PARKINSON-SPENCER REFRACTORIES LTD REFRACTORIES FOR THE FOREHEARTH, DISTRIBUTOR AND FURNACE

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1 PARKINSON-SPENCER REFRACTORIES LTD REFRACTORIES FOR THE FOREHEARTH, DISTRIBUTOR AND FURNACE Since the foundation of the company PSR has only ever been involved in the manufacture of refractories for the glass industry. This specialisation has resulted in the development of a range of bespoke refractory products specifically for glass. Slip casting is PSR s primary manufacturing method for forehearth, distributor and furnace refractories. This ensures total flexibility of production with a range of sizes and shapes to satisfy almost every conceivable situation. Some pressing of standard shapes is undertaken enabling larger quantities of specific glass industry compositions to be undertaken and glass melting pots are manufactured entirely by hand. The glass industry is a very demanding customer and PSR recognises the need to provide consistent products with exact dimensions and tight tolerances. Purpose built casting sheds with humidity controlled drying chambers ensure close control over production procedures. Modern high temperature kilns guarantee precise firing temperatures and software driven cutting and grinding machines ensure close dimensional accuracy. Consistency of manufacturing procedures is vital to the maintenance of uniform production standards and PSR operate a quality management system accredited by CICS (a UKAS accredited certification body) to the international standard ISO 9001:2008. We also pay close attention to our environmental responsibilities and operate an environmental management system accredited by CICS to the international standard ISO 14001:2004. Pre assembly of distributor glass contact blocks in 993 Pre assembly of forehearth channel blocks in 333

2 The Materials The forehearth, distributor and furnace refractory compositions manufactured by PSR reflect the specialised nature of our customer base. None of them are used outside the glass industry and all have been developed for their specific attributes related to the production of glass. SM62 62% Al 2 O 3 SM62 is a high fired reaction bonded alumino-silicate refractory developed specifically in response to the aggressive conditions found in monoblock forehearth and distributor superstructures. Its exceptionally low creep (0.1% at 1425 C*) and high strength make it the ideal material for this application. In laboratory tests its resistance to thermal shock exceeded the sillimanite standard by a factor of 10. Pre-assembly of PSR SM62 distributor roof blocks Recommended uses: forehearth and distributor superstructure, spout covers and spout burner blocks. * Creep in compression 50 C with an applied load of 0.2MN/m -2 Pre-assembly of PSR VC60 bottom blocks Pre-assembly of PSR VC40 bottom blocks PSR LW40 semi insulation tiles Pre-assembly of 333 channel blocks VC60 60% Al 2 O 3 VC60 is a dense super-duty 60% alumina sillimanite type material developed specifically for use as furnace bottom blocks. It is principally used for the back-up courses in melting ends, working ends and distributors, and with full glass contact quality attributes is also suitable for use as the glass contact material in day tanks and less aggressive working ends. Recommended uses: furnace bottom blocks, sidewall back up blocks and glass contact blocks in day tanks and less aggressive working ends. VC40 40% Al 2 O 3 Flux/Chamotte VC40 is a traditional slip-cast fireclay block made from high quality calcined fireclays. It is principally used for the back-up courses in the furnace bottom, and its glass contact qualities also make it suitable for use in day tanks and other less aggressive glass contact applications. Recommended uses: float, flat and container glass furnace bottom blocks, sidewall back-up blocks, day tanks. LW40 40% Al 2 O 3 Insulating fireclay LW40 is a semi insulating fireclay block. It combines good insulation properties with high compressive strength and has been designed specifically for glass tank bottom insulation and sidewall insulation. Recommended uses: bottom insulation tiles, sidewall insulation tiles % ZrO 2 Zircon-mullite 333 for channels is the same industry standard material used for feeder expendables. A direct bonded zircon-mullite material, 333 provides the forehearth channel block with excellent corrosion resistance for long forehearth life irrespective of tonnage throughput. With lower thermal conductivity than fusion cast alternatives substructure heat losses are less and joint penetration reduced. It is also an excellent material for colourant forehearth superstructures where its unique closed pore surface inhibits penetration from the corrosive vapours associated with the frit feeding operation. Recommended uses: channel blocks, skimmer blocks, mantle blocks and colourant forehearth superstructures.

3 Pre-assembly of 993 distributor blocks Pre-assembly of 993 channel blocks % Al 2 O 3 Dense Bonded Alumina 993 is the bonded refractory alternative to fused-cast α-β alumina. Composed entirely of alpha alumina 993 exhibits equivalent corrosion characteristics to fused-cast α-β alumina.* It differs from other high-alumina bonded refractory products by virtue of the fact that it is a single phase material manufactured entirely from alumina grains and powders. Under test for bubble potential 993 had minimal erosion below the glass level, no signs of upward drilling and no visible stone in either the drain-off drip or glass in the crucible. 993 is used as an alternative to fused cast-alumina either as a glass contact refractory block in the distributor or as a channel block in the forehearth. * static corrosion test conducted over 72 hours at 1370 C in soda lime glass. Recommended uses: distributor glass contact blocks and forehearth channel blocks. P56 alumina-silica-zirconia brick P56 is a general purpose high grade refractory brick manufactured for use specifically in the forehearth and distributor. It is a blend of recycled PSR refractory materials and virgin mullite grains and contains a minimum of 60% Al 2 O 3 and 9% ZrO 2. It exceeds all the requirements for its application in the forehearth and distributor but is not supplied as a premium AZS brick. (see P333V below) Recommended uses: forehearth and distributor brickwork. P60 60% Al 2 O 3 andalusite brick P60 is a andalusite brick for forehearth, distributor and furnace applications where a super-duty alumino-silicate brick is required. Recommended uses: forehearth, distributor and furnace brickwork P333V 15% ZrO 2 AZS brick P333V is the version of PSR s 333. It is a premium AZS brick manufactured for use in special forehearth and distributor applications such as colourant forehearths or borosilicate forehearths where corrosive vapours can cause premature corrosion to conventional alumino-silicate refractories. Recommended uses: forehearth, distributor and furnace brickwork. Pre-assembly of 993 distributor blocks 993 blocks and channels on kiln base after firing

4 Patching materials and castables Two grades of patch are supplied for general maintenance of the furnace. Zircon patch 150 is a high purity zircon plastic putty intended for non-glass contact use. Typical applications include repairs to furnace crowns and superstructures, filling expansion joints, and patching regenerator crowns, breast fronts, back walls and port areas. Zirmul patch 160 is a blend of zircon and mullite. It is supplied as a dry powder for mixing with water to a consistency suitable for ramming into a mould or former. Typical applications include glass contact areas of the furnace where a quick turnaround is required. Two grades of castable are supplied for the barrier layers of forehearths and distributors. On site installation of PSR forehearth refractories Korkom 50 is a corrosion resistant concrete manufactured from fused cast alumina grains. It is applied as a monolithic barrier layer beneath channels and in the distributor bottom. Korkom 7G is a fine corrosion resistant mortar manufactured from fused cast alumina grains. It is applied as a top layer over Korkom 50 for bedding the distributor bottom glass contact tiles. Zircon patch 150 Zirmul patch 160 Korkom 50 SiO 2 % Al 2 O 3 % ZrO 2 % CaO % 4 4 Korkom 7G On site installation of 333 channel blocks Pre-assembly of roof blocks for gathering bays in PSR SM62

5 Cutting and Grinding Blocks and channels from PSR are ground to tight tolerances on bespoke diamond grinding, cutting and polishing machines. Pre-assembly ensures that overall dimensions are met. Design PSR have a wealth of experience in the design and specification of forehearth systems and our comprehensive design office is at the client s disposal not only for PSR s own System 500 forehearth but also for any proprietary customer designs. Glass Melting Pots As part of their two centuries of heritage PSR continue to manufacture glass melting pots for the hand gathering glass industry. Manufactured as covered, half-covered or open pots, PSR s glass melting pots are made in the traditional way entirely by hand. Made from locally mined fireclay PSR s G-25 glasshouse potclay is renowned for its suitability with both soda-lime and lead crystal glasses. Glasshouse pots from PSR are supplied unfired for arching and firing by the client prior to use. Full details of recommended arching curves and firing temperatures are available on request. Pot rings are also available.

6 VC40 VC60 SM LW40 P56 P60 P333V SiO 2 % Al 2 O 3 % ZrO 2 % Fe 2 O 3 % TiO 2 % Trace CaO % MgO % Na 2 O % K 2 O % Bulk Density Kg m G25 Hand made Cold compressive strength MPa Apparent Porosity % Refractoriness ºC Reversible thermal expansion C % Creep in compression C (0.2 MN m -2 ) % 0.1 Thermal conductivity Wm -1 K 200 C 600 C C C All values are average and subject to change without notice Parkinson-Spencer Refractories Limited Holmfield, Halifax, West Yorkshire, UK. HX3 6SX Tel: (44) (0) Fax: (44) (0) Internet:

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