Production process of refractory bricks

Different types of refractory bricks may have differences in proportioning, molding, drying, sintering, etc. In the production process, it is necessary to operate in strict accordance with relevant technical standards and specifications to ensure product quality and stability. The following is a detailed introduction to the production process of refractory bricks.
1. Purchase raw materials
Due to the large scale, high output and variety of refractory brick production, the sources of main raw materials are relatively wide. Therefore, strict quality control must be carried out on the purchased raw materials. Before the purchase of raw materials, the supply department and the technical department must inspect the supplier manufacturers, mainly to inspect the product quality, supply capacity, quality assurance, supply reputation, etc. of the supplier manufacturers, and select a few of them as business objects. Supply at a fixed point and before each supply, samples must be taken and tested to pass the test, and the technical and supply departments will write an inspection report, and then notify the supplier to supply the standard sample taken. Otherwise, certain penalties will be imposed on those responsible.
After the raw materials enter the factory, the full-time raw material acceptance personnel of the technical department will first inspect and accept them, and take samples for testing. If only one of the physical and chemical indicators fails, the batch of materials will be considered unqualified and will not be put into use.
Zhengzhou Zhenjin Refractory Co., Ltd. introduced Japanese X-ray fluorescence spectrometer monitoring equipment to quickly and accurately monitor various indicators of refractory brick raw materials to ensure stable performance of raw materials.
2. Inspection of raw materials
For qualified refractory brick raw materials, before they are put into use, they must also pass manual block inspection. Material pickers must be equipped with chisels, hammers, forks, and sieves to remove all molten and low-melting materials in the raw materials. The piles are stacked in different grades, and then checked and accepted by the technical department, and those who pass the test are put into use, and those who are not qualified are reworked and reselected until they are qualified.
3. Crushing raw materials
The selected refractory brick raw materials must be crushed in strict accordance with the requirements of the process regulations, and the materials of various materials must meet the process requirements, and the unqualified ones are absolutely not allowed to flow into the next process.
4. Stirring
It must be carried out according to the process regulations (bonding agents, additives, water, coarse materials, and fine materials are carried out according to the process). At the same time, it is necessary to check whether the water used is pure, the amount of chemical bonding agent added must be accurate, and the stirring time must be guaranteed.
5. Mixing
After kneading, the mud is stored at a certain temperature and temperature for a certain period of time to fully react (sleeping material). The material is mixed evenly, ground, and the binder is added before it can be put into molding.
6. Compression molding
The mixture is formed after kneading or re-kneading after trapping. Multi-clinker products are usually formed by semi-dry pressing. The forming method and forming pressure have an influence on the fine density, structural strength and slag resistance of bricks.
Zhengzhou Zhenjin Refractories Co., Ltd. adopts 2500 tons of hydraulic presses. According to the specifications and sizes of refractory bricks, the models of refractory brick briquetting machines are: 500 tons, 800 tons, 1000 tons, 1500 tons, 2000 tons, 2500 tons and other models. The pressure is high, it can be formed at one time, the pressing density is high, the appearance of the pressed refractory brick product is smooth and beautiful, the output is much higher than other brick machines, the hydraulic system has high efficiency, low energy consumption, and the pressing cycle is short.

7. Drying
The semi-dry pressed compact has low water content and shortens the water evaporation time, so it can be dried quickly, or directly loaded into the kiln. The adobe with more water can be pre-selected for proper natural air drying or hot air heating and drying, otherwise the moisture will be discharged rapidly and cracks will be produced. At the same time, more damage will easily occur during transportation and kiln installation. Therefore, it needs to be dried before being sent to the tunnel kiln.
8. Kiln loading/firing
When loading the kiln car, it needs to be stable and straight. The purpose of firing is to sinter the adobe so that it has a certain strength in terms of size, fineness and porosity. The mechanical strength should be high, the volume stability is good, and the fire resistance is good. .
9. out of the kiln
After the finished refractory bricks are fired, they are released from the kiln according to the requirements. The bricks must be handled with care, and the qualified rate of the finished products should be controlled at above 98%.
10. Brick polishing
For refractory bricks with uneven surfaces, carefully level them with a grinder to prevent uneven force in the kiln and cause them to fall off.
11. Storage
After the finished refractory bricks leave the kiln, they must be checked and accepted, and then they must be cleaned, numbered, and labeled. Each qualified brick must be labeled with a label, and the stacking must be neat.
12. Packaging
After the finished refractory bricks are checked and accepted, they can be packaged as required. When packing, it should be handled with care, the binding rope should be neat, each brick type should be marked, and the inspector can only leave the factory after the package is accepted by the inspector.
Zhengzhou Zhenjin Refractories Co., Ltd. uses palletizing robots for packaging refractory bricks. Palletizing robots, commonly known as mechanical arms, use computer-controlled equipment to replace manual handling, which can improve labor efficiency and save costs.