EFFECTIVE SERVICE OF ALUMINOSILICATE CERAMIC CONCRETES
IN A FURNACE LINING FOR FIRING OBJECTS
IN THE CERAMIC INDUSTRY
M. A. Trubitsyn
Translated from Novye Ogneupory,No.3,pp.6–8,March 2010.
Original article submitted October 1, 2009.
Basic material science approaches are considered for developing and manufacturing the lining of kiln trolleys
of contemporary ceramic industry kilns. Many years of experience is provided of successful service of alumi
nosilicate ceramic concretes in heating units of different ceramic production. It is shown that use of ceramic
concrete composites combined with convenient structural solutions of the company ZAO Teplokhimmontazh
makes it possible to increase the operating life of the lining of kiln trolleys up to five years (not less than 500
Keywords: heating units, lining, kiln trolleys, ceramic binder suspension, aluminosilicate ceramic concrete.
Important factors for increasing the efficiency of con-
temporary ceramic production are modernization of existing
firing kilns, and also introduction into operation of new tun-
nel kilns with a channel width up to 7 m.
As is well known, the lining of kiln trolleys operates un-
der very severe conditions, which naturally govern the very
high specifications for lining construction and also lining
material. Also, no less important are the technological effi
ciency of assembly and repair of linings and their cost. World
and domestic experience shows that achievement of a long
lining life for tunnel kiln trolleys is determined by the suc
cess of combining underlying approaches: a competent mate
rial approach and a successful design concept.
From the point of view of material there are currently
two priority areas. First use of special fired refractory com
ponents, primarily of cordierite composition. Their acknowl
edged international producer is Burton GmbH, FRG. High
quality refractories from this firm demonstrate good life, but
relatively high cost holds back their extensive application in
Russian plants during running repair even for those kiln trol
leys in which refractories from Burton GmbH were initially
The second area, most promising in our view, is applica
tion in linings of unmolded refractories or objects of refrac
tory (heat-resistant) concretes. However, use of heat-resistant
concretes based on Portland cement, alumina cement, water
glass in the contemporary stage is undesirable in the majority
of cases [2, 3]. Objects made from concretes based on sili-
cate and cement binders have a prolonged production cycle,
since it is necessary to hold the objects in a mold for several
hours in order to provide the initial strength. In addition, use
of binders with an application temperature considerably
lower than the working temperature (water glass) or use of
calcium-containing cements leads to a marked reduction in
service life, particularly under conditions of a variable ther
mal load. Although phosphate binders exhibit sufficient re
fractoriness and good heat resistance, they create consider
able ecological problems both during refractory manufacture
and during operation.
A marked increase in the life of kiln trolley linings (up to
400 – 500 cycles), made of heat-resistant concrete with sta
ble uniform optimum conditions (grain size and substance
composition of the material, design solutions) is achieved us
ing concretes with a reduced cement content (2 – 8%) .
These concretes are a multicomponent composite containing
a polyfraction refractory filler, ultrafine synthetic powders,
dispersing and plastifying additions. Whereas use of low-ce
ment concretes in heating units of nonferrous and ferrous
metallurgy is economically correct, the desirability of using
these cheap materials in the ceramic industry is very ques
In addition, in Russia the high efficiency of an alterna
tive technology of cementless concretes has been developed
and is in practice, i.e. ceramic concrete technology that is
Refractories and Industrial Ceramics Vol. 51, No. 2, 2010
1083-4877/10/5102-0064 © 2010 Springer Science+Business Media, Inc.
Belgorod State Univeristy, Belogorod, Russia.