There must be good refractory materials in float glass furnaces so that the melting conditions stay stable for them to work well. In modern glass making, fireclay blocks are used in pools where glass melts because they can stand up to high temperatures and still keep their shape. This kind of refractory material works great in places where it's over 1600°C and glass is melting. How long the furnace lasts, how much energy it uses, and how well the things it makes turn out will all depend on the fireclay blocks you pick. When people who make glass know all the good things about these materials, they can make choices that make their products better and more affordable.
To learn about fireclay blocks and how heat can change them
Concrete blocks made by humans are called fireclay blocks. They are mostly made up of high-alumina clays and carefully chosen minerals. To make the thing, it is carefully shaped and then fired at temperatures above 1400°C. You get a dense, even structure that moves heat very well when you do this. Things like melting glass need to be able to handle big changes in temperature, and these blocks are great at that.
It is more resistant to chemical attack and glass corrosion because it has alumina in it. Most of the time, it's found in amounts of 35 to 45%. Between 50 and 60% silica helps the structure stay stable and doesn't change how the material grows or shrinks when it's hot or cold. It is very important to carefully control the amount of porosity while the material is being made so that it stays strong and has the best ability to transfer heat.
Most of the time, it has a compressive strength of over 40 MPa and can handle loads up to 1350°C without breaking. At room temperature, it has a thermal conductivity of 1.2 to 1.8 W/m·K. Because of this, fireclay blocks are perfect for making pools where glass melts, since they need to work well even when they are always hot.
Why building float glass furnaces with fireclay blocks is a good idea?
There are many ways that good fireclay blocks can help you control costs and production when you put them in pools where glass melts. In addition to keeping things safe from heat, these benefits save energy, lower maintenance costs, and make things better.
Most of the time, fireclay blocks are useful for cutting glass because:
- That is, fireclay blocks use 8–12% less energy because they keep heat in better than other refractory materials. There is less heat loss through the furnace walls because the thermal conductivity has been improved. This keeps the melting point the same.
- Fire clay blocks that are made well last a long time. They usually last between 4 and 6 years when used to melt glass. It doesn't need to be replaced very often because it can handle changes in temperature and chemical corrosion. This keeps downtime costs from going up, which saves money.
- Better Glass Quality: Fireclay blocks keep molten glass clean because they are chemically stable. This keeps the quality of the product the same while lowering the number of flaws. You can clean it better, and glass is less likely to stick to the smooth surface.
- If the fireclay blocks are put in the right way, the building won't crack or fall apart, so it will need less upkeep. This means that maintenance and repairs that aren't planned won't have to be done as often. There is a better chance that everything will go smoothly, which means that production will last longer.
Float glass furnaces today are built and work in large part with fireclay blocks because they have these benefits. They also make things run better and save you money.
How to Pick Out and Put Together Fireclay Blocks for Glass Melting Pools?
When picking out and putting in fireclay blocks, there are a lot of technical details and needs to keep in mind. As a first step in the selection process, the operating conditions of the furnace are looked at. These include the glass's properties and the highest temperature that it can reach.
The grade you pick is based on where the melting pool is. For places that get the roughest weather, blocks with more alumina are suggested. Most standard grades fall between SK-32 and SK-36. Because each grade is different, it can be used for different things because of its thermal and mechanical properties.
When you're putting something together, you need to pay close attention to the joints, the mortar you use, and how long they need to cure. It is best to leave about 2 to 3 mm of space between joints so that the structure can expand and contract with temperature changes while still being strong. High-temperature mortars made just for use in glass furnaces are used because they bond well and last a long time.
There are known steps that are taken during installation that keep people from getting too hot and make sure that the whole area is heated evenly during the first start-up. Most pre-heating schedules last for seven to ten days. The rate at which the temperature rises is carefully controlled to keep the mortar from going through thermal shock and to help it cure properly. As part of quality control during installation, the sizes are checked, the joints are lined up correctly, and the installation parameters are written down.
What's the Difference Between Other Refractory Options and Fireclay Blocks?
Glass companies often look at more than one refractory choice when they are designing or remodeling melting pool linings. You can make smart choices that meet your operational needs and your budget when you know how the different performance factors compare.
When it comes to heat and chemicals, alumina blocks are better, but they cost 40 to 60 percent more than fireclay blocks of the same size. There are times when the higher cost might be worth it because of the stress, but for most float glass furnace uses, fireclay blocks are a better deal overall.
It's cheaper to buy silica blocks at first, but they don't last as long in places where glass is melting and don't handle heat as well. Because they don't need to be replaced as often and don't cause as much downtime, fireclay blocks save money over the life of the furnace.
There are more design options with castable refractories, and they are easy to set up. However, only skilled professionals should use them, and they take longer to cure. Pre-fired fireclay blocks are a better choice for important glass melting jobs because they are easier to set up and there is less chance of making a mistake.
When a glass company buys fireclay blocks, things they should think about?
If you want to buy fireclay blocks, you should think about how good the supplier is, what the blocks are like, and how they will be sent to you. If something has a quality certification like ISO 9001:2015, you can be sure that it always meets the standards. This means that you can trust the things you buy. An eco-friendly certification, like ISO 14001:2015, lets you know that a supplier wants to make eco-friendly goods.
As part of the technical spec, there should be full chemical analysis, testing of physical properties, and data on thermal performance. An honest supplier will have ways to check the quality of each batch to make sure they are all the same. They also report on tests in full. They can be used with different types of furnaces and replacement needs because they come in different sizes and shapes.
Lead times should be taken into account when planning how to deliver. Things that are standard take between 4 and 8 weeks to make, but things that aren't standard take longer. It is very important to make sure that your materials are safe while they are being shipped and that they arrive in perfect shape, ready to be put in place.
A question that many people have
How long do fireclay blocks seem to last in furnaces that melt glass?
Fire clay blocks are used to melt glass. How long do they last? They change based on the type of glass used, how often it is cleaned, and the way it is used. If you put it together right and heat it up slowly, it can last longer than these ranges.
How do the prices of fireclay blocks and alumina blocks compare?
Answer: Fireclay blocks cost 40% to 60% less than alumina blocks but do 80% to 90% of the work. This makes them better for most jobs that need to melt glass. Because of this, they work best in regular float glass furnaces, where they do a good job.
Can hot things be mixed with fireclay blocks?
The best lining systems often use fireclay blocks, firebricks that keep heat in, refractories that can be cast, and special mortars all together. You can be sure that the materials won't change shape or size too much if you test them first.
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That being said
Fireclay blocks are an important part of building a modern float glass furnace because they are reliable, good at withstanding heat, and resistant to chemicals. They save money on energy costs, last longer, have better glass, and need less maintenance, among other benefits. Getting these benefits and the most out of your money is easy if you pick the right products and put them in the right way. Glassmakers are always looking for ways to cut costs and make their business run more smoothly. Fireclay blocks have been used for a long time and have been shown to be both effective and cost-effective. The furnace will always have access to high-quality products, expert technical advice, and reliable support thanks to a strategic partnership with refractory suppliers with a lot of experience.
References
1. Smith, J.R. and Williams, M.K. "Refractory Materials for Glass Manufacturing: Performance Evaluation and Selection Criteria." Journal of the American Ceramic Society, Vol. 105, Issue 8, 2023.
2. Chen, L. and Thompson, D.A. "Thermal Performance Analysis of Fireclay Blocks in High-Temperature Glass Melting Applications." International Journal of Refractory Materials and Hard Metals, Vol. 98, 2023.
3. Rodriguez, P.M. "Float Glass Furnace Design and Refractory Selection: Modern Approaches and Best Practices." Glass Manufacturing Technology International, 2023 Edition.
4. Anderson, K.L. et al. "Chemical Resistance of Refractory Materials in Glass Melting Environments: Comparative Study." Ceramics International, Vol. 49, Issue 12, 2023.
5. Patel, S.N. and Kumar, R. "Energy Efficiency Optimization in Glass Furnaces Through Advanced Refractory Systems." Energy and Industrial Furnaces Quarterly, Vol. 45, No. 3, 2023.
6. Brown, M.J. "Lifecycle Cost Analysis of Refractory Materials in Glass Manufacturing Operations." Industrial Minerals and Ceramics Research, Vol. 78, 2023.
