Guide to Tunnel Kiln Refractory Brick Selection and Masonry Techniques: Practical Methods for Saving Mortar Usage

Selection Criteria and Masonry Techniques for Tunnel Kiln Refractory Bricks: Practical Methods to Save Mortar Usage

This article delves into the selection criteria and masonry techniques of tunnel kiln refractory bricks. It highlights the advanced technological advantages of our company's high - strength mullite insulation bricks and their wide - spread applications in industrial kilns.

Core Raw Materials and Advanced Manufacturing Processes of Mullite Insulation Bricks

Mullite insulation bricks are made from carefully selected raw materials. Through advanced manufacturing processes, these bricks boast excellent thermal stability, high strength, and low thermal conductivity. For example, in the temperature range of 1200 - 1400°C commonly used in industrial kilns, mullite insulation bricks can maintain their structural integrity, reducing heat loss by up to 30% compared to traditional refractory bricks.

Typical Application Scenarios and Selection Requirements for Different Working Conditions

In industrial settings, there are various types of kilns such as electro - ceramic drawer kilns, tunnel kilns, and ceramic roller kilns. Each has different requirements for refractory bricks. For instance, in electro - ceramic drawer kilns, which have relatively small working spaces and frequent temperature changes, high - precision and heat - resistant mullite insulation bricks are preferred. In large - scale tunnel kilns with continuous high - temperature operations, bricks with high strength and long - term stability are more suitable.

Masonry Process of Refractory Bricks

The masonry process of refractory bricks involves several key steps. First, thorough preparation is essential. This includes checking the quality of the bricks, ensuring the flatness of the base, and preparing the appropriate tools. Next, accurate dimension verification is crucial. The size error of the bricks should be controlled within ±1mm to ensure a tight fit during masonry. When it comes to the masonry order, it should start from the bottom and work upwards in an orderly manner. As for the selection of mortar, a high - performance refractory mortar that matches the properties of the bricks should be chosen. The curing time of the mortar is usually about 24 - 48 hours, during which the temperature and humidity should be well - controlled.

Technical Contribution of Dimension - Precise Bricks

Dimension - precise mullite insulation bricks play a significant role in fast - paced masonry and mortar savings. Their precise dimensions allow for seamless connections, reducing the amount of mortar required. In practical projects, it has been found that using these precise bricks can save up to 20% of refractory mortar. Moreover, the tight connections enhance the overall structural stability of the kiln, reducing the risk of cracks and heat leakage.

Key Technical Points and Common Problem Solutions

Here are some key technical points summarized. When handling refractory bricks, avoid rough operations to prevent damage. During masonry, ensure that the joints are uniform and the bricks are firmly bonded. Common problems such as brick cracking and mortar peeling can be solved by proper pre - heating of the bricks, correct mortar mixing ratios, and strict temperature control during the curing process.

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