Refractory Systems for the Ceramic Industry

KERAMIK

Wall, roof and tunnel kiln car systemsfor tunnel kilns

Tunnel kiln carThe kiln car, due to the constant heating and cooling, isthe component in the tunnel kiln exposed to the mostsevere stresses. In BURTON tunnel kiln cars all decisivedemands are taken into account:

- lightweight, energy-saving construction and material selection

- long service life- Airtightness of car interlock and labyrinth

Low weights help to save energy costs up to 30%.

In consultation with the customers BURTON developscomputer-optimized systems. According to the prob-lems arising individual and patented tunnel kiln solu-tions are available.

Tunnel kiln wallA well-insulated wall system is anessential condition for the economicaloperation of the tunnel kiln. The opti-mum kiln wall is as thin as possible,providing effective insulation and com-posed of large-size units.

High wages demand short construc-tion times and therefore large-dimen-sioned, lightweight units which can beassembled quickly on site.

Tunnel kiln suspended roofThe decisive factor for a good roof is its airtightness.In the overlapping unit layout of the suspended roofBURTON has made an outstanding contribution totechnical progress. A modern tunnel kiln suspendedroof today has to satisfy high demands:

- low weight for inexpensive construction- good insulating effect despite low construction

height- large-size construction units in dry-pressed or cast

design for rapid assembly of an airtight suspended roof

- use of optimum materials for corrosive kiln atmos-pheres such as sulphur, salt etc.

Wall and roofing systems for ceramic kiln construction DIN EN ISO 9001certified since 1994

2

Tunnel kiln car assembly for lightweight construction systems

The insulating course is applied

The car core is filled with a high-quality insulatingmaterial and levelled

The patented “Universal Border Block” ofBurcoLight is installed

Röben Works 4, Querenstede

The BURTON lightweight construc-tion systems permit the completionof the tunnel kiln car in the shortestpossible time. The assembly is easy,maintenance presents no problemsand is inexpensive.

3

BURTON Systems for tunnel kiln cars

Tunnel kiln car border with patented BURTON “UniversalBorder Block" in the BuroLight quality

KERAMIK

%1,0

0,5

0

Thermal expansion

Burcotop

Standard fireclay

BurcoLight 13+14/25

°C 200 400 600 800 1000 1200 1300

100908070605040302010

Thermal shock resistanceaccording to DIN 51068(cylinder process)

Standard fireclay Burcotop BurcoLightH BurcoLightH13 + 14/25

15

5070

>_100

The reduction of energy costs is a very acute problemat the present time. It is extremely important to keepenergy consumption under control and at a minimum.

This is particularly required in the case oftunnel kiln cars because of their continualheating and cooling.With the development of the newBurcoLight qualities BURTON has takenaccount of these requirements.

BurcoLight

Burcotop

4

Energy saving in tunnel kiln carsby the new BurcoLight qualities

– low raw density of ~1.3 to 1.5 kg/dm thus resulting in a smaller load imposed on the chassis (lower border blocks approx. 35 % less in weight)

– low thermal conductivity– lower energy costs,

up to ~30 % less (depending on the type of tunnel kiln car and the tunnel kiln temperature)

– lower undercar temperaturesdue to the improved insulating effect

– low thermal expansionof 0.33 to 0.35 % at 1000 °C (DIN 51045)

– excellent thermal shock resistance

Opportunities for the applications of BurcoLight:- for renovations of the car fleet- for re-equipment in the lower border zone and for

cover tiles in areas with low applied load Burcotop 125 H can be substituted for BurcoLight H

- highly suitable for short periods of operation

Pine Hall, Georgia, USA | Tunnel kiln car withBurcoLight car border

1,6001,5001,4001,3001,2001,100

1,0000,9000,8000,7000,6000,500

Temperature [° C]

BurcoLight 13/25 H

BurcoLight 14/25 H

Burcotop

Ther

mal

cond

uctiv

ity [W

/mK]

200 300 400 500 600 700 800 900 1000 1100 1200

3

5

Kiln furniture

Dry-pressed and plastic kiln furniturefor the ceramic industry

- Draught hole blocks- Viaduct blocks- Support structures for side firing- Support blocks and perforated slabs

Austral Brick, Australia | Side-fired tunnel kiln car with patentedcordierite setting beams

Support block and perforated slab Draught hole block

Kiln car structure with supportsand perforated slabs for thefiring of vitrified clay pipesViaduct block

Optimum kiln furniture ensures uniform firing andhence optimum product quality. BURTON offers yousuitable designs for industrial practice for the mosteconomical and scrap-free production.

The development of the most up-to-date CAD tech-nology enables individual requirements by customersto be taken quickly into consideration.

The modern production technologies permit light-weight, thin kiln furniture of uniform wall thicknessfor stress-free, rapid heating and cooling, which is anessential condition for a long service life.

The dry pressing method enables high dimensionalaccuracy, a homogeneous texture and good hot ben-ding properties to be obtained. The manufacture oflarge production quantities is possible in a short time.

KERAMIK6

Tunnel kiln car systems and kiln furniturefor the firing of clay roofing tiles

Silicon carbide as kiln fur-niture for fine and heavyclayware

Nibra, Großsammensleben | Tunnel kiln car forH-cassettes

Jessenberger, Unsleben | Tunnel kilncar with SiC loadbearing beams

Röben Works, Brüggen | Tunnel kiln carfor single-layer firing

Ribbed U-cassette in dry-presseddesign

Smooth U-cassette

- U-cassettes / Ribbed cassettes- Mono-cassettes- Setting frames for fast firing- SiC systems- Setting slabs and perforated slabs- Patented loadbearing beams- Supports and support pipes

Creaton AG, Wertingen | Tunnel kiln carwith ribbed U-cassettes

H-cassettes for thefiring of clay roofing tile DS5

H-cassettes in pressed design

7

BURTON GmbH + Co. KG · Postfach 1 20 · 49308 Melle/Buer · Barkhausener Str. 55 · 49328 Melle/Buer · Germany

Telefon: +49(0)54 27 81-0 · Telefax: +49(0)54 27 81-1 02 · Internet: www.burton.de · eMail: info@burton.de

BURCOTOPWT12

Cordierite

2.00

21.0

20

35

2.0

4.0

30

0.45

2.02.0

BURCOTOPWT50

Cordierite

2.25

21.0

40

50

2.0

30

0.50

2.02.0

BURCOTOP125 HS

Cordierite,Mullite

1.95

20

30

4.0

70

_< 0.45

1.20

1.281.29

1.30

1.351.57

1.01.5

BURTON40 HW

Cordierite,Mullite

2.10

35

35

4.0

80

_< 0.40

1.30

1.301.32

1.35

1.401.50

1.01.5

BURTONS 60 T

Mullite

2.55

16.0

60

60

1.2

40

1600

0.60

1.601.52

1.501.521.65

BURCORIT20 B

Cordierite

2.10

60

53

38

5.0

90

0.35

1.30

BURCORIT30

Cordierite

2.0

20

50

52

40

4.0

90

12.0

1350

0.37

BURCORITCM1

Cordierite,Mullite

2.04

20-23

37

7.6

13.0

18.0

1380

0.23

1.361.451.26

1.261.35

BURCO-LIGHT 14/25

Cordierite

1.40

15

32

8.0

100

0.30

0.690.68

0.700.760.78

1.01.5

BURCORIT20 W

Cordierite

2.10

50

53

38

5.0

100

0.35

1.30

BURCO-LIGHT 13/25

Cordierite

1.30

10

33

7.5

100

0.33

0.540.55

0.580.630.69

1.01.5

Quality

Mineral Content

Bulk density (g/cm3) +/- 5%

Open porosity (Vol. %)

Cold crushing strength(MPa)

SiO2 (%)

AI2O3 (%)

Fe2O3 (%)

MgO (%)

Thermal shockresistance (Cycles) Modulus of Rupture(MPa) Hot Modulus of Rupture1200 °C (MPa)Refractoriness under Loadt0,5 (°C)

Thermal expansion (reversible) 1000 °C (%)Mean specific heatcapacity 20–1200 °C (kJ/kg K)Thermal Conducitivity at200°C/WmK 400°C/WmK 600°C/WmK 700°C/WmK800°C/WmK1000°C/WmK1200°C/WmKPermissible tolerances >_ 100 mm (+/-%) < 100 mm (+/-mm) >_ 150 mm (+/-%) < 150 mm (+/-mm)(Mono and U-cassetteshave separate tolerances)

>_ 200 mm:+/-0.75%

< 200 mm:+/-1.5 mm

>_ 200 mm:+/-0.75%< 200 mm:+/-1.5 mmWarpage max. 0.75 %

of longest dimension (diagonal)A

P D

esig

n,M

elle

08/

04

BURTONS60 HW

Cordierite,Mullite

2.30

35

55

2.0

70

1350

< 0.45

1.50

1.411.32

1.26

1.291.32

1.01.5

Technical Data