WHAT SHOULD BINDERS FOR SHAPED REFRACTORIES HAVE AS CHARACTERISTICS?

Basic, high alumina or silica, fireclay, and insulting are the most common names for refractories. Silicon Carbide, Silicon Nitride, Graphite, Zircon, Zirconia, fused cast, and a few more are examples of "special refractories." The majority of refractories come in premade shapes. Monolithics such as ramming mixes, gunning blends, plastic refractories, and castables are all examples of bonding mortars, and special-purpose clays. Several refractory materials have been designed specifically to fulfill the requirements of a certain technique. Every refractory class's hallmark features are a result of both their raw material foundation and the procedures utilized to manufacture the refractory products.

Shaped Raw material processing, raw material blending, shaping, drying, and firing are all steps in the refractory assembly process. Other forms of refractory procedures, such as the manufacturing of fused goods and the production of ceramic fiber, also guarantee debate.

Forming involves combining the raw components and shaping them into the desired shapes for the formed refractory. Because refractory raw materials are practically non-plastic and do not connect with one another at low temperatures, even though this technique occurs frequently under moist or humid circumstances, the forming procedure is a major test for shaped refractory manufacturers. To avoid breakage and chipping before completing the ceramic bond after firing, most refractory manufacturers must press with high pressure, manage the packing curve of all raw materials to achieve the greatest density, and use binders in their shaping technique.

Starch, Polyvinyl Alcohol (PVA), Resin, Molasses, Dextrin, Phenolic Carboxyl Methyl Cellulose (CMC), Lignosulfonate, and other binders for created refractories to improve compressive strength for pressing, handling, and drying procedures to reduce breakage and chipping are just a few examples. As a result, binder selection may be quite difficult, and manufacturers must take into account a variety of factors to determine which binder is ideal for their product and technique.

The following are some important parameters to consider:

• Type of refractory
• Mixing technologies
• The pressing procedure
• Brick size and shape
• The drying procedure
• Process of handling
• The firing procedure

The following characteristics should be included in the best binder:

• It should be simple to incorporate and integrate with refractory aggregate.
• At both low and high temperatures, it does not react with refractory mixtures.
• After firing, it must leave a modest amount of residue.
• During the firing process, it should easily burn away.
• After pressing, drying, and terminating, it has little effect on the bulk density and apparent porosity.
• The mechanical strength of green and dried bricks must be improved.
• To achieve a constant density throughout the bricks, it must increase the flowability of the mix during pressing.
• It has no effect on the bricks' permanent linear change.
• It has no effect on the blends adhering to the molds.

All-in-one binders do not exist. The choice of a suitable binder is critical for refractory manufacturers to boost production output and reduce costs.

Biopolymer binders provide a unique range of process and quality enhancement options. Hydraulic pressed bricks, plastic-formed bricks, and other unshaped refractory products are among the things that refractory manufacturers in India specialize in.

Benefits that could be gained during the process include:

• The workability and manageability of refractory mixes have improved.
• Dry pressed bricks with less pressing friction.
• Green and dry bricks have improved mechanical strength.
• Extruded bricks have more plasticity.
• Lubrication is required during the forming process.
• Saving energy.
• During the handling and drying process, there were fewer losses.
• Improvements in process and quality.

Recently, refractory and ceramic industries have undergone process changes that require the use of materials that can withstand harsh conditions and provide increased life during use at a minimum price. With the existing raw material quality, it may be possible to introduce a higher-grade special binder. Several binders have been successfully developed, including calcium dialuminate cement, barium aluminate cement, and magnesia-based cement, along with siliceous sol and aluminium hydrate.

Conclusion

Finally, it is critical to seek the advice of experts in the area and to thoroughly evaluate the results in order to select the best binder for your specific refractory manufacturing process.