Zhengzhou Tyreen Refractory Co.,Ltd
Refractory Mortar Introduction
Refractory mortar is a jointing material used for laying and repairing refractory brick masonry. It is applied between refractory bricks to fill joints, improve the integrity of the lining and provide a suitable bond during high-temperature service.
According to the main refractory material used in its formulation, refractory mortar can be classified into clay refractory mortar, high alumina refractory mortar, magnesia refractory mortar and silica refractory mortar. The appropriate mortar should generally be selected according to the type of refractory brick and the operating temperature of the furnace lining.
Tyreen supplies refractory mortar for different types of refractory brick masonry and high-temperature industrial furnace applications.
Refractory Mortar Classification
Clay Refractory Mortar
Clay refractory mortar is formulated mainly from hard clay clinker combined with soft clay or suitable chemical binders.
It is generally used with fireclay bricks and is suitable for operating temperatures up to approximately 1350°C.
Typical applications include:
- Blast furnaces
- Hot blast stoves
- Coke ovens
- Soaking furnaces
- Heat exchangers
- Boilers
- Other furnace linings constructed with fireclay bricks
High Alumina Refractory Mortar
High alumina refractory mortar is designed for use with high alumina refractory bricks. It provides a compatible jointing material for high-temperature masonry and is suitable for operating temperatures up to approximately 1500°C, depending on the specific grade and service conditions.
It is used where higher alumina content and higher temperature resistance are required.
Magnesia Refractory Mortar
Magnesia refractory mortar is formulated for magnesia-based refractory masonry and can be used at temperatures up to approximately 1650°C, depending on the formulation.
It is suitable for use with:
- Magnesia bricks
- Magnesia alumina bricks
- Magnesia chrome bricks
- Other magnesia-based refractory bricks
Magnesia refractory mortar can also be used as a protective coating for magnesia refractory masonry.
Silica Refractory Mortar
Silica refractory mortar is used with silica brick masonry and is particularly important in coke ovens and other high-temperature furnace structures.
Typical applications include:
- Coke oven heating and combustion chambers
- Checker chambers
- Flues
- Furnace roofs
- Furnace end walls
- Riser pipes
- Furnace doors
- Soaking furnace bottoms and walls
- Heating furnace roofs and walls
- Hot blast stoves
- Glass furnaces
- Other silica refractory brick linings
Technical Characteristics
High Refractoriness
Refractory mortar is formulated to maintain its bonding function under high-temperature service. Different refractory mortar grades are designed for different operating temperature ranges.
Selecting a mortar with a suitable temperature rating is important for maintaining the integrity of the refractory lining.
Good Bonding Performance
Refractory mortar provides a strong bond between refractory bricks and helps form a continuous masonry structure.
At elevated temperatures, ceramic bonding develops within the mortar, further improving the integrity and stability of the refractory lining.
Good Workability
The mortar provides good water retention, spreadability and bonding properties, allowing it to be applied evenly between refractory bricks.
During masonry, the mortar should form a continuous and sufficiently full joint without excessive voids.
Dense Masonry Structure
Properly formulated refractory mortar has high filling density and relatively low water consumption. When correctly applied, it helps produce a dense refractory masonry structure and reduces unnecessary open joints.
Resistance to High-Temperature Erosion
Refractory mortar provides good resistance to high-temperature erosion in suitable furnace environments. Its performance depends on the mortar composition, refractory brick being used and actual operating conditions.
Typical Applications
Refractory mortar is used for laying, jointing and repairing refractory brick linings in a wide range of industrial furnaces.
Typical industries include:
- Metallurgy
- Steelmaking
- Cement
- Glass
- Petrochemical
- Building materials
- Machinery
- Power generation
- Boiler systems
Typical furnace applications include:
- Coke ovens
- Blast furnaces
- Hot blast stoves
- Glass furnaces
- Heating furnaces
- Soaking furnaces
- Boilers
- Other industrial furnace linings
Refractory Mortar for Different Refractory Bricks
The refractory mortar should be selected according to the refractory brick being installed.
For example:
- Clay refractory mortar → Fireclay brick
- High alumina refractory mortar → High alumina brick
- Magnesia refractory mortar → Magnesia-based refractory brick
- Silica refractory mortar → Silica brick
Matching the refractory mortar with the brick helps maintain compatible thermal and chemical properties throughout the refractory lining.
Construction Procedure
Before application, refractory mortar should be mixed with the appropriate amount of water according to the required consistency.
The general construction procedure is:
- Add the required amount of water to the refractory mortar.
- Mix thoroughly until the material reaches a uniform consistency.
- Adjust the water addition according to the actual workability required.
- Apply the mortar evenly to the brick joint.
- Keep the mortar joint full and uniform during masonry.
- Remove excess mortar from the exposed surface after positioning the brick.
The amount of water should be controlled carefully. Excessive water can affect the density and performance of the finished refractory joint.
Selection of Refractory Mortar
The appropriate refractory mortar depends mainly on:
- Type of refractory brick
- Operating temperature
- Furnace atmosphere
- Chemical environment
- Required joint thickness
- Construction method
For high-temperature industrial furnace applications, refractory mortar should be selected according to the actual operating conditions rather than temperature alone.
Tyreen can supply different refractory mortar grades for fireclay, high alumina, magnesia and silica refractory brick masonry. Customers can provide the refractory brick type, operating temperature and furnace application for material selection.
Application Temperature
| Type | Approx. Service Temperature | Typical Matching Brick |
|---|---|---|
| Clay refractory mortar | ≤1350°C | Fireclay brick |
| High alumina refractory mortar | ≤1500°C | High alumina brick |
| Magnesia refractory mortar | ≤1650°C | Magnesia-based brick |
| Silica refractory mortar | Application dependent | Silica brick |
The actual service temperature depends on the specific formulation and operating conditions.
