Manufacturing Process of High Alumina Bricks: From Raw Materials

High-alumina fire bricks are one of the most dependable options available as refractory materials, primarily because they possess high tensile strength, are fire-resistant, and can withstand extremely high temperatures. At BM Enterprises, as one of the most dependable fire brick manufacturers, we have developed a manufacturing process that ensures our high-alumina fire bricks are strong enough to withstand high temperatures.

In this blog, the entire process of manufacturing high-alumina bricks, right from the selection of raw material to the final product, is discussed, along with their uses and benefits.

What Are High Alumina Bricks?

High alumina bricks are classified as fire refractory bricks with a high alumina content of around 45% to over 90% alumina or Al₂O₃. The higher the alumina content, the greater the refractoriness, strength, slag, and chemical resistance of the fire bricks. Such fire bricks are used in steel plants, cement kilns, glass furnaces, and power stations.

Step-by-Step Manufacturing Process of High Alumina Bricks

1. Selection of Raw Materials

The production process entails the use of high-quality pure materials. The materials required are composed of the following:

• Calcined bauxite (rich in alumina)
• Alumina powder
• Refractory clays
• Additives & Binders (according to required properties) 

The quality of the raw materials is of great importance in determining the performance of high alumina insulating bricks and dense firebricks.

2. Crushing and Grinding

The required material is crushed and ground to a fine particle size using a jaw crusher, ball mill, and/or roller mill. This is to ensure that the material is of proper particle size distribution, which is needed to ensure:

• Improved packing density
• Enhanced Strength
• Uniform Firing Properties

This is a critical process for obtaining high-quality fire bricks with high alumina content.

3. Batching and Mixing

At this stage, the measured raw materials are mixed as per a fixed formula. While mixing, the following are ensured:

• Uniform alumina distribution.
• Identical physical and chemical properties.
• Better thermal efficiency. 

The use of advanced mixers is required to create homogeneity, and this is a key aspect in the development of high-performance fire bricks.

4. Shaping and Forming

The variously mixed material then undergoes forming into bricks using various methods, including:

• Hydraulic pressing
• High-pressure moulding
• Extrusion - special shapes

This stage gives the brick its final dimensions, density, and mechanical resistance.

5. Drying Process

Freshly molded bricks contain moisture that needs to be removed before firing. Controlled drying is done in dryers to:

• Avoid cracking and warping
• Ensure dimensional stability
• Improve firing efficiency

Proper drying increases the general durability of high alumina bricks.

6. High-Temperature Firing

Firing of the dried bricks is performed in tunnel or shuttle kilns within the temperature interval from 1,400°C to 1,800°C, depending on alumina content. Firing: 

• Develops ceramic bonding
• Improves refractoriness and strength 
• Improves resistance against thermal shock 

This step is crucial to defining the final performance of high-alumina fire bricks.

7. Quality Inspection and Testing

Each batch is then subjected to rigorous quality checks, such as:

• Bulk density
• Apparent porosity
• Cold crushing strength
• Refractoriness under load

As one of the trusted fire brick manufacturers in India, BM Enterprises makes sure every product adheres to industry standards.

8. Finishing, Packing, and Dispatch

The approved bricks are finished off to the required dimensions, packed securely, and then sent to the customers. The packing of the bricks protects them from damage during transit.

Applications of High Alumina Bricks

• Steel & Iron Blast Furnace
• Cement rotary kilns
• Glass Melting Furnaces
• Boilers & Incinerators
• Power plants and petrochemical units

Due to their versatility, they are widely preferred by prominent fire brick manufacturers.

Why Choose BM Enterprises?

BM Enterprises is a reputable manufacturer of fire bricks, offering diverse refractory products and solutions for tough industrial applications. Our fire bricks made of high alumina are renowned for the following qualities:

• Reliable quality and performance
• High alumina purity
• Long Service Life
• Competitive Pricing
• Reliable supply across India

Conclusion

The production process of high alumina bricks is an extremely controlled and technically demanding process that significantly affects the performance of the final product in high-temperature conditions. Right from the choice of the finest raw material to the finest firing and testing processes, each step is extremely important for the production of effective fire bricks. 

If you are searching for trustworthy fire brick suppliers in India, BM Enterprises is the trusted choice for getting high-quality high alumina bricks, high alumina insulating brick, and other refractory materials as per industry requirements.

Frequently Asked Questions (FAQs)

1. What are high alumina bricks used for?

High alumina bricks are used in high-temperature industrial applications such as steel plants, cement kilns, glass furnaces, boilers, and power plants due to their excellent heat resistance and mechanical strength.

2. What is the alumina content in high-alumina fire bricks?

The alumina (Al₂O₃) content in high alumina fire bricks typically ranges from 45% to over 90%, depending on the application and temperature requirement.

3. How are high alumina bricks manufactured?

The manufacturing process includes raw material selection, crushing, mixing, shaping, drying, high-temperature firing, and strict quality testing to ensure durability and performance.

4. What is the difference between high alumina bricks and normal fire bricks?

High alumina bricks contain higher alumina content, offering better refractoriness, strength, and resistance to chemical and thermal stress compared to conventional fire bricks.

5. Are high-alumina insulating bricks different from dense bricks?

Yes. High alumina insulating brick is designed for lower thermal conductivity and energy efficiency, while dense high alumina bricks provide higher mechanical strength and load-bearing capacity.

6. Why choose BM Enterprises as your fire bricks manufacturer?

BM Enterprises is among the reliable fire brick manufacturers in India, offering consistent quality, tested products, customised solutions, and dependable supply for various industries.