Insulation bricks, also referred to as fire bricks or refractory bricks, are specialized bricks that withstand high temperatures, intense chemical reactions, and physical stress.

These bricks consist of materials like silica, alumina, and other elements to make them resistant to abnormal conditions such as extreme temperatures, effective heat insulation, and long durability.

Insulating fire brick manufacturers produce fire bricks according to customer requirements. Bricks are manufactured based on provided details such as shape, size, quality, and other specifications. These bricks find applications in industrial furnaces, kilns, boilers, vessels, chimneys, and chemical industries. Preventing heat loss and isolating components from thermal energy are the primary uses of insulation bricks.

How Insulation Fire Bricks are Manufactured

Manufacturing insulation bricks consists of several steps, and understanding it is easy to comprehend, but building is not. Here we will discuss how insulating fire brick manufacturers proceed step by step:

1. Raw Material: According to customer needs and technical requirements, manufacturers purchase the raw material. Customer needs and requirements are primarily the focus of the manufacturer.

Customers provide details such as the application of the bricks, size, shape, and cost efficiency. Then manufacturers prepare the raw material by considering the final results.

2. Mixing: Raw materials primarily include silica, alumina, and fireclay, which are passed through a crushing process to achieve uniform particle sizes.

Then, the raw materials undergo the mixing process where they blend and create a homogeneous mixture. This mixture becomes the basis of the bricks.

3. Molding: After preparing the homogeneous raw material, it is molded into the bricks’ shape through the molding process. Two common methods for molding are extrusion and pressing. However, the method used depends on the size and shape required.

4. Firing: After molding and drying, the bricks are placed into kilns for firing. The firing temperature reaches 1400°C, transforming the molded bricks into a solid form.

After this entire process, the bricks gradually cool in the kilns, and then manufacturers check the quality of the final results.

Application of Insulation Bricks

Insulation bricks are used in high-temperature applications to prevent heat losses and insulate areas with high temperatures.

Here are real-life examples where fire bricks have been used:

1. Industrial Furnace: Fire bricks, also called refractory bricks, are used on the surface of industrial furnaces to reduce heat loss and increase efficiency.

2. Kilns: Fire bricks are used in kilns for firing ceramics, pots, and bricks, ensuring uniform heat distribution and thermal insulation.

3. Refractory Lining: High-temperature insulation bricks are used as refractory linings in various types of vessels like boilers. They help prevent heat damage to boilers and other components by providing heat isolation.

4. Chimney and Flue: Both industrial and residential settings utilise exhaust systems like chimneys and flues made of fire bricks to prevent heat loss and improve thermal efficiency.

5. Chemical Industries: Insulation bricks not only resist high temperatures but also withstand severe chemical reactions, making them suitable for use in chemical industries.

Specifications of High-Temperature Bricks

Refractory brick specifications such as composition, density, and size vary depending on the requirements of the bricks. However, some specifications are common to all of them.

Composition: High-temperature fire bricks are made from refractory materials like silica, fireclay, and alumina. The quantity of silica varies from 60% to 90%.

Density: Fire bricks have a higher density than normal bricks, enhancing their strength and thermal properties. They weigh around 3 kilograms.

Temperature Level: Bricks are made to resist and withstand high levels of temperature. High-temperature insulation bricks are capable of handling temperatures up to 2100°C.

Thermal Conductivity: Bricks are designed to conduct low thermal energy for insulation and to avoid heat transfer. Thermal conductivity depends on the purity of materials used by manufacturers.

Size and Shape: High-temperature insulation bricks come in different sizes and shapes depending on the application. Their general dimensions range from 9×4×1 to 9×4×4 inches.

Things to Consider When Choosing Bricks

Before you buy fire bricks, consider several factors and then make a decision. You should have an idea of your requirements to choose the best insulation bricks; otherwise, it’s possible to be misled and lose money on the wrong bricks.

Here are some factors you should know before buying high-temperature insulation bricks:

1. Choose the Correct Bricks

When you decide to buy any insulation bricks, first discuss with insulating fire brick manufacturers. Share your requirements and where you will use the bricks.

Most manufacturers are happy to provide basic and technical details like thermal efficiency and durability of the bricks. This guidance will help you choose the type of insulation bricks that suits your needs and budget.

Picking refractory bricks is always a good idea. Here are some other types of insulation bricks you can check out:

  • Cold face insulation bricks
  • Hot face insulation bricks
  • Porosint bricks
2. Firing Temperature and Glaze Quality

Firing temperature is where mixed raw materials are converted into bricks. At that temperature, chemical reactions start in the bricks and form solid bricks. It is important for buyers to know the firing temperature, which generally ranges from 1200°C to 1400°C.

Glaze quality varies among brick manufacturers. It is a layer of mixed materials used to enhance the quality of the bricks. Many manufacturers provide it as an inner layer of the bricks. Asking about it from the manufacturer is also important, as the materials used to create glaze should be as pure as possible for high-quality bricks.

3. Cost and Durability

Before making a decision, you should consider the cost of high-temperature insulation bricks as well as transportation and installation costs, if possible.

Additionally, check the durability and strength of the bricks. Ask the manufacturer about its durability and how long it lasts. The required strength of the bricks also varies depending on the furnace, so ask furnace manufacturers which bricks will suit best.

Conclusion

Choosing the wrong type of bricks and manufacturer can become a nightmare for any company.

That’s why Selecting the correct manufacturer is crucial, and it’s always beneficial to engage in discussions with them before placing orders.

Jindal Refractories stands out as one of the best Insulation brick manufacturing companies in Bhilwara. We provide high-quality bricks tailored to customer requirements. Feel free to contact us for any further discussions.