Production Process of Magnesia Carbon Bricks

Magnesia-carbon bricks are carbon-bonded alkaline bricks that are prepared from magnesia, carbon raw materials, organic binders, and admixtures and are kneaded, high-pressure formed, and treated at low temperatures. This brick takes full advantage of the advantages of alkaline materials and carbon materials, so it has excellent thermal shock resistance, peeling resistance, slag resistance, and high-temperature creep resistance. Magnesia carbon brick is an ideal lining material for metallurgical smelting furnaces and has received great attention from various countries. At present, our country can produce ordinary and high-strength magnesia carbon bricks, as well as functional products such as magnesia carbon breathable bricks, which can basically meet the needs of the development of the metallurgical industry.

Rongsheng Magnesia Carbon Bricks

Magnesium Carbon Refractory Material Furnace Lining

Magnesia-carbon refractory materials are used as furnace lining refractory materials. They effectively utilize the slag corrosion resistance of magnesia and the high thermal conductivity and low expansion of carbon, compensating for the biggest shortcoming of magnesia’s poor spalling resistance. It mainly has the following excellent properties.

(1) High-temperature resistance.

MgO and C have no eutectic relationship at high temperatures, and their melting points are both relatively high. The melting point of magnesium oxide is 2800°C, and the melting point of carbon is above 3000°C. Therefore, the magnesium-carbon refractory material made by combining the two has a higher melting point and better high-temperature resistance.

(2) Strong resistance to alkaline slag corrosion.

MgO itself has strong resistance to alkaline slag and high-speed iron slag. The wetting angle of graphite to slag is large, and its wetting performance with molten slag is very poor.

(3) Good thermal shock stability.

Among magnesia-carbon refractory materials, graphite has a high thermal conductivity, a low thermal expansion coefficient, and a small elastic modulus. Therefore, the refractory material has good thermal shock stability.

The performance of MgO-C bricks is mainly affected by the main and auxiliary raw materials and chemical composition, the relative content of each component, and the mixture structure. However, the type of binder, processing, and molding techniques also play an equally important role.

MgO-C bricks

Magnesia Carbon Bricks Production Process

Selection of raw materials. The raw materials for producing MgO-C bricks (https://rsrefractoryfirebrick.com/magnesia-carbon-bricks) are mainly magnesia. Its technical requirements are high purity, few impurities, complete particle crystal development, uniform texture, low porosity, and high volume density. Magnesia is divided into fused magnesia and sintered magnesia, but gradually replacing part of the sintered magnesia with fused magnesia can significantly improve corrosion resistance. The carbon raw material generally uses natural flake graphite. It has no eutectic relationship with oxides such as MgO and does not form low-melting materials. It has high thermal conductivity, small elastic modulus, low thermal expansion coefficient, and is non-wetting.

The binder is the key material for the production of MgO-C bricks. Its technical requirements include: (1) The wetting angle for carbon materials is small and the affinity is good. (2) The residual carbon rate is high. (3) Less impurities and moisture content. Commonly used binding agents include phenolic resin, modified phenolic resin, and tar asphalt. Nowadays, most MgO-C bricks are produced using synthetic phenolic resin. Admixtures mainly include unit metals and multi-element metal powders such as Al, Mg, Si, Al-Mg, AI-Si, and Al-Mg-Ca. B4C, Al8BC7, Al4SiC4, and other carbon pure substances and complex alkalized substances. As well as borides such as ZrB2, MgB, CaB6.

Proportion. 5-1(3-1)mm magnesia 50~60%. <1mm magnesia 10%. <0.074mm magnesia+graphite+additive 30~40%. Resin 5% (additional).

Drill. The feeding sequence is generally magnesia particles – binder – graphite – magnesia fine powder and mixed fine powder of additives. It is best to perform it in kneading equipment with a heating device so that the resin has good flow properties and can achieve uniform distribution.

forming. When using a hydraulic press to produce MgO-C bricks, the pressure is generally required to reach 115~200MPa. The number of pressurization times cannot be less than 15 times.

Magnesia carbon brick molding

heat treatment. MgO-C bricks are generally processed at a temperature of 200~250℃. heating system. 50~60℃, because the resin softens, it should be kept warm. 100~110℃, a large amount of solvent will be discharged, so it should be kept warm. 200 or 250℃, to complete the reaction, it should be kept warm.

It is not difficult to see that the production of MgO-C bricks has reached its limit from raw materials to technology. Therefore, the performance improvement of existing MgO-C bricks will be slow and very limited. In addition, resources are limited. Since graphite is easily oxidized, the high-temperature reaction between magnesium chloride and graphite always exists, especially in a vacuum metallurgical environment.

The redox reaction of MgO-C bricks and the redox reaction of oxide inclusions and carbon are determined by the nature of the material. The ease of oxidation of graphite is the dominant aspect that determines this nature. Therefore, artificial modification of graphite is an effective way to solve this problem. Only in this way can the chemical compatibility conditions of MgO-C bricks be further improved, thereby promoting the development of MgO-C bricks.

What Technical Measures Should be Taken to Improve the Life of Magnesia Carbon Brick Furnace Walls?

Magnesia carbon bricks have evolved from tar-bonded bricks and fired oil-immersed bricks in recent years. It is made of sintered magnesite or fused magnesite and carbon material graphite as raw materials. Using carbon-containing resin as a binder, after mixing, molding, and heat treatment at about 220°C, the carbon forms a continuous network phase to wrap the periclase grains. Based on the usage characteristics of magnesia carbon bricks and the requirements of the working environment, what technical measures should be taken to improve the life of magnesia carbon brick furnace walls? It is also the common goal of refractory brick material manufacturers and enterprises.

Magnesia Carbon Bricks for Ladle

The main characteristics of magnesia carbon bricks

① When pressed, graphite tends to have a layered structure, and the bonding between graphites and between graphite and periclase is poor and loose. Therefore, the normal temperature strength of magnesia carbon bricks is low. In order to improve the density and strength of bricks, they must be formed by high pressure.

② Graphite has low thermal expansion and high thermal conductivity, and magnesia carbon bricks have good thermal shock resistance.

③ Graphite is not wetted by slag and has high chemical stability. Therefore, when the carbon in magnesia carbon bricks forms a continuous network, it has strong slag resistance.

④ The carbon in magnesia carbon bricks is easily oxidized. When baking at low temperatures, it must be done in isolation from the air and cannot be fired in the air. Adding a small amount of fine powders such as Al, Si, Mg, and carbide to magnesia carbon bricks can also prevent the oxidation of carbon.

RS Magnesia Carbon Bricks for the Steel Ladle

What technical measures should be taken to improve the life of magnesia carbon brick furnace walls?

(1) Increase the proportion of large-grained magnesia and increase the volume density of the furnace lining

The erosion of refractory materials by slag and the redox reaction of MgO-C start from the grain boundaries and foreign substances located at the grain boundaries. The use of high-purity, large crystalline magnesia helps improve the corrosion resistance and oxidation resistance of magnesia carbon bricks.

(2)Using high-purity graphite

The use of high-purity graphite to make bricks has also received attention. The type and particle size distribution of graphite has an impact on the porosity, high-temperature strength, and MgO-C reaction of bricks in oxidizing and reducing atmospheres after carbonization.

(3)Add additives

Metal additives such as Al, Si, and Mg or their mixtures and alloys are easier to react with oxygen than graphite. Therefore, it plays a role in preventing the oxidation of graphite, and the carbide formed can improve the mechanical properties of the brick.

Research on non-oxide additives is increasing day by day, mainly boride, carbide, and nitride have high oxygen affinity. Their oxides can form a liquid protective layer on the surface of the bricks.

(4) Vacuum oil immersion

At high temperatures, CO escapes from magnesia-carbon bricks, resulting in carbon loss. The increase in apparent porosity after carbonization will affect its service life. Oil-immersing the bricks can seal the pores and reduce the porosity after carbonization. Improving corrosion resistance is also a way to improve the quality of magnesia carbon bricks.

After vacuum oil immersion, magnesia carbon bricks are used for slag lines and hot spots in high-temperature areas of electric furnace walls. It not only improves the performance of bricks but also avoids the potential hazards caused by the use of metal additives.

(5)Choose the appropriate binding agent

Phenolic resin binders have high residual carbon content after pyrolysis. The highest residual carbon content is 50% to 60% and rarely reaches 70%. The hardened high-polymer resin has good uniformity, few defects in the network structure, high strength, and less environmental pollution.

Asphalt binders can be better graphitized and have higher antioxidant stability. However, cracks are easy to occur inside the bonded carbon and the strength of the product is reduced.

The application of asphalt-resin composite forms a fine mosaic structure, which enhances the fracture toughness of the carbon bond and strengthens the carbon bond to improve oxidation resistance. The practical application effect is good.

The damage process of magnesia carbon bricks during use is oxidative decarburization ➡ loose structure ➡ erosion ➡ erosion. The oxidation rate of carbon can be slowed down with the help of antioxidants. The practice has proved that adding metal or alloy powder can improve the performance of magnesia carbon bricks, and the use effect is better. When the addition amount is 3%~5%, the high-temperature flexural strength is increased by about 3 times. This is because oxides, carbides, and new mineral phases of corresponding metals are generated in the bricks, which block the pores and reduce the permeability of the product, thereby inhibiting or slowing down the oxidation of carbon and improving the high-temperature performance of the product. Of course, there will also be other shortcomings in the use of magnesia carbon bricks. Through many experiments, improving the raw material configuration of magnesia-carbon bricks and the use of additives will make up for the shortcomings of magnesia-carbon bricks and enable magnesia-carbon bricks to achieve their best performance.

Corrosion Causes and Loss Mechanism of Magnesia Carbon Bricks in Electric Furnace Lining

The inner side of the electric furnace lining carries high-temperature slag liquid, and the discharge of the high-temperature molten liquid will cause the temperature of the furnace wall to drop sharply, causing the refractory material of the furnace lining to withstand the thermal shock of sudden cooling and heating. In addition, the electric furnace lining has to withstand the chemical corrosion of molten slag and the oxidation corrosion of contact with air during the process of the liquid level drop. Therefore, the selection of refractory materials for furnace lining is very demanding. Next, the refractory bricks manufacturer will take you to understand the corrosion and wear mechanism of the electric furnace lining during normal use.

Rongsheng High-Quality Magnesia Carbon Bricks

What are the reasons for the corrosion of the electric furnace lining during normal use?

During normal smelting, the furnace lining is in direct contact with high-temperature molten steel and molten slag, and the working conditions are very harsh. There are reasons for the damage to the lining.

• (1) Thermal spalling and high-temperature chemical corrosion caused by arc radiation.
• (2) The scouring effect of molten slag, molten steel, and furnace gas on the furnace lining.
• (3) The chemical attack of molten slag on the furnace lining.
• (4) Peeling caused by temperature changes.
• (5) Spalling caused by the decomposition of the mineral composition of the lining brick itself.
• (6) The mechanical impact and erosion of the furnace lining when adding scrap steel and adding molten iron.

What is the loss mechanism of electric furnace lining magnesia carbon brick?

General magnesia-carbon bricks are made of high-quality magnesia with high-purity graphite, silicon, silicon carbide, and other additives, and phenolic resin as a binding agent. The basic requirements of the electric furnace for magnesia carbon brick are.

• (1) The thermal conductivity is low to ensure less heat loss and improve the thermal efficiency of the electric furnace.
• (2) High thermal chemical and thermal physical corrosion resistance coefficient, which requires good volume stability.
• (3) Slag resistance, peeling resistance, oxidation resistance, and high compressive strength, so as to obtain low consumption and long life.

When baking a new lining, the following main reactions will occur when the lining temperature reaches 750°C:

The above reaction 1 is mainly the generated magnesium gas and carbon monoxide gas migrate along with the pores to the high-temperature zone. Reaction 2 is that the magnesium gas on the surface of the furnace wall is oxidized to magnesium oxide by terbium again, and forms a high-melting petrographic compound with other trace compounds in the magnesia carbon brick. Therefore, controlling the temperature system of the oven to prevent a large amount of reaction 1 is the key to maintaining the volume stability of the magnesia carbon brick (https://rsrefractoryfirebrick.com/magnesia-carbon-bricks/). This is very important whether in the converter or the electric furnace. The direct consequence of the failure of the oven is the collapse of the furnace lining or the drastic reduction of the life of the furnace lining. This point has a lot of experience and lessons in most domestic manufacturers.

What You Should Know About Refractory Fire Brick – Magnesia Carbon Bricks

If you want to acquire magnesia-carbon bricks from rsrefractoryfirebrick.com, it is important that you understand something abut them before you decide to created your order. The more you understand about the bricks, the easier it will be to create a reasonable order. Read on to learn to choose the best magnesia-carbon bricks for your personal project.

The initial thing you must think of when you are setting up your brick order is the thing that temperature the bricks are going to want to get to and the way quickly the furnaces or kilns will likely be heated up. It is also important to know what substances the bricks will be subjected to.

One of several primary advantages of magnesia-carbon bricks is they are highly immune to corrosion because of the graphite content. Also you can order the bricks with special anti-oxidants that can have them in better condition for prolonged.

These bricks have excellent thermal resistant properties and they are generally also resistant to corrosion. They may also resist spalling. Be sure that the corporation you purchase the bricks from offers high quality bricks and that they provide them at a great price. You never wish to pay too much money for your personal bricks http://rsrefractoryfirebrick.com/magnesia-carbon-bricks/ and you may locate the best prices when you shop around.

The bricks works extremely well in many different applications plus they are durable which means you don’t need to bother about them failing too early. One can learn the specification sheets of the different bricks and you may also get advice from someone from the company you are likely to order from. Be sure you really know what the shipping costs are going to be of course, if there are actually any warranties that are included with the bricks. You would like to choose them wisely.

How To Use Magnesia Carbon Bricks Today

Why you use magnesia carbon bricks is caused by how they may handle heat. These bricks are typically employed by refractory companies, those who are producing components which are utilized in furnaces, fireplaces, and many other locations where extreme heat is going to be component of a project. You will be able to find a company that has these carbon bricks, and you will install them. Let’s take a look at the best way to find these firms that gives you these bricks which you can use in incinerators, furnaces, and lots of other applications.

Where Are You Finding These Firms?

Locating firms that produce http://rsrefractoryfirebrick.com/magnesia-carbon-bricks is actually quite easy. These bricks are used by 1000s of different companies nationwide. You must make sure you have the magnesia within the bricks, or they could struggle to handle the temperature. Without this, they may break very easily. You will discover manufacturers that can make the proper mixture. The most effective companies are going to have a large amount of positive feedback. The one which provides the best reviews is the one that you may use. You need to consider utilizing different types of magnesia bricks which can be more heat resistant. They will use different components and can be a little more expensive.

Other Magnesia Carbon Bricks

As opposed to utilizing the resident bonded and conventional pitch magnesia brick, you might like to have a look at people who use sintered magnesia you instead. They will also have graphite mixed within to boost their ability to handle heat. There could also be those who use just what are called antioxidants to ensure they even more heat resistant. Find one of these companies today that can provide these different products which you can use in your application that creates extreme heat.

Methods To Find Magnesia Carbon Bricks Manufacturers

Using refractory bricks for kiln and finding the best carbon bricks manufacturers is quite difficult. The ideal manufacturers have plenty of experience and they have been making magnesia carbon bricks for quite some time. They can be reliable. Where are you finding them? When you are asking yourself this query, then read on.

Get Recommendation

Begin with the folks you realize. A few of your mates may know magnesia carbon bricks manufacturers. They can refer anyone to their favorite manufacturers.

Speak to individuals this industry. These folks happen to be selling and buying rsrefractoryfirebrick.com/magnesia-carbon-bricks for many of their lives. They may help you pick the right manufacturer.

The truth is, they can tell you to avoid certain manufacturers. These manufacturers could have a negative reputation mainly because they make low-quality magnesia carbon bricks.

Select manufacturers which can be loved by so many individuals. They are reliable.

The Web Online

Nearly all companies have websites currently. These firms know the potential for the net. They search on the internet to promote their products and services. You can actually find these web sites. You only carry out a simple search on your preferred internet search engine.

Search to find the best magnesia carbon bricks manufacturers. There are actually a long list of different manufacturers. Read the reviews from the manufacturers. The ideal companies get good reviews. These are trustworthy and lots of people purchase their bricks.

Avoid manufacturers that will get negative reviews. They will likely just waste your time and expense because their magnesia bricks are not the most effective. People who run these companies may well not have any idea what they are performing.

You know where to find magnesia bricks manufacturers. Choose manufacturers http://rsrefractoryfirebrick.com/ that get good reviews on the web, have sufficient experience plus they must have excellent customer satisfaction. Tend not to go with a manufacturer that you do not know or trust.

How To Use Magnesia Carbon Bricks Today

The reason why you utilize magnesia carbon bricks is due to how they may handle heat. These are typically employed by refractory companies, those that are producing components which can be employed in furnaces, fireplaces, and lots of other areas where extreme heat is going to be element of a task. You should certainly locate a company which includes these carbon bricks, and you may install them. Let’s look at the best way to find these organizations that provides you with these bricks which you can use in incinerators, furnaces, and several other applications.

Where Do You Find These Firms?

Locating companies that produce these bricks is in fact rather easy. These bricks are being used by a huge number of different companies nationwide. You have to be sure that you may have the magnesia in the bricks, or they can be unable to handle the warmth. Without one, they can break effortlessly. You can get companies that will make the appropriate mixture. The best companies are going to have a substantial amount of positive feedback. One which has the best reviews is one that you should utilize. You must also consider using different kinds of magnesia bricks which can be a lot more heat resistant. They will use different components and can be a a bit more expensive.

Other Magnesia Carbon Bricks

As opposed to utilizing the resident bonded and conventional pitch magnesia brick, you may want to look at people who use sintered magnesia you instead. They will also have graphite mixed within to enhance their ability to handle heat. There may also be people who use exactly what are called antioxidants to ensure they are more heat resistant. Find one of these simple companies today that can provide these different products which can be used within your application that produces extreme heat.

How to find Magnesia Carbon Bricks Manufacturers?

Finding the optimum carbon bricks manufacturers is very difficult. The most effective manufacturers have plenty of experience and they have been making magnesia carbon bricks for many years. They are reliable. Where do you find them? In case you are questioning this, then read on.

1 – Get Recommendation

Get started with the folks you understand. A number of your buddies may know magnesia carbon bricks manufacturers. They are able to refer you to their best manufacturers.

Talk with folks this industry. These individuals have been buying and selling magnesia carbon bricks for most of the lives. They will help you pick the right manufacturer.

In reality, they can let you know to prevent certain manufacturers. These manufacturers could have a negative reputation since they make low-quality magnesia carbon bricks.

Select manufacturers which can be loved by so many people. They are reliable.

2 – The World Wide Web

Virtually all companies have websites nowadays. These organizations know the potential for the internet. They use the web to promote their products and services. It is easy to find websites like these. You only carry out a simple browse your favorite internet search engine.

Search for the very best magnesia carbon bricks manufacturers. There are actually a long list of different manufacturers. Search for the reviews of the manufacturers. The ideal companies get good reviews. These are trustworthy and a lot of people purchase their bricks.

Avoid manufacturers which get negative reviews. They will likely just waste your money and time because their magnesia bricks are not the ideal. Those who run these organizations might not even know whatever they are performing.

You now know where to find magnesia carbon bricks manufacturers. Choose manufacturers that get good reviews online, have enough experience and they also should have excellent customer support. Do not go with a manufacturer you do not know or trust.

Where to locate Magnesia Carbon Bricks Manufacturers?

Locating the best carbon bricks manufacturers is quite difficult. The very best manufacturers have sufficient experience and they are making http://rsrefractoryfirebrick.com/magnesia-carbon-bricks for quite a while. They may be reliable. Where do you find them? In case you are questioning this, then read more.

1 – Get Recommendation

Start out with the people you know. A number of your pals may know magnesia carbon bricks manufacturers. They could refer anyone to their best manufacturers.

Talk with folks this industry. These people have already been selling and buying magnesia carbon bricks for almost all of the lives. They can assist you select the best manufacturer.

Actually, they will tell you to avoid certain manufacturers. These manufacturers may have a negative reputation mainly because they make low-quality magnesia carbon bricks.

Select manufacturers which are loved by a lot of people. They can be reliable.

2 – The Internet

Almost all companies have websites today. These firms know the possibility of the internet. They use the internet to advertise their products and services. You can actually find these websites. You just execute a simple browse your favorite internet search engine.

Search for the best magnesia carbon bricks manufacturers. You can find a listing of different manufacturers. Look for the reviews of the manufacturers. The very best companies get good reviews. They can be trustworthy and lots of people buy their firebricks.

Avoid manufacturers that get negative reviews. They may just waste your time and cash because their magnesia bricks are not the ideal. Those who run these companies might not have any idea what they are doing.

You now know how to find magnesia bricks manufacturers. Choose manufacturers that will get good reviews on the internet, have sufficient experience plus they ought to have excellent customer service. Will not select a manufacturer you do not know or trust.

What You Need To Find Out About Magnesia-Carbon Bricks

When you need to buy magnesia-carbon bricks, it is vital that you understand something abut them prior to come up with your order. The greater number of you know about the bricks, the simpler it will be to put together an acceptable order. Read on to learn how to choose the best magnesia-carbon bricks for your project.

The first thing you should think about if you are putting together your brick order is what temperature the bricks are likely to should get to and the way quickly the furnaces or kilns will likely be heated up. Also, it is important to understand what substances the bricks will be in contact with.

One of several great things about magnesia-carbon bricks is they are highly proof against corrosion because of their graphite content. Also you can order the bricks with special anti-oxidants that will have them in better condition for longer.

Http://rsrefractoryfirebrick.com/magnesia-carbon-bricks have excellent thermal resistant properties and they are also resistant against corrosion. They will likely also resist spalling. Make certain that the company you buy the bricks from offers good quality bricks and that they offer them at the great price. You never want to pay too much money for the bricks and you will look for the best prices when you shop around.

The bricks may be used in a variety of applications and are generally longer lasting so you don’t need to worry about them failing too early. One can learn the specification sheets in the different bricks and you could will also get advice from someone from the company you are going to order from. Make sure you determine what the shipping costs will be of course, if there are actually any warranties which come with the bricks. You need to choose them wisely at Rsrefractoryfirebrick.com.