Refractory material for copper melting furnace

Requirements for the use of refractory materials in the induction furnace for melting copper
1, the damage mechanism of refractory material in induction furnace
The channel refractory damage is mainly caused by the molten metal, metal oxide, slag penetration and thermal stresses. Because the lining body exists in large temperature gradient, when molten metal, oxide or slag along the liner crack or pore penetration into the deep inside, then the following occurs:

1. molten metal occurs after reduction, or generate low melting point material, resulting in the lining of the body by etching or spalling.
2. The molten metal and refractory oxidized, and accompanied by the volume expansion caused by the expansion and collapse lining.
3. The flow of molten metal or slag alkalinity is very good, the more serious of lining erosion and erosion.

Red copper is a strong permeability in copper alloy, the melting point of 1083℃,the penetration of molten metal copper into the inner lining during smelting,Oxidation and accompanied by volume expansion,when copper is oxidized to Cu2O, the volume increases 0.64 times,Oxidation into Cuo, the volume increased 0.75 times.As the copper oxide caused by volume change in the organizational structure of the channel refractory lining material of cracks,In addition, under a certain temperature, the oxide of copper can react with some oxides in the refractory lining to generate the liquid phase.For example, the liquid phase of copper oxide and SiO2 is 1060℃, and the liquid phase of MgO is 1135, and the liquid phase of Al2O3 is 840℃.Due to the formation of the low melting point, the structure of the lining material is destroyed,And the occurrence of corrosion phenomenon, reduce the service life of the material.The temperature of the molten metal is more than 1300℃.Viscosity and water approximation, so its liquidity and permeability are very strong, easy to penetrate into the lining,The lining can break through the change of the volume of cold and hot, especially when the temperature changes, it is easy to cause the collapse of the lining.

2, the use of induction furnace refractory material
The use condition of the refractory material in the melting ditch of the central induction melting copper furnace is very bad. Channel induction furnace of copper in water through heating by induction melting in the trench, and recycling convection temperature and heat insulation. Therefore, the highest in the molten copper liquid temperature, generally up to 1350℃. Therefore, the melting groove material should have high temperature resistance, high temperature melt in the melting groove of the electromagnetic force is very large, and to withstand the pressure of the furnace of copper liquid, Therefore, the melt channel material must also have the very high strength and the shearing resistance. In addition, the melt material must also have a high chemical stability. Melting channel is a very small cross section of the channel, its  changes will significantly affect the operation of the entire furnace, It is not allowed to have new material deposited on the channel, are not allowed to be refractory copper etching liquid. The material under the high temperature since the formation of mullite. Dimensional stability, anti permeability, with excellent high temperature performance, can meet the needs of all kinds of smelting copper alloy.

3, the characteristics and properties of refractory materials
On the basis of fully analyzing the physical and chemical action and the requirements of the refractory material in the process of using, after a lot of laboratory performance test and industrial operation test. We have developed a refractory material which is especially suitable for refractory copper furnace fusion. The material with high alumina content as the main raw material, add a special bond, so as to give the unique thermal properties of the whole material. The material is a kind of heat setting refractory material, which is formed by the dry type vibration or stamping, and is not needed to maintain and long curing period, The hot surface strength is very high, the heat penetration is very low, and the non sintered liner layer keeps the granular filling state. The liner layer is modified to prevent local stresses, which can absorb the crack and remove the penetration of the metal ribs in case of hot surface cracking. With copper and copper alloy does not react, not infiltration and so on.

Plastic for copper furnace
The copper melting furnace can be used as raw material with high alumina content, and the compound bond is adopted to improve the physical and chemical properties of the crushed material at low temperature, moderate temperature and high temperature. Can be different  the traditional plastic molding material, it inherited the common Dao material density, high strength, not easy to crack the advantages, but also has the advantages of dry molding material. That is close to the hot surface layer with high strength, and cold zone near the low strength, can absorb stress, prevent the characteristics of crack development in depth. Once the forming end can be baked.
It is mainly used for plastic copper melting furnace throat and bottom by forming inductor.

Copper induction furnace with refractory physicochemical index

class	DL-202	DL-202K	RAM A33
Major chemical components	AL2O3  72% SIO2    25%	AL2O3   78% SIO2     20%	AL2O3   87% SIO2    10%
mineral  phase	mullite  >70% Corundum   25% glass phase  <5%	mullite  >70% Corundum   25% glass phase 5%	mullite  >70% Corundum   <20% glass phase  <10
volume density	>2.75	>2.75	>2.8
porosity	<20	<19
normal temperature anti-pressure strengh(MPa) 800℃×3h 1000℃×3h 1300℃×3h	≥6.0           >12         >18	>15           >25         >30	>7.0 >13.0
refractoriness under load(2Kg/cm2)	>1630℃	>1650℃	>1300℃
after-expansion	<+0.30%	<+0.30%
Anti copper corrosion resistance Anti copper slag corrosion resistance	excellent	excellent
Initial sintering temperature	<850℃	<850℃	<850℃

Taurus Refractory ramming mass Factory mainly engaged in professional manufacturer of development, production and sales of the refractory mixture such as melting copper, aluminum and zinc furnace lining. And supply castable refractory for copper smelting, ramming mass for molten copper,fire clay,refractory mortar, refractory cement ,refractory mixture, refractory concrete and silica sand for copper smelting.
Website: http://www.jnrefractory.com  
Contact: Mr. Niu
Tel: +86-371-64372566
Fax: +86-371-64372588
Mobile Phone: +86-15137151612
Email: info@jnrefractory.com
          gyjinniu@163.com
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