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[October 2004]
Insalcor Bricks Successful in Hot Face Application
Three high temperature batch kilns lined with Thermal Ceramics Insalcor bricks on the hot face have been operating successfully for over two years at Thermal Ceramics' own plant in England. With 60 to 85 cycles per year for each kiln, these fast fire units have soak temperatures in the range of 1400°C to 1600°C. No significant maintenance has been undertaken on the Insalcor brick linings in any of the kilns and all of the wall and roof linings are reported to still be in excellent condition.
The Insalcor brick has performed better than the dense brick construction of the previous kilns, which periodically required extensive rebuilding of the structure, usually every two years. The low density of the Insalcor product has also contributed to a significant reduction in energy use during these high temperature kiln cycles. Combined with the minimal maintenance requirements, substantial reductions in overall operational costs have been achieved.
The three kilns involved are a 12 cubic metre two-car batch kiln, a 4.5 cubic metre fixed hearth, swing door kiln and a 1 cubic metre elevator kiln. All the kilns are gas fired and the two large kilns are exhausted through the loading deck. These kilns fire an extensive range of refractory components in a variety of alumina, magnesia and zirconia compositions.
Over 21,000 Insalcor straight, arch and tongue and groove bricks were used in the construction of the three kiln hot face linings and flues. The bricks are tied back to the structure with Cerox anchor bricks and stainless steel anchors.
Insalcor is a 77% alumina, mullite bonded, bubble alumina brick. It has a 1785°C maximum service use limit, excellent high temperature strength and good thermal shock resistance. This medium density brick also features insulation thermal conductivity values half those of conventional dense alumina firebrick.
www.thermalceramics.com
ENDS