Refractories for Ceramic & Red-Bricks Industries

Refrattari per Industria Ceramica E Laterizi

MISANO GROUP

Misano Group is a leading supplier of refractory products with a range of services and solutions for the

global industries. Founded in 1970 by Mr. Dante Signorelli, with headquarter and plant in Misano Gera

d’Adda (Bergamo, Italy), Misano Group operates worldwide. Nowadays, Misano Group manufactures a

full range of refractory products for Iron & Steel Industries, and Ceramic Industries.

Misano Group’s experienced team is composed by experts in refractories who can provide an excellent

and quick aftersales service also due to the fact that the technicians are locally based and close to the

industries. Through investments for upgrading the existing facilities and updating the technical staff,

Misano Group has been committed to improving and optimizing refractory performance so as to

developing new products. This approach has been playing a strategical importance in building and

keeping partnerships with leading industries based around the globe.

Misano group in the last few years has also reached a worldwide primary position in the graphite

electrode field. From 15 years, Misano Group has been working only with ISO 9001 certified plants that

carry on strict quality control programs.

Misano Group’s fast development has led to the birth of three new entities:

Misano Middle East, located in Ras-Al-Khaimah (United Arab Emirates), which has allowed

Misano Group to quickly become an important player in the ever growing Middle East market.

Misano Far East, which attends to raw material suppliers and to graphite electrodes quality

control. Our technical staff coordinates and inspects on daily basis the production of refractory

materials and graphite electrodes of Misano Group’s partners.

Misano Engineering, which provides an effective and reliable customer service in order to

optimize the production/manufacturing cycles in the industries.

TABLE OF CONTENTS

INTRODUCTION 01

TECHNICAL INFORMATION 02

SHAPES & DIMENSIONS 03 – 07

RAW MATERIALS – CORDIERITE 08

RAW MATERIALS – LOW ALUMINA MULLITE 09

PRODUCTS – SOLID BATTS 10

PRODUCTS – EXTRUDED BATTS 11

PRODUCTS – PILLAR & STRUT ATTACHMENT 12

PRODUCTS – KILN BODY STRUCTURE 13

PRODUCTS – SPECIAL KILN FURNITURE, SAGGERS 14

APPLICATIONS 15 – 17

INTRODUCTION

The kiln furniture division belongs to the Ceramics material division of Misano Group. We are a global

supplier of kiln furniture and technical ceramics. Moreover, the location of Misano Middle East allows a

direct access to significant markets, with the possibility to arrange not only quick deliveries but also to

provide a fast and efficient customer service with our technical staff in the GCC area.

Misano facilities in Italy (headquarters), United Arab Emirates and China

Misano Group can master the whole range of refractory products of any size and quantity. Misano Group

has developed a number of complex, high performing products; based on extrusion process specifically

for red bricks and ceramic industries. These materials are mainly based on Cordierite and Mullite, the

only compound of Alumina and Silica that is stable at high temperatures. These materials range in density

from 1.9 g/cm2 to 2.7 g/cm2 and are generally used for applications up to around 1380°C.

1

TECHNICAL INFORMATION

Mullite-cordierite kiln furniture are made by mullite, cordierite and other materials by vacuum extruding,

pressing, rolling and then calcining. This furniture has good thermal shock resistance at high working

temperatures. It is the best material used under 1300˚C. We research and develop some type of high

quality kiln furniture for ceramic and other industries according to difference of ceramics, kiln type,

temperature, cycle, loading and so on.

The following type of technical data is the real-tested data available by now. We understand that

professional cast quality, technology would lead the future. Hence, we work continuously and vigorously

to improve our product quality. We shall offer the best suited materials by the user conditions.

PHYSICO-CHEMICAL PROPERTIES

RM 48 MC RM 65 M RM LAT STD 2 RM LAT STD 8 RM LAT HIGH

Mullite &

CordieriteMullite Mullite & Cordierite Mullite & Cordierite Mullite & Cordierite

Al2O3 46 - 48 64 - 66 40 - 45 40 - 45 45 - 50 %

MgO 5.5 - 7 1.9 - 2.3 7 - 8.5 4 - 5 %

SiO2 43 - 45 31 - 33 40 - 45 40 - 45 35 - 40 %

2 - 2.2 2.4 - 2.6 2.1 - 2.2 1.9 - 2.1 1.8 - 2 g/cm3

25 - 27 18 - 20 23 - 25 23 - 25 28 - 30 %

★★★★★ ★★★ ★★★★ ★★★★ ★★★★★★

(Based on application)

1250 1300 1300 1350 1300 ˚C

Ceramic Industries Ceramic IndustriesRed Bricks

Industries

Red Bricks

Industries

Red Bricks

Industries˚CAPPLICATIONS

PROPERTIES

UNITS

COMPONENTS

BULK DENSITY

CHEMICAL

COMPOSTION

TYPE OF KILN-FURNITURE

THERMAL SHOCK RESISTANCE

MAX. WORKING TEMPERATURE

APPARENT POROSITY

2

SHAPES & DIMENSIONS

Standard Supports

Dimensions (mm)

A H B Thickness

240 125 200 -350 25 - 30

250 90 200 -350 25 - 30

250 120 200 -350 25 - 30

250 160 200 -350 25 - 30

250 180 200 -350 25 - 30

290 90 200 -350 25 - 30

290 160 200 -350 25 - 30

290 180 200 -350 25 - 30

Additional sizes are available on request

3

SHAPES & DIMENSIONS

Load Bearing Plate

Dimensions (mm)

a (max) b (max) s

300 500 25

300 500 35

300 500 40

350 500 25

350 500 35

350 500 40

400 500 25

400 500 35

400 500 40

500 500 25

500 500 35

500 500 40

4

SHAPES & DIMENSIONS

Load Bearing Plate

Type Dimensions (mm)

a b c h s

B 100 100 - 155 30

B 60 120 - 120 30

B 120 155 - 220 50

B 193 150 - 285 60

B 160 330 - 205 60

F 475 520 550 200 -

F 550 320 350 200 -

5

RO

OF O

F TUN

NEL K

ILN FO

R B

RIC

K P

RO

DU

CTIO

N

6

LI

GH

T LI

NIN

G O

F B

RIC

K C

AR

S

7

RAW MATERIALS

a. CORDIERITE

Cordierite, a mineral with the theoretical composition 2MgO.2Al2O3.5SiO2 is a major component of Cordierite-Mullite kiln furniture. It is produced with high quality raw materials by wet-milling and extruding technology. It has a homogenous composition, properties, and high cordierite content. Extremely low coefficient of thermal expansion explains the outstanding thermal shock resistance of these kiln furniture materials which makes it an ideal raw material for cordierite ceramics and other refractories. It is widely used in producing kiln furniture, honeycomb ceramics and so on.

PHASE COMPOSITION

[%]

SiO2 Al2O3 MgO CORDIERITE

Synthetic Cordierite 50 35.5 13.5 ≥ 1.9 < 25 1.8 > 95

RAW MATERIALBULK DENSITY

[g/cm3]

APPARENT

POROSITY

[%]

C.T.E.20-1200˚C

[x10-6K-1]

CHEMICAL COMPOSITION

i. MICROSTRUCTURAL APPEARANCE i ii. NAKED-EYE APPEARANCE

8

RAW MATERIALS

a. LOW Al2O3 MULLITE

Mullite, a mineral with the theoretical composition of 2Al2O3.3SiO2 in combination with Alumina, is

widely used in kiln furniture in ceramic industries. It is manufactured by choosing natural materials,

homogenously mixing and calcining at high temperature. It has a special microstructure of needle-like

mullite and SiO2 glass complex phases, and is very suited to produce high quality Mullite-Cordierite kiln

furniture as aggregate for its excellent physical and chemical properties.

A wide variety of Mullite-Alumina kiln furniture materials are commercially available that are applied for firing ceramics in high temperature ranges. Mullite is widely used in the production of kiln furniture, investment casting, refractory bricks, etc.

SiO2 Al2O3 Mullite Glass

Low Al2O3 Mullite 54 43 ≥ 2.5 < 4.0 4.4 55 45

PHASE COMPOSITION

[%]RAW MATERIAL

CHEMICAL COMPOSITIONBULK DENSITY

[g/cm3]

APPARENT

POROSITY

[%]

C.T.E.20-1200˚C

[x10-6K-1]

i. MICROSTRUCTURAL APPEARANCE iiii. NAKED-EYE APPEARANCE

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PRODUCTS

a. SOLID BATTS

We are very careful in considering

and designing about the materials,

proportioning and performance

index. It is one of the common kiln

furniture. Mostly it’s made by press

machine, while some of thicker batts

by extruding machine.

Based on the appearance, we call

them flat batts, trapezoid batts,

perforated batts, grooved batts, and

round batts. They are widely used in

table ware, foamed ceramics,

building ceramics, and electric

ceramics industry. Now our products

can basically meet up all industries’

requirement.

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PRODUCTS

b. EXTRUDED BATTS

Mullite-Cordierite extruded batts are produced

by vacuum extruding technology. Its typical

characters are high loading capability, good

creep resistance at high temperature, long

service life, energy saving etc. It is widely used in

crystallized glass, sanitary ware, building

ceramics, kiln roof system and other fields.

We can produce the thickness 25 mm, 30 mm, 38

mm, 45 mm, 70 mm and width under 700 mm,

length under 1650 mm.

Also we can drill holes, cut rabbets, dig setter for

wash basin on the extruded batts according to

customers’ requirements.

Size Minimum Maximum

Width 220 mm 550 mm

Length 900 mm 1600 mm

Thickness 25 mm 38 mm

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0

PRODUCTS

c. THE PILLAR AND THE STRUT

ATTACHMENT

These products are used for supporting the

extruded slab, solid slab etc. These are

manufactured mainly by extrusion molding,

compression molding, and some shaped pillar

by ramming method. According to the shape,

these can be in general divided into diamond

shaped pillar, round pillar, -shaped pillar,

-shaped pillar, -shaped pillar, the pillar of

dumb-bell shaped concave, etc.

Accessories include a pillar, pillar cap,

connecting pieces, special accessories; and

more with even more complex shape. The cap

is mainly used to connect the pillar and the

beam. The connectors are mainly used for the

connection between the pillar and the pillar

accessories, mainly for the special

requirements of special products to support

each other and kiln location lock.

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PRODUCTS

d. THE KILN BODY STRUCTURE

The kiln body structure mainly comprises of a furnace ceiling structure, and a hollow brick kiln car side structure.

The main products are suspended ceiling structure, hollow I-shaped rail hanger, hanger, hanging plate, hollow flat

plate. The kiln car structure is based on the size and shape of each kiln car, kiln wall curved seam and the kiln car

side curved seam between bricks with specially designed products. With energy saving and environmental

protection, reasonable structure, light and heat insulation, safety and reliability, convenient construction, long

life, etc.; our products ensure a satisfactory operation.

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PRODUCTS

e. SPECIAL KILN FURNITURE, SAGGER

Special kiln furniture is used in various fields

according to the different specific requirements of

the production, including full support of ceramics

for table ware with triangle bracket, sanitary

ceramics with the stool, crystallized glass with

brick, and foam ceramic with stent edge and so on.

Based on the shape, it is divided into circular

sagger, square sagger, profile sagger, and special-

shaped sagger; mainly used in table ware ceramics,

electronic ceramics, and powder sintering industry.

14

APPLICATIONS

The kiln furniture is widely used in the following fields: Sanitary ware, crystallized glass, table ware, foamed

ceramics, kiln construction, building ceramics, high-voltage insulators, electric ceramics, technical ceramics,

powdered metals, abrasives, glass ware, steel industry, etc. We illustrate here some commonly used kiln furniture.

a. SANITARY CERAMICS

In sanitary ceramics industry, at present, the use of Mullite-

Cordierite kiln furniture has become a trend. The kiln comprises a

hollow plate and a solid plate, diamond shaped pillar, pillar cap,

-shaped pillar, connecting piece, hollow platform support, back

support, etc. This kind of kiln, produced by Misano, has strong

resistance to deformation and cracking, and thus gives a long

service life, stable performance, no residue in the use process.

b. CRYSTALLIZE GLASSS INDUSTRY

Crystallize glass industry is building decoration materials

for environmental health. The use of kiln in crystallize glass

industry comprises extruded batts, solid plate, frame,

brick silicon carbide. Misano supports the concept of

energy saving to create a good durability of kiln. With

nearly ten years development of crystallize glass industry,

Misano provides durable crystallize glass industry high

ratio of kiln products, reduce the production cost of

crystallize glass manufacturer, the product of this green

broader human services, make life more beautiful, healthy

people around the world.

10

0

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c. PORCELAIN CERAMICS

As the name implies, refers to the use of ceramics for daily use porcelain, the people daily life essential living

species, so the product shape, kiln type, kiln firing temperature, firing cycle is different, so the choice of kiln

furniture is also more complex, select the appropriate kiln furniture can improve furnace loading, reduce fuel

consumption, reduce worker strength, saving the cost of production. Misano with technical experience

accumulated over the years, to provide most suitable products and a full range of solutions for the ceramics

industry.

d. CERAMIC FOAM INSULATION BOARD

Ceramic foam insulation board is a new type of high porosity ceramic materials is a closed cell, fireproofing and

heat preservation materials. The ecological deterioration, global climate warming. The development of energy-

saving materials has become the needs of all mankind, foam ceramic industry in recent years the rapid rise. Misano

with energy saving and environmental protection experts in scientific research, the first company to develop a set

of foam kiln ceramic kiln firing scheme, solved a series of problems appeared in the process, the market share of

more than 95%. The development of energy-saving materials, for the benefit of human society, and do a good job

of kiln furniture, a sense of social responsibility of the enterprise is our mission.

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e. KILN INDUSTRY

Misano is the first kiln body material of Mullite-Cordierite material widely used in kiln industry, ceiling structure

can ensure the kiln operation in a clean environment, keep no dust, no dregs. Hollow kiln car side brick, greatly

reduce the weight of the kiln car, fully reduce energy consumption, and improve the service life. Misano after

many years of practical experience, has now become the most reliable cooperation partner of kiln industry.

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MISANO SPA Via Fornace, 6

24040 Misano di Gera d’Adda Bergamo (Italy)

Phone: +39 0363 848295 Fax: +39 0363 848295

MISANO MIDDLE EAST LLC Free Zone Industrial Area

Plot Warehouse wfz 08-02 P.O. Box 31291 Al Jazeera/Al Hamra

Ras Al Khaimah – United Arab Emirates Phone: +971 7 2434321

Fax: +971 7 2434322

info@misanogroup.com www.misanogroup.com