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- Abrasion Of Refractories: Wearing away of the surfaces of refractory
bodies in service by the scouring action of moving solids
- Absorption:
As applied to ceramic products, the weight of water which can be absorbed
by the ware, expressed as a percentage of the weight of the dry ware.
- Abutment:
The structural portion of a furnace which withstands the thrust of an
arch.
- Acid-Proof Brick:
Brick Having low porosity and permeability, and high resistance
to chemical attack or penetration by most commercial acids and some
other corrosive chemicals.
- Acid Refractories:
Refractories such as silica brick which contain a substantial proportion
of free silica and which when heated, can react chemically with basic
refractories, slags, and fluxes.
- Aggregate: As applied to refractories, a ground mineral material, consisting of
particles of various sizes, used with much finer sizes for making formed
or monolithic bodies.
- Air-Ramming: A method of forming
refractory shapes, furnace hearths, or other furnace arts by means of
pneumatic hammers.
- Air-Setting Refractories: Compositions
of ground refractory materials which develop a strong bond upon drying.
These refractories include mortars, plastic refractories, ramming
mixes and gunning mixes and gunning mixes. They are marketed in both
wet and dry condition. The dry compositions require tempering with water
to develop the necessary consistency.
- Alumina:Al2O3, the oxide of aluminum;
melting point 3720oF
(2050oC);in combination with
H2O(water). alumina forms
the minerals diaspore, bauxite and gibbsite; in combination with SiO2
and H2O, alumina forms kaolinite and other clay minerals.
- Alumina-Silica Refractories:
Refractories consisting essentially of alumina and silica, and including
high-alumina, fireclay and kaolin refractories.
- Amorphous: Lacking crystalline
structure or definite molecular arrangement; without definite
external form.
- Andalusite: A brown, yellow,
green, red or gray orthorhombic mineral: Al2SiO5. Specific gravity 3.1-3.2.
Decomposes on heating, beginning at about 2460oF
(1350oC) to form mullite
(Al6Si2O13) and free silica.
- Anneal: To remove internal stress
by first heating and then cooling slowly.
- Apparent Porosity:
The relationship between the volume of a mass and the volume of water
absorbed when the mass is immersed in the water. See Also Porosity
of Refractories
- Arc: As applied to circles,
any portion of a circumference; as applied to electricity, the luminous
bridge formed by the passage of a current across a gap between two conductors
or terminals.
- Arc Furnace: A
steel melting furnace in which heat is generated by an arc between
graphite electrodes and the metal.
- Arch, Flat: In furnace construction,
a flat structure spanning an opening and supported by abutments at its
extremities; the arch is formed by a number of special tapered brick,
and the brick assembly is held in place by their keying action. Also
called a jack arch.
- Arch, Sprung: In furnace construction,
a bowed or curved structure which is supported by abutments at the sides
or ends only, and which usually spans an opening or space between two
walls.
- Arch, Suspended: A furnace roof
consisting of brick shapes suspended from overhead supporting members.
- Arch Brick: A brick shape
having six plane faces (two sides, two edges and two ends), in which
two faces (the sides) are inclined toward each other and one edge face
is narrower than the other.
- Asbestos: Commercially, any
mineral which remains after burning a fuel or other combustible material.
- Ash: The noncombustible residue
which remains after burning a fuel or other combustible material.
- Attrition: Wearing away by friction;
abrasion.
- Auger Machine: A machine for
extruding ground clays in moist and stiffly plastic form, through a
die by means of a revolving screw or auger.
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- Calcination: A heat treatment to which many ceramic
raw materials are subjected, preparatory to further processing or use,
for the purpose of driving off volatile chemically combined
components and effecting physical changes.
- Calcite: A material having the composition CaCO3. Specific
gravity 2.71 for pure calcite crystals. Calcite is the essential constituent
of limestone, chalk and marble and a minor constituent of many other
rocks.
- Cap or Crown: The arched roof
of a furnace, especially a glass tank furnace.
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Carbon
Deposition:
The deposition of amorphous carbon, resulting from the decomposition
of carbon monoxide gas into carbon dioxide and carbon within a critical
temperature range. When deposited within the pores of a refractory
brick, the carbon can build up such a pressure that it destroys the
bond and causes the brick to disintegrate.
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Carbon
Refractory:
A manufactured refractory comprised substantially or entirely of carbon
( including graphite) . ASTM Standard definitions C71-57; or ASTM
" Tentative Definitions" are used where applicable.
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Carbon - Ceramic
Refractory: A manufactured refractory comprised of carbon (including
graphite) and one or more ceramic materials such as fire clay and
silicon carbide.
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Castables Refractory:
a mixture of a heat-resistant aggregate and a heat-resistant hydraulic
cement ; for use, it is mixed with water and rammed, cast or gunned
into place.
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Catalyst: A substance
which causes or accelerates a chemical change without being permanently
affected by the reaction.
-
Cement: A finely
divided substance which is workable when first prepared but
which becomes hard and stonelike as a result of chemical reaction
or crystallization; also, the compact groundmass which surrounds and
binds together the larger fragments or particles in sedimentary rocks.
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Ceramic Bond: In
a ceramic body, the mechanical strength developed by a heat treatment
which causes the cohesion of adjacent particles.
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Ceramics: Originally
, the term ceramics referred only to ware formed from clay and
hardened by the action of heat, and to the art of making such
ware. However, its significance has gradually been extended by
usage, and it is now understood to include all refractory materials,
cement, lime, plaster, pottery, glass, enamels glazes, abrasives,
electrical insulation products and thermal insulation products made
from clay or from other inorganic nonmetallic mineral substances.
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Checkers: Brick
used in furnace regenerators to recover heat from outgoing hot gases
and later to transmit the heat to cold air or gas entering the furnace;
so-called because the brick are arranged checkerboard patterns,
with alternating brick units and open spaces.
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Chemically-Bonded Brick: Brick manufactured by processes in which mechanical strength
is imparted by chemical bonding agents instead of by firing.
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Chord: As applied
to circles, a straight line joining any two points on a circumference.
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Chrome Brick: A
refractory brick manufactured substantially or entirely of chrome
ore.
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Chrome-Magnesite Brick: A refractory brick which can be either fired or chemically
bonded, manufactured substantially of a mixture of chrome ore and
dead-burned Magnesite, in which the chrome ore predominates by weight.
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Chrome Ore: A rock
having as its essential constituent the mineral chromite or chrome
spinel, which is a combination of FeO and MgO with Cr2O3,
Al2O3, and
usually a small proportion of Fe2O3. The composition, which is represented
by the formula (Fe,Mg) (Cr, Al)2O4, is extremely variable. Refractory
grade chrome ore has only minor amounts of accessory minerals and
has physical properties that are suitable for the manufacture of refractory
products.
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Clay: A natural
mineral aggregate, consisting essentially of hydrous aluminum silicates
(See also Fire Clay).
-
Collector Nozzle: Please
See Nozzle Brick.
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Colloid: (1) A particle-size
range of less than 0.00024 mm, i.e. smaller than clay size; (2) originally,
any finely divided substance that does not occur in crystalline
form; in a more modern sense, any fine-grained material in suspension,
or any such material that can be easily suspended.
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Conductivity: The
property of conducting heat, electricity or sound.
-
Congruent Melting:
The change of a substance, when heated, from the solid form to a liquid
of the same composition. The melting of ice is an example of
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Continuous Casting:
Continuous forming of semi-finished steel,
e.g.. slabs, blooms and billets, direct from molten steel.
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Continuous Type Furnace:
A furnace used for heat-treating materials that progress continuously
throughout the furnace, entering one door and being discharged from
another.
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Convection: The
transfer of heat by the circulation or movement of the heated parts
of a liquid or gas.
-
Corbel: A supporting
projection of the face of a wall; and arrangement of brick in a wall
in which each course projects beyond the one immediately below it
to form a support, baffle or shelf.
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Corrosion of Refractories:
Deterioration or wearing away of refractory bodies largely at their
surface through chemical action of external agencies.
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Corundum: A natural
or synthetic mineral theoretically consisting solely of alumina (Al2O3).
Specific gravity 4.00-4.02. Melting point 3720oF
(2050oC). Hardness
9.
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Course: A horizontal
layer or row of brick in a structure.
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Cryptocrystalline:
A crystalline structure in which the individual crystals are so small
that they cannot be made visible by means of the petrographic microscope
but can be seen with an election microscope. Various so-called amorphous
minerals are actually cryptocrystaline.
-
Crystal: (1) A homogeneous,
solid body of a chemical element, compound or isomorphous mixture
having a regularly repeating atomic arrangement that can be outwardly
expressed by plane faces: (2) rock crystal.
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Crystalline: Composed
of crystals.
-
Cupola: A
cylindrical, vertical furnace usually lined with refractories, for
melting metal in direct contact with coke by forcing air under
pressure through openings near its base.
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Dead-Burned Dolomite:
A coarsely granular refractory
material prepared by firing raw dolomite with or without additives,
to a temperature above 2800oF
(1538oC), so as to form primarily lime
and magnesia in a matrix that provides resistance to hydration and
carbonation.
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Dead-Burned Magnesite:
A coarsely granular dense refractory material composed essentially
of periclase (crystalline magnesium oxide): prepared by fire raw magnesite
(or other substances convertible to magnesia) at temperatures sufficiently
high to drive off practically all of the volatile materials, and to
effect complete shrinkage of the resultant magnesia, thereby producing
hard dense grains which are entirely inert to atmospheric hydration
and carbonation and free from excessive shrinkage when again subjected
to a high temperature.
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De-airing: Removal
of air from firebrick mixes in an auger machine before extrusion by
means of a partial vacuum.
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Density: The mass
of a unit volume of a substance. It is usually expressed either in
grams per cubic centimeter or in pounds per cubic foot.
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Devitrification:
The change from a glassy to a crystalline condition.
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Diaspore: A mineral
having the theoretical composition Al2O3-H2O (85 percent alumina:
15 percent water). Specific gravity 3.45.
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Diaspore Clay:
A rock consisting essentially of diaspore bonded by flint clay.
Commercial diaspore clay of the purest grade usually contains between
70 and 80 percent alumina after calcination.
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Diatomaceous Earth:
A hydrous form of silica which is soft, light in weight and
consists mainly of microscopic shells of diatoms or other marine organisms.
It is widely used for furnace insulation.
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Division Wall: Wall
dividing any two major sections of a furnace.
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Dobie: A molded
block of ground clay or other refractory material, usually crudely
formed and either raw of fired.
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Dolomite: The mineral
calcium-magnesium carbonate: CaMg(CO3)2. Specific gravity 2.85-2.95.
The rock called dolomite consists mainly of the mineral of that name
and can also contain a large amount of the mineral calcite (CaCO3).
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Dry Pan: A pan-type
rotating grinding machine, equipped with heavy steel rollers or mullers
which do the grinding and having slotted plates in the bottom through
which the ground material passes out.
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Dusting: Conversion
of a refractory material either wholly or in part into fine powder
or dust. Dusting usually results from (1) chemical reactions such
as hydration: or (2) from mineral inversion accompanied by large and
abrupt change in volume, such as the inversion of beta to gamma dicalcium
silicate upon cooling.
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Dutch Oven: A combustion
chamber built outside and connected with a furnace.
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Eccentric Bottom Tapping (EBT): A
steel-making process used to ensure slag free liquid metal into the
Ladle Refining Furnace (LRF). Specifically, this method allows
efficient tapping without tilting the vessel, and is desirable for
maintaining the cleanliness of the molten steel, because the carry
over of oxidizing slag into the ladle during tapping can be prevented.
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Electron Beam Furnace:
A furnace in which metals
are melted in a vacuum at very high temperatures by bombardment with
electrons.
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Electric Arc Furnace (EAF):
Steel-making Arc furnace where the scrap is generally 100% of the
charge. Heat is supplied from the electricity that arcs from the
graphite electrodes to the metal bath. Furnaces maybe either
alternating current (AC) or direct current (DC). DC units consume less
energy and fewer electrodes, but they are more expensive. See also
Arc Furnace
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Emissivity, Thermal:
The capacity of a material for radiating heat: commonly expressed
as a fraction or percentage of the ideal "black body" radiation of
heat which is the maximum theoretically possible.
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Erosion of Refractories:
Mechanical wearing away of the surfaces of refractory bodies in service
by the washing action of moving liquids, such as molten slags or metals.
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Eutectic Temperature:
The lowest melting temperature in a series of mixtures of two or more
components.
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Exfoliate: To expand
and separate into rudely parallel layers or sheets, under the action
of physical, thermal or chemical forces producing differential stresses.
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Expansion Joint: Joint
or separation made between different materials that have different
expansion rates
to allow for expansion when heated.
A filler strip is placed in the joint.
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Extrusion:
A process in which plastic material is forced through a die by the
application stresses.
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Fayalite: A
mineral having the composition Fe2SiO4. Specific gravity 4.0-4.1.
Melting point 2201oF
(1205oC).
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Feldspar: A group
of aluminum silicate minerals with a general formula MAl (Al,Si)3O8
where M=K, Na, Ca, Br, Rb, Sr and Fe. The most important feldspars
are: (1) the potash group, of which orthoclase and microcline (k)
are the most common, and (2) the soda-lime group, of which albite
(Na) and anorthite (Ca) form the end members of a continuous series
of solid solutions. Specific gravity 2.55-2.76. Melting points 2050o
to 2820oF (1120o to
1550oC).
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Fillet: The concave
curve junction of two surfaces which would otherwise meet at an angle.
Fillets are used at reentrant angles in the design of brick shapes
to lessen the danger of cracking.
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Firebrick: Refractory
brick of any type.
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Fireclay Brick:
A refractory brick manufactured substantially or entirely from fire
clay.
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Flat arch: An arch
in which both outer and inner surfaces are horizontal planes.
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Flint: A hard fine-grained
crytocrystalline rock, composed essentially of silica.
-
Flint Clay: A hard
or flint-like fire clay which has very low natural plasticity and
which usually breaks with a smooth or shell-like fracture. Its principal
clay mineral is halloysite.
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Flux: A substance
or mixture which promotes fusion of a solid material by chemical action.
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Fluxing: Fusion
or melting of a substance as a result of chemical action.
-
Forsterite: A mineral
having the composition Mg2SiO4. Specific gravity 3.21. Melting point
approximately 3450oF
(1900oC).
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Friable: Easily
reduced to a granular or powdery condition.
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Furnace Chrome:
A mortar material prepared from finely ground chrome ore, suitable
for laying brick or for patching or daubing in furnaces.
-
Furnace Magnesite:
A mortar material prepared from finely ground dead-burned magnesite,
suitable for use as a joint material in laying magnesite brick, and
for patching or daubing furnace masonry.
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Fused -Cast Refractories:
Refractories formed by electrical fusion followed by casting and annealing.
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Fused Quartz: Silica
in the glassy state produced by melting clear quartz crystalline feed
. It is clear without entrapped gas bubbles or other impurities or
diluents. Synonyms include quartz glass and vitreous quartz.
-
Fused Silica: Silica
in the glassy or vitreous state produced by arc-melting sand. It always
contains gas bubbles. Synonyms include vitreous silica and silica
glass.
-
Fusion: A state
of fluidity or flowing in consequence of heat: the softening of a
solid body, either through heat alone or through heat and the action
of a flux, to such a degree that it will no longer support its own
weight, but will slump or flow. Also the union or blending of materials,
such as metals, upon melting, with the formation of alloys.
-
Fusion Point: The
temperature at which melting takes place. Most refractory materials
have no definite melting points, but softer gradually over a range
of temperatures.
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Ganister: A
dense, high-silica rock (quartzite), suitable for the manufacture
of silica brick. Confusion sometimes results from the use of this
term, because it is also applied in some parts of the United States
to crushed firebrick or to mixtures of either crushed firebrick or
silica rock with clay, for use in tamped linings.
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Gas Purging: Where
the risk assessment has identified the presence or possible presence
of flammable or toxic gases or vapors, there may be a need to purge
(purify) the air, gas or vapor from the confined space. This will be
done with air or an inert gas where toxic contaminants are present,
but with inert gas only where there are flammable contaminants.
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Gibbsite: A white
or tinted monoclinic mineral: Al(OH)3. Specific gravity 2.3-2.4.
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Glass: An inorganic
product of fusion which ha cooled to a rigid condition without crystallizing.
A.S.T.M. Standard Definitions C 71-57: or A.S.T.M. "Tentative Definitions"
are used where applicable.
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Grain Magnesite:
Dead-burned magnesite in the form of granules, generally ranging in
size from about 5/8 inch in diameter to very fine particles.
-
Grain Size: As applied
to ground refractory materials, the relative proportions of particles
of different sizes; usually determined by separation into a series
of fractions by screening.
-
Grog: A granular
product produced by crushing and grinding calcined or burned refractory
material, usually of alumina-silica composition.
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Ground Fire Clay:
Fire clay or a mixture of fire clays that have been subjected to no
mechanical treatment other than crushing and grinding
-
Grout: A suspension
of mortar material in water, of such consistency that when it i poured
on horizontal courses of brick masonry, it will flow into vertical
open joints.
-
Gunning: The application
of monolithic refractories by means of air-placement guns.
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Halloysite: One of the clay minerals; a hydrated silicate of alumina similar
in composition to kaolinite, but amorphous and containing more water;
Al2SiO5(OH)42H20.
-
Header: A brick
laid on flat with its longest dimension perpendicular to the face
of a wall.
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Heat-Setting Refractories:
Compositions of ground refractory materials which require relatively
high temperatures for the development of an adequate bond, commonly
called the ceramic bond.
-
Hematite: The mineral Fe203 (red iron ore). Specific gravity 4.9 - 5.3.
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High-Alumina Refractories:
Alumina-silica refractories containing 45 percent or more alumina.
The materials used in their production include diaspore, bauxite,
gibbsite, kyanite, sillimanite, andalusite and fused alumina (artificial
corundum).
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High-Duty Fireclay Brick: Fireclay brick which have a P.C.E. not lower than Cone 31 1/2
or above 32 1/2 - 33.
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HMOR: Hot Modulus
of Rupture. See Modulus of Rupture
-
Hot Modulus of Rupture
(HMOR): See Modulus of Rupture
-
Hydrate (verb):
To combine chemically with water.
-
Hydraulic-Setting
Refractories: Compositions of ground refractory materials in which
some of the components react chemically with water to form a
strong hydraulic bond. These refractories are commonly known as castables.
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Illite: A group of three-layer, mica-like minerals
of small particle size, intermediate in composition and structure
between muscovite and montmorillonite.
-
Impact Pad: A
refractories board in ladle / tundish which is helpful for enhanced
the furnace life
-
Impact Pressing:
A process for forming refractory shapes, in which the ground particles
of refractory material are packed closely together by rapid vibration.
-
Incongruent Melting:
Dissociation of a compound on heating, with the formation of another
compound and a liquid of different composition from the original compound.
-
Ingot Mold: A mold
in which ingots are cast.
-
Insulating Refractories:
LIghtweight, porous refractories with much lower thermal conductivity
and heat-storage capacity than other refractories. Used mostly as
backing for brick of higher refractoriness and higher thermal conductivity.
These materials provide fuel economy through lower heat losses, increased
production due to shorter heat-up time, economy of space (size and
weight) because of thinner walls and improved working conditions.
Insulating refractories are available as brick or monoliths.
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Inversion: A change
in crystal form without change in chemical composition; as for example,
the change from low-quartz to high-quartz, or the change from quartz
to cristobalite.
-
Isomorphous Mixture:
A type of solid solution in which mineral compounds of analogous chemical
composition and closely related crystal habit crystallize together
in various proportions.
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Jack Arch:
See Arch, Flat.
-
Jamb: (1) Avertical
structural member forming the side of an opening in a furnace wall,(2)
a type of brick shape intended for use in the sides of wall openings.
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Kaldo Process (Stora):
An oxygen process for
making steel.
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Kaliophilite: A
Hexagonal mineral of volcanic origin; KAISi04.
-
Kaolin: A white-burning
clay having kaolinite as its chief constituent. Specific gravity 2.4
- 2.6. The P.C.E. of most commercial kaolins ranges from Cone 33 to
35.
-
Kaolinite: A common
white to grayish or yellowish clay mineral; AI2Si205(OH)4. Kaolinite
is the principal constituent of most kaolins and fireclays. Specific
gravity is 2.59. The P.C.E. of pure kaolinite is Cone 35.
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Key: In furnace
construction, the uppermost or the closing brick of a curved arch.
-
Key Brick: A brick
shape having six plane faces (two sides, two edges and two ends),
in which two faces (the edges)are inclined toward each other and one
of the end faces is narrower than the other.
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K-factor: The thermal
conductivity of a material, expressed in standard units.
-
Kyanite (Cyanite):
A blue or light-green triclinic mineral;AL2Si05. Specific gravity
3.56 - 3.67. Decomposition begins at about 2415oF
(132555oC) with the
formation of mullite and free silica.
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Ladle: A refractory-line vessel used for the
temporary storage or transfer of molten metals.
-
Ladle Metallurgy
Furnace: An intermediate steel processing unit that further
refines the chemistry and temperature of molten steel while it is
still in the ladle. The ladle metallurgy step comes after the steel is
melted and refined in the electric arc or basic oxygen furnace, but
before the steel is sent to the continuous caster.
-
Ladle Nozzle: See
Nozzle Brick and Ladle.
-
Lance / Lance Pipe:
A length of pipe used to convey gas
-
L-D Process: A process
for making steel by blowing oxygen on or through molten pig
iron, whereby most of the carbon and impurities are removed
by oxidation.
-
Limestone: A sedimentary
rock composed essentially of the mineral calcite (CaCO3) or of calcite
mixed with dolomite, CaMg(CO3)2. Specific gravity 2.6 - 2.8.
-
Limonite: A mineral
consisting of hydrous ferric oxides; the essential component
of "brown ore." Specific gravity 3.6 - 4.0.
-
Lintel: A horizontal
member spanning a wall opening.
-
Loss on Ignition:
As applied to chemical analyses, the loss in weight which results
from heating a ample of material to a high temperature, after preliminary
drying at a temperature just above the boiling point of water. The
loss in weight upon drying is called "free moisture;" that which occurs
above the boiling point, "loss on ignition."
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Low-Duty Fireclay Brick: Fireclay brick which have a P.C.E. not lower than Cone 15 nor
higher than 28 - 29.
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Magnesioferrite: One
of the spinel group of minerals: (Mg, Fe) Fe2O4.
Rarely found in nature; usually constitutes the brown coloring
material in magnesite brick. Specific gravity 4.57 - 4.65.
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Magnesite: A Mineral
consisting of magnesium carbonate; MgCO3. A rock containing the mineral
magnesite as it essential constituent (See also Magnesite, Caustic
and Dead-Burned Magnesite).
-
Magnesite Brick:
A refractory brick manufactured substantially or entirely of dead-burned
magnesite which consists essentially of magnesia in crystalline form
(periclase).
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Magnesite, Caustic:
The product obtained by calcining magnesite, or other substances convertible
to magnesia upon heating at a temperature generally not exceeding
2200oF
(1205oC). The product is readily reactive to water and to atmospheric
moisture an carbon dioxide.
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Magnesite-Chrome Brick: A refractory brick which can be either fired or chemically
bonded, manufactured substantially of a mixture of dead-burned magnesite
(magnesia) and refractory chrome ore, in which the magnesite predominates
by weight.
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Magnesium Hydroxide:
The compound of magnesium oxide an chemically combined water; Mg(OH)2.
Naturally occurring magnesium hydroxide is known as brucite.
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Magnetite: A black,
isometric, strongly magnetic, opaque mineral of the spinel
group;(Fe,Mg)Fe2O4.
Specific gravity 5.17 - 5.18. Melting point about 2901oF
(1594oC).
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Medium-Duty Fireclay Brick: A fireclay brick with a P.C.E. value not lower than Cone 29
nor higher than 31 - 31 1/2.
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Melting Point: The
temperature at which crystalline and liquid phase having the same
composition coexist in equilibrium. Metals and most pure crystalline
materials have sharp melting point, i.e. they change abruptly from
solid to liquid at definite temperatures. However, most refractory
materials have no true melting points, but melt progressively over
a relatively wide range of temperatures.
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Metalkase Brick:
Basic brick provided with thin steel casings.
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Metal Zone: An
area or region (such as in a furnace) that contains, stores or
is in contact with metal.
-
Mica: A group of
rock minerals having nearly perfect cleavage in one direction and
consisting of this elastic plates. The most common varieties are muscovite
and biotite.
-
Micron: The one-thousandth
part of a millimeter (0.001 mm); a unit of measurement used in microscopy.
-
Mineral: A mineral
species is a natural inorganic substance which is either definite
in chemical composition and physical characteristics or which varies
in these respects within definite natural limit. Most minerals have
a definite crystalline structure; a few are amorphous.
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Modulus of Elasticity
(Physics): A measure of the elasticity of a solid body; the ratio
of stress (force) to strain (deformation) within the elastic limit.
-
Modulus of Rupture (MOR):
A measure of the transverse or "crossbreaking" strength of a solid
body.
-
Monolithic Lining:
A furnace lining without joints, formed of material which is rammed,
cast, gunned or sintered into place.
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Monticellite: A
colorless or gray mineral related to olivine; CaMg SiO4. Specific
gravity 3.1 - 3.25. Melts incongruently at 2730oF
(1499oC) to form MgO
and a liquid.
-
Montmorillonite:
A group of expanding-lattice clay minerals containing variable percentages
of one or more of the cations of magnesium, potassium, sodium and
calcium. A common constituent of bentonites.
-
MOR: See Modulus
of Rupture
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Mortar (Refractory):
A finely ground refractory material which becomes plastic when mixed
with water and is suitable for use in laying refractory brick.
-
Mullite: A rare
orthorhombic mineral AI6Si2O13. Specific gravity 3.15. An important
constituent of fireclay and high-alumina brick. Melting point under
equilibriumC) conditions approximately 3362oF
(1850oC).
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Mullite Refractories:
Refractory products consisting predominantly of mullite (AI6Si2O13)
crystals formed either by conversion of one or more of the sillimanite
group of minerals or by synthesis from appropriate materials employing
either melting or sintering processes.
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Muscovite: A mineral
of the mica group; KAI2 (AISi) O10 (OH)2. It is usually colorless,
whitish or pale brown and i a common mineral in metamorphic and igneous
rocks and in some sedimentary rocks.
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Nepheline (Nephelite):
A hexagonal mineral of
the feldspathoid group; (Na,K)AISiO4. A common reaction product in
furnaces wherein slags or vapors of high soda content come into contact
with fireclay or high-alumina brick. Stable at 2278oF
(1248oC) at which
temperature it inverts to the artificial mineral carnegieite, which
has the same composition, but a different crystalline form. Natural
nepheline contains a small amount of potash. Specific gravity 2.67.
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Neutral Refractories:
A refractory material which is neither acid nor base such as carbon,
chrome or mullite.
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Nine Inch Equivalent:
A brick volume equal to that of a 9 x 4 1/2 x 2 1/2 inch straight
brick (101.25 cubic inches); the unit of measurement of brick quantities
in the refractories industry.
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Nodule Clay: A rock
containing aluminous or ferruginous nodules, or both bonded by flint
clay; called "burley" clay or "burley flint" clay in some districts.
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Nosean (Noselite):
A feldspathoid mineral of the sodalite group; Na8AI6Si6O24
(SO4).
It is grayish, bluish or brownish and is related to hauyne.
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Nozzle Brick: A
tubular refractory shape used in a ladle (or collector) with a hole through which
steel is teemed at the bottom of the ladle, the upper end of the shape
serving as a seat for the stopper.
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Olivine: (1)
An olive-green, grayish-green or brown orthorhombic mineral; (Mg,Fe)2SiO4.
It comprises the isomorphous solid-solution series forsterite-fayalite.
(2) A name applied to a group of minerals forming the isomorphous
system (Mg,Fe,Mn,Ca)2SiO4, including forsterite, fayalite, tephroite
and a hypothetical calium orthosilicate. Specific gravity 3.27 - 3.37,
increasing with the amount of iron present.
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Overfiring: A heat
treatment which causes deformation or bloating of clay or clay ware.
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Oxiduction: Alternate
oxidation and reduction.
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Oxygen-arc Cutting: Thermal
cutting in which the ignition temperature is produced by an electric
arc, and cutting oxygen is conveyed through the centre of an
electrode, which is consumed in the process.
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Oxygen Lance: A
length of pipe used to convey oxygen onto a bath of molten metal.
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Oxygen Lancing: A
thermal cutting process in which oxygen-lance is used.
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Oxygen Process:
A process for making steel in which oxygen is blown on or through
molten pig iron, whereby most of the carbon and impurities are removed
by oxidation.
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Periclase: An
isometric mineral; MgO. Specific gravity 3.58. Melting point approximately
5070oF
(2800oC).
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Perlite: A siliceous
glassy rock composed of small spheroids varying in size from small
shot to peas; combined water content 3 to 4 percent. When heated to
a suitable temperature, perlite expands to form a lightweight glassy
material with a cellular structure.
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Permeability: The
property of porous materials which permits the passage of gases and
liquids under pressure. The permeability of a body is largely dependent
upon the number, size and shape of the open connecting pores and is
measured by the rate of flow of a standard fluid under definite pressure.
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Plasma Jet: Ionized
gas produced by passing an inert gas through a high-intensity arc
causing temperatures up to tens of thousands of degrees centigrade.
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Plastic Chrome Ore:
An air-setting ramming material having a base of refractory chrome
ore and shipped in plastic form ready for use.
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Plastic Fire Clay:
A fire clay which has sufficient natural plasticity to bond together
other materials which have little or no plasticity.
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Plastic Refractory:
A blend of ground refractory materials in plastic form, suitable for
ramming into place to form monolithic linings.
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Plasticity: That
property of a material that enables it to be molded into desired forms
which are retained after the pressure of molding has been released.
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Pores: As applied
to refractories, the small voids between solid particles. Pores are
described as "open" if permeable to fluids; "sealed: if impermeable.
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Porosity of Refractories:
The ratio of the volume of the pores or voids in a body to the total
volume, usually expressed as a percentage. The "true porosity" is
based on the total pore-volume; "apparent porosity" on the open pore-volume
only.
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Porous Plugs: This
structurally integrated product consists of porous refractories, the
pore diameter and porosity of which are adjusted to the specified gas
flow, and a covering of a high strength castable refractory material,
which gives it excellent corrosion resistance.
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Power Pressing:
The forming of refractory brick shapes from ground refractory material
containing an optimum amount of added water by means of high pressure
applied vertically in a power-driven press.
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Pug Mill: A machine
used for blending and tempering clays in a moist or stiffly plastic
condition.
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Purging Plug: A
kind of porous plug
which
used to feed gas into the
EAF/converter
or Ladle's molten steel to force the impurities to float to the
top surface of the molten steel. This
plug
is characterized by stable structure, high
permeability, high erosion and corrosion resistance, spalling
resistance and long life.
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Pyrite: The most
common sulfide mineral; FeS2. Specific gravity 4.9 - 5.2. Color, brass-yellow.
Used mainly for making sulfuric acid and sulfates.
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Pyrometric Cone:
One of a series of pyramidal-shaped piece consisting of mineral mixtures
and used for measuring time-temperature effect. A standard pyrometric
cone is a three-sided truncated pyramid; and is approximately either
2 5/8 inches high by 5/8 inch wide at the base or 1 1/8 inches
high by 3/8 inch wide at the base. Each cone is of a definite mineral
composition and has a number stamped on one face and when heated under
standard conditions it bends at a definite temperature.
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Pyrometric Cone
Equivalent (P.C.E.): The number of that Standard Pyrometric Cone whose
tip would touch the supporting plaque simultaneously with a cone of
the refractory material being investigated when tested in accordance
with the Method of Test for Pyrometric Cone Equivalent (P.C.E.) of
Refractory Materials.
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Pyrophyllite: A
mineral consisting of hydrated silicate of aluminum; AISi2O5(OH).
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Pyroplasticity:
The physical state induced by soaking heat which permits a refractory
body to be readily deformed under pressure or by it own weight.
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Quartz: A common mineral consisting of silica
(SiO2). Sandstones and quartzites are composed largely of quartz.
Specific gravity 2.65.
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Quartzite: A Hard
compact rock consisting predominantly of quartz. There are two types:
(1) metaquartzite, a metamorphic rock usually derived from sandstone;
and (2) orthoquartzite, a sedimentary rock consisting of grains of
silica sand cemented together by a least 10 percent of precipitated
silica.
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Ramming Mix: A
ground refractory material which is mixed with water and rammed into
place for patching shapes or for forming monolithic furnace linings.
Usually of a less plastic nature than plastic refractories.
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Ramming Mass: See
Ramming Mix
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Recuperator: A system
of thin-walled refractory ducts used for the purpose of transferring
heat from a heated gas to colder air or gas.
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Refractories: Nonmetallic
materials suitable for use at high temperatures in furnace construction.
While their primary function is resistance to high temperature they
are usually called on to resist other destructive influences also,
such as abrasion pressure, chemical attack and rapid changes in temperature.
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Refractories, Acid:
See Acid Refractories
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Refractories, Basic:
See Basic Refractories
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Refractories, Neutral:
See Neutral Refractories
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Refractoriness: In
refractories, the capability of maintaining a desired degree of
chemical and physical identity at high temperatures and in the
environment and conditions of use.
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Refractory (adj.):
Chemically and physically stable at high temperatures; The quality
of resisting heat.
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Refractory Chrome Ore:
A refractory ore consisting essentially of chrome-bearing spinel with
only minor amounts of accessory minerals, and with physical properties
that are suitable for making refractory products.
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Refractory Clay:
An earthy or stony mineral aggregate which ha as the essential constituent
hydrous silicate of aluminum with or without free silica; plastic
when sufficiently pulverized and wetted, rigid when subsequently dried
and of sufficient purity and refractoriness for us in commercial refractory
products.
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Refractory Composite
Coating: A combination of heat-resistant ceramic materials applied
to a metallic substrate which may or may not require hear treatment
prior to service. This term may also be used for coatings applied to
nonmetallic substrates, for example graphite.
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Refractory Magnesia:
A dead-burned refractory material consisting predominantly of
crystalline magnesium oxide.
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Refractory Metal: A
metal having an extremely high melting point. In broad sense, it
refers to metals having melting points above the range of iron, cobalt
and nickel.
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Regenerator: A refractory
structure in which thermal energy from hot furnace gases is alternately
absorbed by checker brick work and released to cold air or gas.
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Regenerator Checkers:
Brick used in furnace regenerators to recover heat from hot outgoing
gases and later to release this heat to cold air or gas entering the
furnace; so-called because of the checkerboard pattern in which the
brick are arranged.
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Relining: Once it
wears out, the brick lining of a furnace must be cooled, stripped and
replaced. This process is called Relining.
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Rise of Arches:
The vertical distance between the level of the spring lines and the
highest point of the under surface of an arch.
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Rock: A naturally
occurring mineral aggregate consisting of one or more minerals. For
example, quartzite rock is an aggregate consisting essentially of
crystals of the mineral quartz; granite is an aggregate consisting
essentially of spar and quartz.
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Rotary Kiln: A cylindrical,
refractory lined, gas-fired kiln that rotates at an angle and in which
the charge is introduced into the higher end and travels down the
slope of the kiln to the discharge end.
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Rowlock Course:
A course of brick laid on edge with their longest dimensions perpendicular
to the face of wall.
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Rutile: A mineral
consisting of titanium dioxide (Ti2O). Specific gravity 4.18 - 4.25.
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Screen Analysis:
The size distribution
of noncohering particles as determined by screening through a series
of standard screens.
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Secondary Expansion:
The property exhibited by some fireclay and high-alumina refractories
of developing permanent expansion at temperatures within their useful
rang; not the same as overfiring. A behavior not to be confused with
the bloating caused by excessive temperatures which impair the useful
properties of a refractory.
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Semi-Silica Fireclay Brick: A firclay brick containing not less than 72 percent
silica.
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Serpentine: A group
of rock forming minerals; (mg.Fe)3Si2O5(OH)4. Specific gravity 2.5
- 2.7. Also, a common rock consisting essentially of serpentine minerals.
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Silica: SiO2, the
oxide of silicon. Quartz and chalcedony are common silica materials;
quartzite, sandstone and san are composed largely of free silica in
the form of quartz.
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Silica Brick: A
fired refractory consisting essentially of silica and usually made
from quartzite bonded with about 1.8 to 3.5 percent of added lime.
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Silica Fire Clay:
A refractory mortar consisting of a finely ground mixture of quartzite,
silica brick and fire clay of various proportions; often called silica
cement.
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Silicon Carbide:
A compound of silicon and carbon; SiC.
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Silicon Carbide Refractories: Refractory products consisting predominantly of silicon
carbide.
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Sillimanite: A brown,
grayish, pale-green or white orthorhombic mineral; AI2SiO5. Specific
gravity 3.24. At about 2785oF
(1530oC) it begins to dissociate into
mullite and free silica.
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Sintering: A heat
treatment which caused adjacent particles of material to cohere at
a temperature below that of complete melting.
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Skewback: The course
of brick, having an inclined face, from which an arch is sprung.
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Slag: A substance
formed in any one of several ways by chemical action and fusion at
furnace operating temperatures: (1) in smelting operations, through
the combination of a flux, such as limestone, with the gangue or waster
portion of the ore: (2) in the refining metals, by substances, such
as lime, added for the purpose of effecting or aiding the refining;
(3) by chemical reaction between refractories and fluxing agents,
such as coal, ash or between two different types of refractories.
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Slagging of Refractories:
Destructive chemical action between refractories and external agencies
at high temperatures resulting in the formation of a liquid.
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Slag Zone: An
area or region (such as in a furnace) that contains, stores or
is in contact with slag.
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Sleeves: Tubular
refractory shapes used to protect the metal rod which holds the stopper
head in the valve assembly of a bottom-pouring ladle.
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Slurry: A suspension
of finely pulverized solid material in water of creamy consistency.
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Soapstone: A metamorphic
rock consisting mainly of talc and derived from the alteration of
ferromagnesian silicate minerals.
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Soldier Course:
A course of brick set on end; little used in the case of refractories
except in the bottoms of some types of furnaces.
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Solid Solution:
A homogeneouse crystalline phase with a variable composition. The
most common solid solutions involve two or more substances having
the same crystalline structure. However, the term can also refer to
the solution of small proportions of a material in a seemingly unrelated
substance.
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Spalling of Refractories:
The loss of fragment (spalls) from the face of a refractory structure,
through cracking and rupture, with exposure of inner portions of the
original refractory mass.
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Specific Gravity:
The ratio between the weight of a unit volume of a substance and that
of some other standard substance under standard conditions of temperature
and pressure. For solids and liquids the specific gravity is based
on water as the standard. The "true specific gravity" of a body is
based on the volume of solid material excluding all pores. The bulk
or volume specific gravity is based on the volume as a whole, ie.
the solid material with all included pores. The apparent specific
gravity is based on the volume of the solid material plus the volume
of the sealed pores.
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Specific Heat: The
quantity of heat required to raise the temperature of a unit mass
of a substance one degree.
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Spinel: (1) The
mineral composed of magnesium aluminate; MgAI2O4. Specific gravity
3.6. Melting point 3875oF
(2135oC). (2) A group of minerals of general
formula; AB2O4 where A represents magnesium, ferrous iron, zinc or
manganese or any combination of them and B represents aluminum, ferric
iron or chromium.
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Spring Line: The
line of contact between the inside surface of an arch and the skewback.
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Sprung Arch: An
arch which is supported by abutments at the side or ends only.
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Stretcher: A brick
laid on flat with its length parallel to the face of the wall.
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Superduty Fireclay Brick: Fireclay brick which have a P.C.E. not lower than Cone 33 and
which meet certain other requirements as outlined in A.S.T.M. Designation
C 27-58T.
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Suspended Arch:
An arch in which the brick shapes are suspended from overhead supporting
members.
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Taconite: A
compact ferruginous chert or slate in which the iron oxide is do finely
disseminated that substantially all of the iron-bearing particles
are smaller than 20 mesh. Typical analyses of the ore grade show total
iron at 32 percent.
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Talc: A hydrous
magnesium silicate mineral; Mg3Si4O10(OH)2. Specific gravity 2.7 -
2.8. Hardness 1.
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Thermal Conductivity:
The property of matter by virtue of which heat energy is transmitted
through particles in contact.
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Thermal Expansion:
The increase in linear dimensions and volume which occurs when materials
are heated and which is counterbalanced by contraction of equal amount
when the materials are cooled.
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Thermal Shock: A
sudden transient temperature change.
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Tolerance: The permissible
deviation in a dimension or property of a material from an established
standard or from an average value.
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Tridymite: A mineral
form of silica;SiO2. Stable from 1598 to 2678oF
(870o to
1470oC). Specific
gravity 2.26. An important constituent of silica brick.
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Trough: An open
receptacle through which molten metal is conveyed from a holding device
or furnace to a casting mold or another receptacle.
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True Porosity: Please
see Porosity of Refractories
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Tundish: The
shallow refractory lined basin on top of the continuous caster. It
receives the liquid steel from the ladle, prior to the cast, allowing
the operator to precisely regulate the flow of metal into the
mold.
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Tuyere Brick: A
refractory shape containing one or morel holes through which air and
other gases are introduced into a furnace.
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Vacuum Degassing: An advanced
steel-refining method wherein a ladle of molten metal is placed within
a chamber which is then evacuated. This reduces gas content,
particularly hydrogen, thus reducing non-metallic inclusions to
produce a purer and cleaner form of the metal.
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Vacuum Furnace: A furnace using low
atmospheric pressures instead of a protective gas atmosphere, like
most heat-treating furnaces. Vacuum furnaces are categorized as
"hot wall" or "cold wall", depending on the
location of the heating and insulating components.
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Vacuum Pressing:
A method of forming brick
shapes by which they are subjected to a partial vacuum during pressing
in a power press.
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Vermiculite: A group
of micaceous minerals, all hydrated silicates, varying widely in composition;
(Mg.Fe,AI)3(AISi)4O10(OH)2.4H2O. When heated above
302oF
(150oC)
vermiculite
exfoliate and increases greatly in volume.
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Vesicular: Having
a cellular structure; applied to fire clays which have become bloated
by over-firing.
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Vibratory Pressing:
A process for forming refractory shapes in which the ground particles
of refractory material are packed closely together by rapid impact--type
vibrations of the top and bottom dies; also called impact pressing.
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Vitrification: A
process of permanent chemical and physical change at high temperature
in a ceramic body, such as fire clay, with the development of a substantial
proportion of glass.
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Warpage: The
deviation of the surface of a refractory shape from that intended,
caused by bending or bowing during manufacture.
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Wedge Brick: A brick
shape having six plane faces (two sides, two edges an two ends), in
which two faces (the sides) are inclined toward each other and one
end face is narrower than the other.
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Wetting: The adherence
of a film of liquid to the surface of a solid.
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Wollastonite: A
triclinic mineral; CaSiO3. Specific gravity 2.9. Inverts at
2192oF
(1200oC) to pseudowollastonite. Melts incongruently at
2811oF -
1544oC.
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Yield: The load per unit of
original cross section at which, in soft steel, a marked increase in
deformation occurs without increase in load.
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Young's Modulus:
In mechanics, the ratio
of tensile stress to elongation within the elastic limit; the modulus
of elasticity.
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Zircon:
A mineral; ZrSiO4. Specific
gravity 4.7. Begins to melt incongruently at 3045oF
(1685oC) forming
ZrO2 solid solution plus liquids; completely melted at about
4800oF
(2650oC).
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Zirconia: Zirconium
oxide; ZrO2. Specific gravity 5.8. Melting point 4890oF
(2700oC). Its
chief source is the mineral baddeleyite.
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