with their excellent high-temperature resistance, ensure that the kiln cars remain structurally stable and do not deform or get damaged under such conditions. For example, in the firing of ceramic products, refractory bricks can withstand prolonged exposure to high temperatures, guaranteeing the normal operation of the kiln cars.
2. Thermal Insulation
Refractory bricks have good thermal insulation properties, which effectively reduce heat transfer. This not only minimizes heat loss from the kiln cars themselves but also protects the steel structure parts from high-temperature erosion. Good thermal insulation can significantly extend the service life of kiln cars and improve firing efficiency by reducing energy consumption.
3. Corrosion Resistance
The firing environment is complex and may involve the erosion of chemical substances. Refractory bricks, with their strong corrosion resistance, can withstand the erosion of acids, alkalis, and other chemicals, thereby extending the service life of kiln cars. For example, in the firing of glass products, refractory bricks can effectively resist the erosion of molten glass, ensuring the long-term stable use of kiln cars.
4. Structural Stability
Refractory bricks, with their high strength and density, can withstand significant weight and pressure. Kiln cars, which carry a large number of ceramic products or other firing materials during operation, rely on refractory bricks to provide adequate support and ensure structural stability. Additionally, the wear resistance of refractory bricks reduces wear caused by frequent use.
5. Service Life
High-quality refractory bricks can significantly extend the service life of kiln cars. The durability of refractory bricks reduces the frequency of maintenance and replacement, lowering production costs. For example, kiln cars using high-quality refractory bricks can be used continuously for many years without frequent replacement, which is significant for improving production efficiency and reducing production costs.
6. Energy-Saving Effects
The thermal insulation properties of refractory bricks can reduce heat loss and thus improve the thermal efficiency of the kiln. This not only reduces energy consumption but also reduces carbon emissions during the production process, meeting environmental requirements. For example, kiln cars using highly efficient insulating refractory bricks can reduce heat loss by more than 30%, significantly lowering energy costs.
The Importance of Rigorous Manufacturing Steps for Kiln Cars
Rigorous manufacturing steps are key to ensuring the quality and performance of kiln cars. Here are the specific aspects of their importance:
1. Design and Planning
The design of kiln cars is the first step in the manufacturing process. A rigorous design ensures that the structure is rational and the functions are complete. The design phase needs to consider various factors such as the size of the kiln car, its load-bearing capacity, operating speed, and high-temperature resistance. Through precise design, the structure of the kiln car can be optimized to improve its operating efficiency and service life.
2. Material Selection
Choosing high-quality materials is the foundation for manufacturing high-quality kiln cars. Refractory bricks, steel structure materials, insulating materials, and others all need to be carefully selected to ensure they meet design requirements. High-quality materials can improve the high-temperature resistance, corrosion resistance, and structural stability of kiln cars. For example, using high-quality refractory bricks and high-strength steel can significantly extend the service life of kiln cars.
3. Manufacturing Process
The manufacturing process of kiln cars is crucial. A rigorous manufacturing process includes precise cutting, welding, assembly, and other steps. For example, welding processes need to ensure the strength and sealability of the welds to avoid structural failures due to welding defects. During the assembly process, operations must be carried out strictly according to the design drawings to ensure that all parts are installed accurately.
4. Quality Control
Strict quality control during the manufacturing process is key to ensuring the quality of kiln cars. Each process needs to be inspected for quality to ensure compliance with design standards. For example, the laying of refractory bricks needs to be flat and tight, avoiding gaps or voids. The steel structure parts need to undergo strength tests to ensure they can withstand the designed load.
5. Testing and Commissioning
After the kiln car is manufactured, it needs to undergo rigorous testing and commissioning. Testing includes running tests, high-temperature resistance tests, load-bearing capacity tests, and more. Through testing, potential problems can be identified and adjustments and repairs can be made in a timely manner. For example, during running tests, the smoothness of the kiln car's operation can be checked to ensure its reliability in actual use.
6. Maintenance and Care
Rigorous manufacturing steps also include a maintenance and care plan for kiln cars. High-quality kiln cars require regular inspection and maintenance to ensure long-term stable operation. For example, regularly inspecting the wear of refractory bricks and promptly replacing damaged parts can extend the service life of kiln cars.
By following rigorous manufacturing steps, the quality and performance of kiln cars can be ensured, improving production efficiency, reducing production costs, and extending the service life of kiln cars.