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Insulating Firebrick (IFB)

  • Mullite Insulating Firebrick (IFB)

    Mullite Insulating Firebrick (IFB)

    Mullite Insulating Firebrick (IFB) are using for Hot Surface and Back-up lining insulation, and it has a characteristic of light weight, low thermal conductivity, low heat storage, small reheat shrinkage, high thermal stability and suitable for superior resistance to reductive atmosphere.

    Mullite Insulating Firebrick are made from a variety of oxides, most commonly fireclay or mullite. The desirable features of these brick are their light weight and low thermal conductivity, which usually results from a high degree of porosity.

    The high porosity of the Mullite Insulating Firebrick is created during manufacturing by adding polystyrene microsphere or a fine organic material to the mix, such as sawdust. During firing, the organic addition burns out, creating internal porosity. Another way to accomplish high porosity involves the addition of a foaming agent to slip. Using this approach, insulating brick can be cast instead of dry pressed. Additions of lightweight aggregates like diatomite, haydite, etc., is another approach.

    Because of their high porosity, Mullite Insulating Firebrick inherently have lower thermal conductivity and lower heat capacity than other refractory materials. ASTM classifies fireclay and highalumina insulating refractories in the following sequence: 16, 20, 23, 26, 28, 30 and 33. These numbers multiplied by 100 represent the nominal service temperature in degrees Fahrenheit to which the refractory can be exposed in service. Typically a 150 to 200°F safety factor is used in selecting the appropriate brick. Products numbered from 16 to 26 are made from a fireclay base and products numbered from 28 to 33 are made from a high-alumina base.
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    Typically, Mullite Insulating Firebrick are used as backup materials, but they can also be used as working linings of furnaces where abrasion and wear by aggressive slag and molten metal are not a concern. Special insulating refractories offering significantly higher strength than standard IFB’s are also available. These can be used in applications requiring load bearing ability.

    Another type of IFB brick is those based on high purity hollow sphere alumina. These products can be used in high temperature ceramic kiln application and some high corrosive applications as either hot face or back up lining materials.

    Where they can be used, Insulating Firebrick offer several distinct advantages:

    Savings in fuel cost due to decreased heat losses through the furnace lining and less heat loss to the refractory.

    Faster heat-up of the lining due to the insulating effect and lower heat capacity of the insulating refractory.

    Thinner furnace wall construction to obtain a desired thermal profile.

    Less furnace weight due to the lower weight of the insulating refractory.

    A variety of insulating brick provide a range of thermal efficiencies and strengths.

    OSYMEN also manufacturers a full range of insulating castable, gunning mixes, and ceramic fiber products to provide additional insulating lining options.

     

    References

    1. ^ Modern Refractory Practice, Fifth Edition (Harbison–Walker Refractories: Pittsburgh, Pennsylvania, 1992), Page CR-2
    2. ^ Modern Refractory Practice, Fifth Edition (Harbison–Walker Refractories: Pittsburgh, Pennsylvania, 1992), Page CR-3
    3. ^ Refractory Engineering. Die Deutsche Bibliothek. 2004. ISBN 3-8027-3155-7.

    Further reading

    More+

    Mullite Insulating Firebrick (IFB) are using for Hot Surface and Back-up lining insulation, and it has a characteristic of light weight, low thermal conductivity, low heat storage, small reheat shrinkage, high thermal stability and suitable for superior resistance to reductive atmosphere.

    Mullite Insulating Firebrick are made from a variety of oxides, most commonly fireclay or mullite. The desirable features of these brick are their light weight and low thermal conductivity, which usually results from a high degree of porosity.

    The high porosity of the Mullite Insulating Firebrick is created during manufacturing by adding polystyrene microsphere or a fine organic material to the mix, such as sawdust. During firing, the organic addition burns out, creating internal porosity. Another way to accomplish high porosity involves the addition of a foaming agent to slip. Using this approach, insulating brick can be cast instead of dry pressed. Additions of lightweight aggregates like diatomite, haydite, etc., is another approach.

    Because of their high porosity, Mullite Insulating Firebrick inherently have lower thermal conductivity and lower heat capacity than other refractory materials. ASTM classifies fireclay and highalumina insulating refractories in the following sequence: 16, 20, 23, 26, 28, 30 and 33. These numbers multiplied by 100 represent the nominal service temperature in degrees Fahrenheit to which the refractory can be exposed in service. Typically a 150 to 200°F safety factor is used in selecting the appropriate brick. Products numbered from 16 to 26 are made from a fireclay base and products numbered from 28 to 33 are made from a high-alumina base.
    Mullite Insulating Firebrick 01 www.osymen.com  Mullite Insulating Firebrick 02 www.osymen.com

    Mullite Insulating Firebrick 03 www.osymen.com  Mullite Insulating Firebrick 04 www.osymen.com

    Mullite Insulating Firebrick 06 www.osymen.com  Mullite Insulating Firebrick 05 www.osymen.com

    Mullite Insulating Firebrick 07 www.osymen.com e1693989875865  Mullite Insulating Firebrick 08 www.osymen.com    

    Typically, Mullite Insulating Firebrick are used as backup materials, but they can also be used as working linings of furnaces where abrasion and wear by aggressive slag and molten metal are not a concern. Special insulating refractories offering significantly higher strength than standard IFB’s are also available. These can be used in applications requiring load bearing ability.

    Another type of IFB brick is those based on high purity hollow sphere alumina. These products can be used in high temperature ceramic kiln application and some high corrosive applications as either hot face or back up lining materials.

    Where they can be used, Insulating Firebrick offer several distinct advantages:

    Savings in fuel cost due to decreased heat losses through the furnace lining and less heat loss to the refractory.

    Faster heat-up of the lining due to the insulating effect and lower heat capacity of the insulating refractory.

    Thinner furnace wall construction to obtain a desired thermal profile.

    Less furnace weight due to the lower weight of the insulating refractory.

    A variety of insulating brick provide a range of thermal efficiencies and strengths.

    OSYMEN also manufacturers a full range of insulating castable, gunning mixes, and ceramic fiber products to provide additional insulating lining options.

     

    References

    1. ^ Modern Refractory Practice, Fifth Edition (Harbison–Walker Refractories: Pittsburgh, Pennsylvania, 1992), Page CR-2
    2. ^ Modern Refractory Practice, Fifth Edition (Harbison–Walker Refractories: Pittsburgh, Pennsylvania, 1992), Page CR-3
    3. ^ Refractory Engineering. Die Deutsche Bibliothek. 2004. ISBN 3-8027-3155-7.

    Further reading

    OSYMEN BRAND

    INS-JM23

    INS -JM25

    INS-JM26

    INS-JM28

    INS-JM30

    INS-JM32

    Classification Temperature

    °C

    1260

    1370

    1430

    1540

    1650

    1760

    Properties measure at ambient condition (23°C/50% RH)

    BD

    Kg/m3

    560

    800

    800

    890

    1020

    1200

    CCS

    MPa

    1.2

    2.0

    2.0

    2.6

    3.0

    4.0

    MOR

    MPa

    0.9

    1.2

    1.5

    1.6

    2.0

    2.1

    High Temperature Performance

    PLC
    at ( )°C x 24h

    %

    -0.2

    (1230)

    -0.3

    (1350)

    -0.5

    (1400)

    -0.4

    (1510)

    -0.8

    (1620)

    -0.9

    (1730)

    Thermal Conductivity (ASTM C-182) at mean temperature of

    400°C

    W/M.K

    0.16

    0.24

    0.24

    0.30

    0.38

    0.49

    600°C

    W/M.K

    0.18

    0.28

    0.27

    0.35

    0.39

    0.50

    800°C

    W/M.K

    0.22

    0.32

    0.30

    0.34

    0.40

    0.51

    1000°C

    W/M.K

    0.25

    0.37

    0.32

    0.36

    0.41

    0.53

    1200°C

    W/M.K

    0.35

    0.38

    0.42

    0.55

    Chemical Composition % (tr=trace)

    Al2O3

    %

    45.0

    50.0

    58.0

    67.1

    73.4

    77.0

    SiO2

    %

    50.0

    45.0

    39.1

    31.0

    25.1

    21.5

    Fe2O3

    %

    1.0

    1.0

    0.7

    0.6

    0.5

    0.4

    TiO2

    %

     

     

    0.1

    0.1

    0.1

    Tr

    CaO

    %

     

     

    0.1

    0.1

    Tr

    Tr

    MgO

    %

     

     

    0.2

    0.1

    Tr

    0.1

    K2O+Na2O

    %

    1.1

    1.1

    1.0

    0.8

    0.8

    0.1

    BD: Bulk Density  |  CCS: Cold Crushing Strength | MOR: Modulus of Rupture | PLC: Permanent Linear Change

    Close
  • Hollow Sphere Alumina Brick

    Hollow Sphere Alumina Brick

    Hollow Sphere Alumina Brick / Light Weight Brick , also named Bubble Alumina Brick, are for applications up to 1800°C/3270°F. These bricks have excellent insulating properties and high hot strengths. Bubble alumina bricks are made with tiny hollow insulating spheres made from high-purity alumina (also called bubble alumina).
    Alumina raw materials are melted in an electric arc furnace at 2200°C. When pouring the melt out, blow the melt with high-pressure air to make the melt dispersed into small droplets. During the cooling process, the droplets form alumina hollow balls due to surface tension effects. The hollow balls are screened to remove fine powder and big fragments and particles. Iron is removed with the magnetic iron. Broken balls are removed with a ball selecting machine. Then the alumina hollow spheres are packed as the finished products.

    Alumina does not exhibit high thermal conductivity, and when in the form of hollow spheres, its thermal conductivity is additionally reduced. Both properties make Hollow Sphere Alumina Brick an excellent insulating material that can withstand exceptionally high temperatures. Typical applications for Bubble alumina bricks include gas or electrically heated kilns and furnaces, and glass making industries.

    The Hollow Sphere Alumina Brick that contains high-alumina bubbles are often used as the working lining in ceramic kilns, backup linings in gasifiers for coal and petroleum coke, gas/oil (with heavy residue feed stock), and industrial waste. These IFBs are also used in hazardous waste and fluorine processing incinerators, hydrogen generators, auto thermal reactors for methanol production, and ammonia reformers.

    High-purity Hollow Sphere Alumina Brick are designed to withstand high temperatures and demanding environments. These bubbles themselves are an important component in refractories used for many different applications, including insulation of kiln brick and ceramic tile linings in gas turbines, backup linings in reactors, and working linings in manufacturing high-purity quartz for the electronics industry.

    Hollow Sphere Alumina Brick

    Hollow Sphere Alumina Brick / Light Weight Brick Typical Applications:

    Bright Annealing Furnace (for stainless steel, non-ferrous alloy metal), Metal Ceramic Sintering Furnace, Brazing Furnace, Semiconductor Firing Furnace and Hydrogen Atmosphere Furnace.

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    Hollow Sphere Alumina Brick 07 www.osymen.com Hollow Sphere Alumina Brick 08 www.osymen.com

    More+

    Hollow Sphere Alumina Brick / Light Weight Brick , also named Bubble Alumina Brick, are for applications up to 1800°C/3270°F. These bricks have excellent insulating properties and high hot strengths. Bubble alumina bricks are made with tiny hollow insulating spheres made from high-purity alumina (also called bubble alumina).
    Alumina raw materials are melted in an electric arc furnace at 2200°C. When pouring the melt out, blow the melt with high-pressure air to make the melt dispersed into small droplets. During the cooling process, the droplets form alumina hollow balls due to surface tension effects. The hollow balls are screened to remove fine powder and big fragments and particles. Iron is removed with the magnetic iron. Broken balls are removed with a ball selecting machine. Then the alumina hollow spheres are packed as the finished products.

    Alumina does not exhibit high thermal conductivity, and when in the form of hollow spheres, its thermal conductivity is additionally reduced. Both properties make Hollow Sphere Alumina Brick an excellent insulating material that can withstand exceptionally high temperatures. Typical applications for Bubble alumina bricks include gas or electrically heated kilns and furnaces, and glass making industries.

    The Hollow Sphere Alumina Brick that contains high-alumina bubbles are often used as the working lining in ceramic kilns, backup linings in gasifiers for coal and petroleum coke, gas/oil (with heavy residue feed stock), and industrial waste. These IFBs are also used in hazardous waste and fluorine processing incinerators, hydrogen generators, auto thermal reactors for methanol production, and ammonia reformers.

    High-purity Hollow Sphere Alumina Brick are designed to withstand high temperatures and demanding environments. These bubbles themselves are an important component in refractories used for many different applications, including insulation of kiln brick and ceramic tile linings in gas turbines, backup linings in reactors, and working linings in manufacturing high-purity quartz for the electronics industry.

    Hollow Sphere Alumina Brick

    Hollow Sphere Alumina Brick / Light Weight Brick Typical Applications:

    Bright Annealing Furnace (for stainless steel, non-ferrous alloy metal), Metal Ceramic Sintering Furnace, Brazing Furnace, Semiconductor Firing Furnace and Hydrogen Atmosphere Furnace.

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    Hollow Sphere Alumina Brick 05 www.osymen.com Hollow Sphere Alumina Brick 06 www.osymen.com

    Hollow Sphere Alumina Brick 07 www.osymen.com Hollow Sphere Alumina Brick 08 www.osymen.com

    OSYMEN

    Unit

    HSA99 -1.4

    HAS99 -1.6

    HSA99 -1.8

    HSA95 -1.4

    HSA95 -1.6

    HSA95 -1.8

    HSA90 -1.4

    HSA90 -1.6

    HSA90 -1.8

    Bulk density

    g/cm³

    1.4

    1.6

    1.8

    1.4

    1.6

    1.8

    1.4

    1.6

    1.8

    lb/ft³

    87

    100

    112

    87

    100

    112

    87

    100

    112

    Cold Crushing Strength

    Mpa

    6

    10

    12

    8

    12

    16

    10

    14

    18

    lb/in²

    870

    1450

    1739

    1160

    1739

    2319

    1450

    2029

    2609

    Refractoriness under load T0.5

    °C

    1700

    1700

    1700

    1700

    1700

    1700

    1650

    1650

    1680

    °F

    3092

    3092

    3092

    3092

    3092

    3092

    3002

    3002

    3056

    Thermal conductivity

    1000°C

    W/(m.K)

    0.9

    1.1

    1.2

    0.9

    1.1

    1.2

    0.9

    1.1

    1.2

    1832°F

    BTU/(ft²×h×°F/in)

    6.24

    7.63

    8.33

    6.24

    7.63

    8.33

    6.24

    7.63

    8.33

    Permanent Linear Change

    1600°C x3h

    %

    -0.3/0.3

    -0.3/0.3

    -0.3/0.3

    -0.3/0.3

    -0.3/0.3

    -0.3/0.3

    -0.3/0.3

    -0.3/0.3

    -0.3/0.3

    2912°F x3h

    %

    -0.3/0.3

    -0.3/0.3

    -0.3/0.3

    -0.3/0.3

    -0.3/0.3

    -0.3/0.3

    -0.3/0.3

    -0.3/0.3

    -0.3/0.3

    Chemical Analysis: Approximate (Calcined Basis)

     Al2O3

    %

    99

    99

    99

    95

    95

    95

    90

    90

    90

    Fe2O3

    %

    0.2

    0.2

    0.2

    0.2

    0.2

    0.2

    0.2

    0.2

    0.2

    SiO2

    %

    0.3

    0.3

    0.3

    Close
  • Insulating Firebrick (IFB): “B” and “C” Series

    Insulating Firebrick (IFB): “B” and “C” Series

    Insulating Firebrick (IFB) –

    series, the brick is inexpensive and offer balanced properties such as strength and thermal insulation. Therefore, they are widely used in place of other same grade products with similar service temperature.

    Typical Applications:
    > Hot Surface lining insulation of Dry furnace and Low-temperature furnace, Back-up lining insulation of Industrial furnace. (B1)
    > Hot Surface and Back-up lining insulation of Industrial furnace. (B2-B6)


    C series,
    the brick that increase the strength of compression, and it is used when the strength is insufficient in JIS B series. It is used for place of load bearing, vibration or wear for various industrial furnace.

    Typical Applications:
    > Hot Surface lining insulation of Industrial furnace

    We can produce KOREA Standard Insulating Firebrick

    Insulating Firebrick

    We can produce JAPAN Standard Insulating Firebrick

    Insulating Firebrick

    More+

    Insulating Firebrick (IFB) –

    series, the brick is inexpensive and offer balanced properties such as strength and thermal insulation. Therefore, they are widely used in place of other same grade products with similar service temperature.

    Typical Applications:
    > Hot Surface lining insulation of Dry furnace and Low-temperature furnace, Back-up lining insulation of Industrial furnace. (B1)
    > Hot Surface and Back-up lining insulation of Industrial furnace. (B2-B6)


    C series,
    the brick that increase the strength of compression, and it is used when the strength is insufficient in JIS B series. It is used for place of load bearing, vibration or wear for various industrial furnace.

    Typical Applications:
    > Hot Surface lining insulation of Industrial furnace

    We can produce KOREA Standard Insulating Firebrick

    Insulating Firebrick

    We can produce JAPAN Standard Insulating Firebrick

    Insulating Firebrick

    OSYMEN BRAND

    B1

    B2

    B3

    B4

    B5

    B6

    B7

    C1

    C2

    C3

    Classicification Temperature

    °C

    900

    1000

    1100

    1200

    1300

    1400

    1500

    1300

    1400

    1500

    Properties measure at ambient condition (23°C/50% RH)

    PLC, <±2%

    °C

    900

    1000

    1100

    1200

    1300

    1400

    1500

    1300

    1400

    1500

    BD

    Kg/m3

    700

    700

    750

    800

    800

    900

    1000

    1100

    1200

    1250

    CCS

    Kg/cm2

    30

    32

    32

    32

    32

    33

    40

    50

    70

    100

    Thermal Conductivity at mean temperature of

    350°C

    W/M.K

    0.18

    0.22

    0.26

    0.29

    0.29

    0.33

    0.37

    0.40

    0.48

    0.58

    400°C

    W/M.K

    0.19

    0.23

    0.27

    0.30

    0.30

    0.34

    0.38

    0.41

    0.49

    0.59

    600°C

    W/M.K

    0.22

    0.26

    0.30

    0.33

    0.33

    0.37

    0.41

    0.44

    0.52

    0.62

    800°C

    W/M.K

     

     

    0.34

    0.35

    0.36

    0.41

    0.44

    0.47

    0.57

    0.65

    1000°C

    W/M.K

     

     

     

     

     

    0.45

    0.49

     

    0.62

    0.70

    Chemical Composition

    Al2O3

    %

    20.0

    20.0

    25.0

    42.0

    42.0

    46.0

    70.0

    42.0

    46.0

    70.0

    SiO2

    %

    65.0

    65.0

    60.0

    54.0

    54.0

    50.0

    28.0

    54.0

    50.0

    28.0

    Close
Last updated: 2024-01-03
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