163
G o m m u n i s t Labor t e a m h a s been awarded to the b r i c k p r e s s -
ing t e a m headed by S .S. Marehenko and also to the t e a m
headed by P . K . D e m s k e n k o , an e x c a v a t o r o p e r a t o r , which
fulfills h i s quota by 110-115%.
First to gain the title of Communist Labor shock workers
was electric locomotive engineer N.P. Kharehenko who has
not only learned to drive electric locomotives, but also to
repair the basic parts of them.
The f i r e r s t e a m at the B e l o k a m e n s k Chamotte P l a n t ,
headed by P .N. Rudchenko, which h a s gained the title of
C o m m u n i s t Labor t e a m , h a s been the initiator of competition
for an i n c r e a s e in the r a t e of t u r n o v e r of k i l n s . The e x -
p e r i e n c e of the t e a m h a s been put to u s e by other f i r e r s .
At the Velikiy-Anadol Chamotte P l a n t the title of C o m m u -
n i s t Labor t e a m h a s been awarded to the p r e s s i n g t e a m
headed by P . A . Kulik, who completed his n o r m by 115%
without any s p o i l a g e , the b a t c h e r s t e a m headed by S .I.
T r e s i l o v , which h a s fulfilled its n o r m by 121%.
At this plant the title of C o m m u n i s t Labor shift h a s been
awarded to the t r a n s p o r t section shift headed by C o m m u n i s t
V . V . Kryuehkov.
At the M a y d a n - B i l s k i y Chamotte P l a n t the title of C o m m u -
n i s t Labor t e a m h a s been awarded to the f i r e r ' s t e a m led by
A.F. Metel'skiy.
At the Shehekina Chamotte Plant the team headed by
press operator Ye.N. Borisova carries out exemplary
work and her team was the first at the plant to gain the
title of Communist Labor team. Team-leader Borisova
has learned three trades while the other members of the
team have mastered two.
At the Nikitovka Dolomite Combine the team of rotary
kiln firers headed by Communist V.I. Titskiy has gained
a well-deserved reputation for labor; the team has con-
siderably overfulfilled its obligations.
PRODUCTION
TECHNOLOGY
V.D.
(Ukrainian Scientific Research
The technology of lightweight f o r s t e r i t e p a r t s u s i n g
m a g n e s i u m s i l i c a t e s with f e r r o u s c o m p o s i t i o n s and p r o p -
e r t i e s h a s been developed o v e r a n u m b e r Of y e a r s (1).
The mixture for forsterite lightweight parts used to be
obtained by mixing asbestos waste (fiber length O .8 mm) with
crude magnesite in a rolling mill in the proportion of 7:1,
and wetting to 8 - 10%.
The g r e e n m a t e r i a l was p r e s s e d in hydraulic p r e s s e s
at 700 - 800 k g / c m 2, and fired at 1300 ~ a f t e r d r y i n g . On
account of the high d e g r e e of s h r i n k a g e , which often r e a c h e d
11-12%, it was n e c e s s a r y to polish the p a r t s .
In B r i t a i n they u s e the plastic method of making f o r s t e r i t e
lightweight p a r t s with fired s e r p e n t i n e and m a g n e s i u m ob-
At the Yauskiy Dolomite Combine the title of Communist
Labor shift has been awarded to the shift headed by foreman
N.I. Sidorov. In 1960 the shift completed its program by
103.5% and increased the output of first-grade production.
The ohamotte-firing shop of the Suvorov Mine Administra-
tion has been given the great honor of the title of Communist
Labor shop. The staff of the shop have honorably carried
out the extra obligations that they undertook, producing 5,800
tons of chamotte over and above the plan, reducing the cost
of production by 3.1% and increasing labor productivity by
6 .i~0 over and above what was planned. At the Chelyabinsk
Mine Administration the shift from sector No. 3 engaged in
mining refractory clay has joined in the competition for
Communist Labor at the initiative of excavator operator
P.I. Kul'byakin and foreman M.A. Nesmeyanov. The shift
has achieved high output figures in 1960 and still greater ones
in 1961. The shift productivity has been increased from 400
tons to 452 tons, or by 13%. All members of the shift are
improving their qualifications, are untiringly seeking new
ways of improving labor productivity and are taking an active
part in social life. The shift has been awarded the honorable
title of Communist Labor shift.
The m o v e m e n t of C o m m u n i s t Labor collectives and shock
w o r k e r s embodies all the v e r y b e s t things which have been
developed over the m a n y y e a r s of p r a c t i c e of s o c i a l i s t c o m -
petition and r e p r e s e n t s a h i g h e r phase of d e v e l o p m e n t . It
is a g r e a t f o r c e .
We must ensure the further expansion of the movement
for Communist Labor, for completion of the seven-year
program ahead of schedule and for technical progress in
our industry.
Let us m e e t the f o r t h c o m i n g XXII C o n g r e s s of the C o m m u -
n i s t P a r t y of the Soviet Union with new labor v i c t o r i e s .
OF L I G H T W E I G H T BRICK
Tsigler and B.Ye. Pindrik
Institute of Refractories)
tained from sea water with the addition of wood shavings
(2). In the Polish People's Republic these parts used to be
made by the foam method from magnesite, fireclay and
lime. The initial materials were ground fine enough to
pass through a 0.2 mm mesh, cast in metal molds, dried
and fired at 1450 ~ for three hours, after which they were
polished (3). The properties of forsterite foam light-
weight are compared with other types of lightweight in
Table 1.
At the Ukrainian Research Institute, the writers of
this article developed a method of manufacturing fors-
terite lightweight using combustible additives and press-
ing by the semidry method.
A d e s c r i p t i o n of the r a w m a t e r i a l u s e d is given in Tables 2 and 3.
164 V . D . T s i g l e r and B . Y e . P i n d r i k

TABLE 1

Properties of lightweight forsterite refractories.

Content, % I
Method of
production

Semidry
SlO= 1 ~zO
Additional
s h r i ~ a g e at

Not d e t e r m i n e d
i650 ~ , %
ISpaliing r e s i s -
itaace a i r cool-
ing heating c y c l e s
Porosity,
%

41,0
Bulk

g/cm3
I
density,
compres-
sive
strength
k~lom~
1,89 100--150
'

[ll*
.

Plastic Not determined 1,3 52.3--

57,2 l 1,59
,45-- 14--35
[~l**
:Foam method
[31
24,0 I 63,97 61,8 !,14 56
*Refractoriness under load of i kg/em 2 1340-1380 ~ Recommended temperature for use not above 1550 ~
**Failure point under load of 0.7 kg/cm 2 ]600 ~ in 6 to 22 minutes.
NOTE: Comma represents decimal point.

TABLE 2

Chemical composition and refractoriness of raw material

Chemical composition, % Re-

fractori-
Material SiO~ +TiO, c,.o.IF..o.tF.o c,oI I so. heSS,
~ i

~tus dunite 34,810,98 0.45]5,0914,160,4542,57 -- 11,44 1720

I;i red magnesite ........... 3,70 t 1,34 --

........ 0,46
Crude magnesite 0,92 ] 0,34
........ 0,65[--[1 90145,75.- 00.!01
Ovruch quartzite . . . . . . . . 96,901,,44 l, 031-- --L - -- -- 1750

37,61117,72 --110,63-- 33 14,917,525,691

Oil coke a s h * . . . . . . . . . . .

Ash from coke dust screen-

ings from gas generation
station at Krasnogorovka
plant
4Ft2,,~ -- 123,~ ~_1,30 t
*Ash content of oil coke 3%, coke dust screenings 12%.
NOTE: Comma represents decimal point~

The mixtures were mixed in laboratory rolling mills
and moistened with sulfite-eellulose liquor (1% per dry
residue} with the addition of w a t e r . C u b e - s h a p e d s p e c i -
m e n s with a 50 m m edge and p r i s m s 110 x 30 x 30 m m w e r e
p r e s s e d at 250 k g / e m 2 , d r i e d at 110-'40 ~ and fired in a
m a z u t - f i r e d kiln at 1500~
The effect of the c o m b u s t i b l e additive on the p r o p e r t i e s
of the lightweight w a s studied in a s e r i e s of c h a r g e s with
the addition of 10, 20, 30 o r 4 0 % oil c o k e w i t h a 4:1 r a t i o of
c r u d e dunite to f i r e d m a g n e s i t e . The dunite and oil coke
u s e d w e r e f i n e r than 1 r a m , while the m a g u e s i t e was l e s s
than 0~ r a m . The v a r i a t i o n in the p r o p e r t i e s of the
 Technology of Lightweight Brick 165

TABLE 3 rlSb

Grain composition of powders, mm %

f730
t
Raw m a t e r i a l I--0,5 0 ,088
O, 5-- <0,088

I
Uktus dunite
Fired magnesite
3 326 51
98
f69o.~gL
Ovrueh quartzite 3 97
Oil coke 39 17
Coke dust screenings... 34 34 32 e~

t650 ~3~

lightweight as a function of the addition of oil coke is
shown in F i g . 1. When up to 40% oil coke is added to the
c h a r g e , the r e f r a c t o r i n e s s of the lightweight is not reduced;
the addition of 30% e n s u r e s s a t i s f a c t o r y p o r o s i t y and bulk
d e n s i t y , but the s t r e n g t h of the lightweight is insufficient
in this c a s e .
To i m p r o v e the s t r e n g t h of the m a t e r i a l , duaite and oil
coke of a different g r a i n composition w e r e t r i e d out, and
quartzite was a l s o added. The addition of finely d i s p e r s e d
quartzite h a s a good effect on the s i n t e r i n g of the p a r t s (4)
and also on the f o r m a t i o n of f o r s t e r i t e (5,6).
A s e r i e s of c h a r g e s to which 30% c o m b u s t i b l e additive
had been added w e r e u s e d to study the effect of the g r a i n
composition of dunite and oil coke, The dunite and m a g -
n e s i t e ratio was 4:1. It was d i s c o v e r e d t h a t the thinning of
the dunite h a s a good effect on the s t r e n g t h of the lightweight
m a t e r i a l . A content of about 50-65% dunite finer than 0.088
m m is found to be optimal 9
The u s e of oil coke finer than 2.1 and 0.5 m m showed that
as the g r a i n composition b e c o m e s c o a r s e r , the bulk density
and c o m p r e s s i v e s t r e n g t h a r e i n c r e a s e d . The identical
~o ~ o 2 I ["""~
0 fO 20 30 ~0
Fig, 1. P r o p e r t i e s of lightweight as function of
addition of oil coke:
1 -- total l i n e a r shrinkage; 2 -- bulk density; 3 -- c o m -
p r e s s i v e s t r e n g t h ; 4 -- r e f r a c t o r i n e s s ,
characteristics of lightweight when using oil coke with grains
finer than I and 0.5 mm make it possible to recommend a
fraction less than i ram. With this grain composition in
the dunite and coke, the compressive strength is raised from
9 to 24 k g / c m 2 .
F u r t h e r i m p r o v e m e n t in the s t r e n g t h of the lightweight
was achieved by partially replacing the dunite by f i n e -
ground O v r u c h q u a r t z i t e (finer than 0. 088 m m ) i n c r e a s i n g
the addition of m a g n e s i t e (to keep the m a g n e s i t e - s i l i e a t e
modulus between 1.4 and t.72} and by r e p l a c i n g oil coke
by sifted coke d u s t (Table 4).
It was d i s c o v e r e d t h a t the m o i s t u r e content of the m i x t u r e s

TABLE 4
Composition of c h a r g e s and p r o p e r t i e s of lightweight

Composition, m m , % P r o p e r t i e s of lightweight

eo

b~0 q~ g~
~03

~ ~.~
~V ho

18 56 14 3O 1,82 6,8 1,85 1730 5,8 58,0 1,40 24

30 49 17,5 3,5 30 1,72 6,3 l, 73 -- 6,0 57,4 I ,41 22
27 49 14 7 30 1,40 6,0 I, 73 1750 6,7 57,0 1,41 35
43 37 23 I0 30 1,56 6,5 1,86 1745 4,3 58,6 1,34 33
75 37 23 I0 30 I ,52 6,8 1,95 1750 4, 7 57, I 1,42 57

NOTE: Comma represents decimal point.

166 V.D. Tsingler and B.Ye. Pindrik

OD

i
@

~2

r 300 ~00 700 ~N leO0 r ~SOO

Fig, 2. Variation in characteristics of lightweight green material when

heated,.
I - bulk density of green material from charge No. 43; 2 - the same
from charge NO o 51; 3 - loss in weight of green material from charge
No. 43; 4 -- same from charge No. 51.

-~70 I
i 50
\
\
9
r~ #fOO -300 ~0~ 700 900 tI0# t300"~
I
"~ ~6 ~00 300 5O0 7O0 900 .oo t300 ~',,'W~'

Fig. 3. Variation in compressive strength of light- Fig, 4. Thermal expansion of lightweight

weight green material from charges Nos. 43 and 51 green material from charges Nos. 43
when heated~ and 51 o

should be about 7-8%, and the specific pressing pressure
should not be less than 200 kg/cm 2 . Having obtained
positive results through the addition of quartzite, a series
of specimens was prepared for the purpose of ascertaining
the possibility of producing lightweight directly from quartz-
ire and fired magnesite, using a combustible additive.
The Ovruch quartzite and fired magnesite were used in
a fine-grotmd form (finer than 0.088 ram) while the additive
was finer than 1 ram, Charge No. 51 proved to be the best.
It contained: 45% rnagaesite, 25% quartzite and 30% oil
coke. The synthesized forsterite lightweight fired at 1500 ~
showed a refractoriness of 1770 ~ , apparent porosity 61 ~176
bulk density 1.26 g/cm30 and compressive strength 55
kg/cm2 o
T h e bulk of t h e l i g h t w e i g h t c o n s i s t e d of f o r s t e r i t e with
r e f r a c t i v e index 7 = 1 . 6 7 4 + 0 . 0 0 2 and a = 1 . 6 4 0 + 0 . 0 2
a n d m a x i m u m g r a i n s i z e 0 . 2 m m ( g r a i n s 0,015 to 0 , 0 4 m m
predominated). Among the periclase grains were segre-
g a t i o n s , 0 . 2 5 m m in s i z e , of a y e l l o w i s h - b r o w n c o l o r , w h i c h
b e l o n g e d to t h e p e r i c l a s e w h i c h h a d not r e a c t e d . V i t r e o u s
m a t t e r w a s a l s o p r e s e n t to a s l i g h t e x t e n t ,
The phase composition of the lightweight was: 90-92%
forsterite~ 8-10% perieiase~ and less than 1% vitreous
matter.
We studied the variation in properties of green material
from charges No. 43 and 51 over the range 100-1500 ~ . The
bulk density and loss of weight were determined from plates
75 x 75 x 30 ram, the compressive strength was calculated
in the heated state from cylinders 30 mm in diameter and
length, the thermal expansion from cylinders 30 mm in
diameter and 80 mm long. Results of the calculations are
given in Figs. 2-4.
T h e s h a r p v a r i a t i o n in bulk d e n s i t y and l o s s in w e i g h t
b e g a n w h e n t h e t e m p e r a t u r e r e a c h e d 300 ~ a n d w a s p a r t i c u -
l a r l y a p p a r e n t f r o m 500 to 900 ~ i , e . , b e f o r e t h e c o n t a i n e r
s i n t e r e d . Above 900 ~ t h e c h a n g e in p r o p e r t i e s is s l i g h t
on a c c o u n t of a l m o s t total c o m b u s t i o n of t h e c o k e . T h e
l o s s e s in w e i g h t a t 1500 a m o u n t e d to 32-34%; h e r e t h e bulk
d e n s i t y d r o p p e d a c c o r d i n g l y f r o m 1 . 8 - 1.76 to 1.29 - 1.12
g/cm 3 .
The compressive strength declined sharply as the temper-
a t u r e r o s e , r e a c h i n g 9 . 3 - 7 . 4 k g / c m 2 at 900~ at h i g h e r
 T e c h n o l o g y of L i g h t w e i g h t B r i c k 167

TABLE 5

C h a r a c t e r i s t i c s of m i x t u r e s .

Composition, wt. % Mois- Grain composition, mm, %

No. of
charge
Dunite Magnesite
Ovrush
qtl~rtzite
Oil c o k e
Coke d u s t
screenings
c ol unrtee -n t
% 2--1 0+, 00..1o0..
43 37 23 10 30 -- 7,1 l0 28 62
75 37 23 10 30 9,1 18 23 53
51 45 25 3O -- 6,7. -- 9 9 ll 80
79 45 25 30 8.5 12 16 68

NOTE: C o m m a r e p r e s e n t s d e c i m a l point.

TABLE 6
C e r a m i c p r o p e r t i e s of l i g h t w e i g h t .

No. of Total linear Additional Apparent Bulk Specific Compressive Gas

charge shrinkage shrinkage porosity, densit$, gravity strength, permeability,
a t 1600 ~ % % g/em',t kg/em z 1 9 m/m 2 9
hr 9 mm H20

43 9,0 0,4 53--55 1,46--I ,52 28--44 23--35

75 4,3 1.0 51--56 1,42--I .55 3, 26 53--113 49--62
51 8,9 0.8 51,4 1,57 75--83 23.4
79 3,0 61,9 1,23 3,25 36--47 17.3

NOTE: C o m m a p r e p r e s e n t s d e c i m a l point.

temperatures there was plastic deformation. The nature (per d r y weight); t h e m i x t u r e s w e r e w o r k e d a f t e r m o i s t e n i n g

of t h e c h a n g e in t h e c o m p r e s s i v e s t r e n g t h of l i g h t w e i g h t f o r 10-12 m i n u t e s . A d e s c r i p t i o n of t h e m is g i v e n in T a b l e 5 .
g r e e n f o r s t e r i t e i s d i f f e r e n t f r o m t h a t in t h e k a o l i n o r h i g h - T h e g r e e n m a t e r i a l w a s p r e s s e d on a f r i c t i o n p r e s s to a b u l k
a l u m i n a m a t e r i a l in w h i c h it did not d e c r e a s e a s t h e t e m p e r - d e n s i t y of 1 . 9 - 2 . 0 g / c m 3 a n d f i r e d in a g a s b a t c h f u r n a c e .
a t u r e r o s e , b u t in t h e c a s e of g r e e n k a o l i n it a c t u a l l y i n - T h e b r i c k s w e r e b a t e h e d in one r o w in m u f f l e s .
c r e a s e d ( 7 , 8 ) . A r e d u c t i o n in t h i s p r o p e r t y in g r e e n
f o r s ~ e r i t e r e s t r i c t s t h e p o s s i b i l i t y of b a t c h i n g it f o r f i r i n g T h e t e m p e r a t u r e w a s r a i s e d f r o m 20 to 600 ~ at 25 ~ a n
several rows high. h o u r , f r o m 600 to 1100 a t 10 ~ a n h o u r , a n d f r o m 1100 to 1500
at 25 ~ an h o u r . T h e f i r i n g t i m e at t h e m a x i m u m t e m p e r a t u r e
The expansion of the lightweight green material from was about 8 hours.
charge No. 43 ended at 900-1000 ~ , after which there was
sharp shrinkage up to 1400 ~ , and then a slight increase 9 The chemical composition and properties of the light-
In the case of green material from charge No. 51 expansion weight material are given in Tables 6 and 7.
continued up to i000 ~ , after which it showed shrinkage, and
then only a slight increase at 1400 ~ . The forsterite lightweight showed reduced spalling resist-
ance (when heated to 800 ~ 2-4, and when heated to 1300 ~ 1 air
T h e s e f i g u r e s s h o w t h a t , a s with t h e p r o d u c t i o n of k a o l i n heating-cooling cycle); this is due to the high coefficient
and h i g h - a l u m i n a l i g h t w e i g h t p a r t s , t h e f i r i n g of t h e g r e e n of thermal expansion; a 20-1000 ~ ~ i0.0 x 10-6; ai000-
f o r s t e r i t e o v e r t h e r a n g e in w h i c h t h e fuel b u r n s (600-1100 ~ 1400 ~ ~ (18.5 - 22.0) 9 10 -6 .
s h o u l d be c a r r i e d out a t a r e d u c e d r a t e in o r d e r to l e t the
c o m b u s t i o n of t h e fuel and by t h e t i m e t h e m a t e r i a l b e g i n s The lightweight was characterized by the following phase
to s i n t e r . If t h e c o m b u s t i o n of t h e fuel and t h e s h r i n k a g e of composition:
t h e m a t e r i a l o c c u r t o g e t h e r , c r a c k s f o r m in t h e p a r t s . Content %
No. of charge Forsterite Perielase
On the basis of laboratory work, the experimental plant
of the Ukrainian Research Institute made a batch of light- 75 82 -85 15 -18
weight bricks 230 x 113 x 65 mm in size. 79 88-90 10-12

The mixtures were tempered in rolling mills, moistened It is clear from these figures that the production technique
with water with the addition of 1% sulfide-cellulose liquor based on semi-dry pressing of the mixture of dunite, magnesite,
168 V.D. T s i n g l e r and BoYe. Pindrik

TABLE 7

Chemical composition and properties of lightweight.

F Refractoriness
under load of
Chemical composition, % I k g / c m 2 ,~
No, Of
~harge

StO= AI,Os FesOs FeO CaO blgO

43 35.11 I, 75 6,38 1,06 30 54,3C 1,54 1750 1490 1545 O, 275 0,51
75
79
35,88 I ,71
34,60 2,65
7,02
2,82
1,06
0,66
Ii,45
I. 70
52,72 l ,47
57,5(] 1,66
1760
1770
1545
1420
1565
1440
O, 279
O, 280
0,57
0,63

NOTE: Comma. r e p r e s e n t s decimal point,

quartzite containing combustible additives, including sifted CONCLUSIONS

coke dust (charge No. 75) makes it possible to obtain for-
We worked out the main specifications for the manufacture
sterite lightweight parts with satisfactory properties - with
of lightweight forsterite by the combustible additive method
a coefficient of thermal conductivity approximately 2 or 3
times smaller than in ordinary (dense) forsterite parts. Lightweight forsterite may be used in the working lining at
1500-1550 ~ without suffering mechanical effect or the effect
The interaction of lightweight forsterite from charge of melted metal or slag; it may be used at the same temperature
No. 75 at 1400, 1500 and 1600 ~ was studied while in contact for intermediate heat insulation at the contact point between
with high-alumina (80% A1203), dolomite, magnesite, magnesite, magnesite-chrome and ehrome-magnesite brick.
magnesite-chrome and chrome-magnesite refractories. Industrial tests should be carried outto find out more about the
The specimens of these refractories (cylinders 30 mm in field in which forsterite lightweight brick can be used
diameter and length) were placed on top of cylinders made
BIBLIOGRAPHY
of lightweight forsterite and heated in a cryptol furnace;
the temperature was raised to the maximum in two or three i. K.K. Strelov, and P.S. Mamykin Prec. 4th Confer-
hours and then kept for four or five hours. ence on experimental mineralogy and petrography of
AS USSR, 1953, issue II.
It was discovered that at 1400- 1600 lightweight forsterite
does not weld to the above mentioned refractories, except 2, J.H. Chesters, T.W. Hewic, andT R. Lynam. Trans.
for dolomite, with which it begins to react at 1400 ~ . As the Brit. Cer. See,, 1947, v. 46, No. 9.
temperature is raised to 1500 ~ the interaction is intensified,
3. S. Pawlowski Praca Inst. Min. Hutnietwa, 1954, No. 6.
and a light gray film forms on the contact and crumbles in
air; at 160(I ~ it is extremely intense and the specimen is 4 A.S. Berezhnoyo C o l l . s c i . p r o c . VNIIO, 1958, i s s u e
deformed~ The least interaction is observed at the contact 2 (XLIX) o
point with the high-alumina refractory at 1500~ it increases
5. A.A. Pirogov. Ogneupory, 1955, No. 6.
at 1600~
6. F. Baumhauser. Patent FRG, No. 914477~ 1952.
It was found that lightweight forsterite may be used in
an intermediate insulating layer in contact with magnesite~ 7o V D. Tsig!er and others. Ogneupory, 1957, No. 9o
magnesite-ehrome and chrome-magnesite parts when the
temperature at the join is eo greater than 1550 ~ 8, V~ Tsigler and others. Ogneupory, 1960, No. 7.