Various industries, such as petrochemicals, machinery, energy, on and steel, non-ferrous metal, military, and others, widely use refractories in multiple applications. Refractory materials play a crucial role in ensuring the seamless manufacturing operations of the above-stated industries.
According to a report by Extrapolate, the global refractories market size is projected to grow to $29.5 billion by 2028, expanding at a CAGR (compound annual growth rate) of 5.6% between 2022 and 2028.
In this blog, let us have a look at the various types of refractories available.
Best Refractory Materials
Following are the different types of refractory materials that can be used in various industrial applications:
1. Fired Refractory Products
Refractory materials derived by molding, drying, kneading, and high-temperature firing of granular and powdery refractory resources and binders are referred to as fired refractory materials.
Fired refractory products are utilized in a wide range of high-temperature industrial applications because of their excellent thermal stability, mechanical strength, and resistance to chemical corrosion. Metallurgical, cement, glass, ceramic, energy, petrochemical, incineration, and waste treatment are a few of the industries where fired refractories are used.
2. Non-Fired Refractory Products
Non-fired refractory products are materials designed to withstand high temperatures, chemical corrosion, and mechanical wear without being subjected to the high-temperature firing process typically used to produce traditional refractory products.
Non-fired refractory products find applications in various industrial processes where high temperatures, chemical resistance, and durability are required. Steel and metal industries used it in steelmaking, casting, and forging operations to line furnaces, ladles, tundishes, and other high-temperature equipment. It offers thermal insulation and erosion resistance and can withstand thermal cycling.
3. Special Refractory
A type of refractory material with particular properties derived from one or more oxides with high melting points, carbons, or refractory non-oxides is Special refractory.
Special refractories are designed for specific applications where standard refractories may not meet the required performance criteria. These materials are tailored to withstand extreme conditions such as high temperatures, aggressive chemical environments, rapid thermal cycling, or mechanical stress.
Special refractories find applications in the non-ferrous metals industry, foundries, glass industry, aerospace and defense, electronics and semiconductor industry, and other industries.
4. Monolithic Refractories
Monolithic refractories are also referred to as refractory concrete or bulk refractory. It has refractory materials with a substantial gradation of granular, powdery refractory resources, binders, and multiple admixtures that are not fired at high temperatures. Additionally, they are utilized directly post mixing, molding, and grilling the material.
They find various applications across multiple industries where they offer flexibility, ease of installation, and superior performance in challenging environments. Monolithic refractories are used in facilities for hazardous waste treatment, where they withstand high temperatures and aggressive chemicals. It also has a wide range of applications in other industries as well.
5. Functional Refractory Materials
Both fired or non-fired refractory materials, which are assorted with granulated and powdered refractory resources and binders to create a specific shape and have particular smelting applications, are functional refractory materials.
Functional refractory materials are specialized materials that go beyond traditional refractories to provide additional functionalities beyond thermal insulation and resistance to high temperatures. The materials improve thermal insulation properties, reducing heat loss and improving energy efficiency in industrial kilns, furnaces, and reactors. It offers effective resistance to chemical attack from molten metals, acids, alkalis, and slag in industries such as petrochemicals, chemicals, and non-ferrous metals.
6. Clay Bricks
Aluminum silicate refractory materials made from glass phase, cristobalite, and mullite with aluminium oxide content of 30% to 48% are clay bricks. Refractories bricks made from clay are generally used in glass kilns, rotary kilns, hot blast stoves, and masonry blast furnaces.
7. High Alumina Bricks
Refractories with an aluminum oxide content of more than 48% and mainly made from glass, mullite, and corundum are referred to as high alumina bricks.
The applications of high alumina bricks are found in the metallurgy industry to develop the plug and nozzle of a hot air furnace, pouring system, blast furnace, electric furnace roof, and steel drum.
8. Silica Bricks
There is a difference between silicon and silica. Silicon is present as a single element in nature. Additionally, it has a brittle crystalline structure.
On the other hand, silica is a composite material of silicon and oxide. Refractory bricks made from silica act as a good refractory material. These silica bricks have a content of more than 93%. Glass, phosphorous quartz, residual quartz, and cristobalite are the other components. These bricks are used in the construction of glass-melting furnaces due to their high resistance to thermal shock and ability to withstand the corrosive action of molten glass. It is also commonly used in the construction of coke oven walls, where they endure prolonged exposure to high temperatures and acidic gases.
Refractories ceramic kilns can withstand high temperatures and thermal cycling. Silica bricks are leveraged in the lining of hot blast stoves in iron and steel manufacturing due to their excellent high-temperature performance.
In other high-temperature industrial furnaces, these bricks are suitable for use where their high refractoriness and resistance to acidic environments are beneficial.
9. Magnesium Bricks
Alkaline refractory materials manufactured with press-molded and sintered raw materials like fused magnesia or sintered magnesia are magnesium bricks. These bricks are popular for their high refractoriness, excellent resistance to basic slags, and good thermal conductivity.
The applications of magnesium refractory bricks are found in mixed iron furnaces, electric furnaces, and open-hearth furnaces. It is also used as a flue gas desulfurization system to resist corrosion from acidic gases and high temperatures in power plants and industrial facilities. They are also leveraged in lime recovery kilns in the pulp and paper industry, providing durability and resistance to thermal cycling and chemical corrosion.
10. Corundum Bricks
Refractories that have alumina content greater than or equal to 90% and corundum as the main phase are corundum bricks.
The corundum bricks are utilized in fining outside the furnace, sliding nozzles, and blast furnaces.
Wrapping Up
Various types of refractory materials meet different industrial requirements. Many players are in the process of manufacturing and supplying refractories. Harbisonwalker International, IFGL Refractories Ltd, and Kurosaki Harima Corporation are a few of the key players in the refractory industry. Enterprises should look out for uncompromised quality refractory materials at the best price for their industrial equipment.
