Kiln furnitures produced by Estiva Refratários, besides the intrinsic qualities of cordierite and cordierite-mullite, presents an excellent dimensional stability, very good thermal shock performance and high resistance to hot deformation in conventional and fast firing cycles. Operating temperatures can reach up to 1350 ° C, with high performance and creep resistance under load.
Estiva solutions always are being projected to increase ceramic load to be fired, as well as are designed to minimize the refractory mass-inert and consequent improvement in the energy consumption of the furnaces.
The range of products for kiln furniture are:
– Extruded, casted and pressed batts – flat, ribbed or perforated and in various designs, such as square, rectangular, round, hexagonal, bore-gride, etc;
– Columns and post caps (round, square, hexagonal, etc.);
– X-pans support and support benches;
– Lavi setters and supports for firing sinks and columns;
– Firing setters and special parts.
Estiva Refratários is Latin America leader in the manufacture of ceramic rollers and has an updated technology and strict process control to guarantee the best quality to the rollers.
The use of Estiva refractory rollers guarantees optimum performance for ceramic kilns, resulting in higher productivity, reduction in maintenance costs, shutdowns and roller changes due to its higher resistance to thermal shock and attack caused by the combustion gases and alkaline vapors.
Main refractory product used in the production of ceramic articles, Estiva batts are manufactured in cordierite and cordierite-mullite through the extrusion, slip casting and pressing processes.
Regardless of how they are made, our batts have excellent dimensional stability, high flexural strength under normal and application temperature, and excellent thermal shock resistance.
To maximize the useful space of ceramic load to be fired, our staff evaluates the conditions of use of each project to propose the best solution, seeking to reduce weight (refractory mass-inert), improving the firing cycles and reducing energy consumption.
Batts can be manufactured in a variety of shapes and geometries, such as: hollowed and solid, flat or ribbed, bore-gride or with special designs (such as cuts, grooves, etc.) to suit customer needs.
Estiva Refratários low mass car kiln perimeter blocks can be used in tunnel and shuttle kilns, operating at temperatures up to 1350 ° C.
The concept of using air as a thermal insulation is widely used in the production of the cast and/or drained parts, bringing to the product excellent thermal performance. Designs of our perimeter blocks are customized for each customer and dimension of the car kilns, be the pieces made by extrusion or slip casting, without loss of their properties.
In addition to the great ease of assembly, Estiva Refratários suspended roof systems and kiln linings have a lighter weight per area and, combined with insulating fibers, result in a significant reduction in fuel consumption.
Its use in intermittent furnaces as a protection element of the ceramic fibers is also very widespread, protecting the fiber itself from the attack of the flue gases, as well as reducing the number of defects of the ceramic pieces in function of avoiding contaminants fallen from the insulating materials.
Designed to meet the process characteristics of each of our customers, Estiva saggars and trays are manufactured through slip casting and with variations in formulation to support the process specifications. The design can be from a simple box to more complex formats on demand.
Besides batts, columns, firing supports, lavi rings and other refractory products produced by Estiva, there is also the possibility of manufacturing taylor made parts for different purposes, with direct alignment between customer need, product properties and exclusive designs.
As an example of some special parts, we can highlight: pins, burner blocks, tableware and roofing tile setters, roller blocks, heating elements support, special saggars and columns, among others.
Refractories based on silicon carbide (SiC) are widely used in ceramic applications due to high refractoriness, excellent mechanical strength, high thermal conductivity and good resistance to thermal shock. As result of these characteristics, the use of this type of material, besides the inherent durability of the products, has as main benefit the decrease of the refractory pieces weight and consequent reduction of the furnaces energy consumption.
In order to supply these materials, Estiva has established a partnership with Schunk (Germany) to operate in several countries and aims to assist our customers from the technical specification process to the supply of flat plates, bore-gride, bars / beams, lavi rings , firing supports, burner nozzles and radiant tubes, among others.
Generally, the production of structural ceramics is very aggressive towards the refractories, considering the type of fuel, atmosphere of the furnace, heavy load on the parts, high soaking times and firing cycles.
To solve a large part of these problems, Estiva is a partner of Resco/Paco (USA) for supplying of special refractory based on pyrophyllite. These products are manufactured by extrusion in various formulations for different applications and present a performance far superior to the silicon-alumina refractories commonly used in the production of bricks and tiles.