Refractory Brick Material Brown Fused Alumina Grains Aluminium Oxide
Brown fused alumina also known as electro corundum, corundum and aluminum oxide is obtained mineral ally while fusing bauxite in an electric arc furnace. Its main component is alumina Al2O3. Brown fused alumina is ecologically clean and extremely hard material. It is used in production of abrasives, refractory and in dry- and wet-blasting applications where it is reusable. Due to sharp, and self-renewable edges brown fused alumina is highly grinding. Brown fused alumina is free of not respirable crystalline silica (SiO2).
Brown Fused Alumina also called Brown Fused Aluminum Oxide, Brown Aluminum Oxide or Brown Corundum. It is a material produced by fusion process of bauxite (source of aluminum oxide) and other fillings and crushed and screened into grits of different sieving distribution. It is a brown, dense, tough, hard, heat resistant, abrasion resistant material widely used for abrasives, refractory and sandblasting purposes.
Main production process
Fusion/Smelting
Calcined Bauxite, Anthracite and Iron Fillings are the main raw materials for producing of Brown Fused Alumina. NY TWO choose the best quality calcined bauxite which contains about 88% aluminum oxide, which is the main source of Al2O3 in BFA. These raw materials are mixed together at certain proportion and fused/smelted in electric arc furnace in about 2200℃. Common furnaces are Fixed Furnace or Tilting Furnace (Dumping Furnace). During fusion process, iron contents settle at the bottom of the furnace, carbon contents go to surface of furnace, and aluminum oxide contents in the middle. The raw materials are crystallized and impurities are reduced. This is the most important process for Brown Fused Alumina which decided purity and hardness of it.
BFA Lumps & Crushing
The fused BFA are cooled down and crushed into big lumps which look brown. This is material of high aluminum oxide content. BFA lumps are then crushed into smaller sizes for further production.
Screening/Sieving
Brown Fused Alumina lumps grits are then put into crushers for further crushing into smaller sizes and screened into grits of different sieving distribution. This is coarse finer grades of good sieving distribution suitable for abrasives and refractory purposes. There is different quality standard such as GB, FEPA, JIS, ANSI standards. After screening, content of Aluminum Oxide (Al2O3) is about 95%, with little content of Iron Oxide (Fe2O3), Titanium Oxide (TiO2) and Silicon Oxide (SiO2) and little magnetic contents. Magnetic contents are then removed relevant equipment, which process is important as for refractory and abrasives applications magnetic contents will harm the finished products. For Al2O3, the finer(smaller) the grit is, the lower the content is.
Washing
Brown Fused Alumina grits are then washed by water or acid to remove dust, magnetic contents and impurities. These unnecessary contents are easy to cause scratch, corrosion, cracks and dark spots on abrasives and refractory products. Washing process also helps get harder and purer materials which have better performance and better for recycling.
Packing
After production, Brown Fused Alumina are packed and shipped to customers. Most common packing are Big Bags of 1 metric ton, 1.2 or 1.3 metric tons. Or packed into 25kg woven plastic bags or 25kg paper bags, and 40 bags on a pallet.
Brown Fused Alumina Applications
Brown Fused Alumina is the most widely used abrasive due to its many applications. Its versatility lends itself to the following uses:
- Anti-Skid – BFA grains are added to fresh concrete, paint, and bonding to surfaces using adhesives and resin cements in order to help prevent vehicle skidding.
- Anti-Slip – Like the anti-skid methods, BFA grains are added to the surface material that is used in high traffic areas to prevent pedestrians from slipping.
- Blasting Media – BFA can be used as a blasting media that is used to prepare and clean surfaces prior to coating.
- Bonded Abrasives – BFA is used to make bonded abrasives like cutting-off and grinding wheels, snagging wheels, mounted wheels, segments, honing stones, plugs, cones, etc.
- Coated Abrasives – BFA is used to make coated abrasives such as sandpaper and are available in sheets, discs, rolls, belts, pads, flap wheels, and other forms.
- Coatings – BFA is often used as an additive to coating mixes to provide added protection against corrosion, wear and abrasion.
- Pressure Blasting – Blasting is used to clean, polish, cut, or finish surfaces. It is done by propelling media against surfaces using high-pressured blasting cabinets or blasting guns. Blasting can be done with a wet or dry process and is available in numerous grit sizes.
- Refractory – BFA has hundreds of applications as a refractory material due to its ability to withstand continuous exposure to the combination of heat, corrosion, abrasion and impact.
- Surface Preparation – BFA is used as a finishing media for cleaning and surface preparation products.
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