In the high - temperature industrial sectors such as glass manufacturing, the choice of refractory materials is crucial for the smooth operation of production. Traditional refractory bricks often face various problems in high - temperature environments, which seriously affect production efficiency and cost. This article will introduce the outstanding performance of zircon mullite bricks in high - temperature environments through real - world failure cases of traditional refractory bricks.
Traditional refractory materials frequently encounter issues like thermal shock instability, peeling, and corrosion in high - temperature working conditions. For example, in a glass factory, traditional refractory bricks in the melting furnace had to be replaced every 6 - 8 months due to severe corrosion and peeling. This not only led to high replacement costs but also caused long - term production halts, reducing the overall production efficiency by about 20%.
Zircon mullite bricks, as high - performance refractory materials, offer a solution to these problems. They are mainly made from fused zircon mullite and sintered alumina, using hydrated alumina as a binder and going through a high - temperature sintering process. This process creates a product structure with high density and high purity.
The raw materials play a vital role in the performance of zircon mullite bricks. Fused zircon mullite provides a stable crystal structure, while sintered alumina enhances the overall strength. The hydrated alumina binder helps to form a strong bond between the particles during the sintering process, ensuring the integrity of the product structure.
The component ratio of zircon mullite bricks is also carefully designed. With over 70% corundum phase, over 19% baddeleyite, and over 7% mullite, this scientific proportion significantly contributes to the product's high density and purity. The high - density structure reduces the porosity of the bricks, making them more resistant to penetration by molten substances. The high purity minimizes the presence of impurities that could react with the surrounding environment at high temperatures.
These characteristics translate into excellent thermal shock stability, anti - peeling, and anti - corrosion properties. In terms of thermal shock stability, zircon mullite bricks can withstand rapid temperature changes without cracking. For instance, in a test where the temperature was raised from room temperature to 1200°C and then rapidly cooled, zircon mullite bricks showed no visible cracks after 50 cycles, while traditional refractory bricks cracked after only 10 cycles.
The anti - peeling property is also remarkable. In a glass kiln, zircon mullite bricks maintained their surface integrity even after long - term exposure to high - temperature glass melt, while traditional bricks started to peel off after a few months of use. The anti - corrosion performance is equally outstanding. In a chemical plant's high - temperature reaction furnace, zircon mullite bricks showed only minor corrosion after 12 months of continuous operation, while traditional refractory bricks were severely corroded and had to be replaced within 6 months.
| Properties | Zircon Mullite Bricks | Traditional Refractory Bricks |
|---|---|---|
| Thermal Shock Cycles (without cracking) | Over 50 | Less than 10 |
| Service Life in Glass Kiln | Over 24 months | 6 - 8 months |
| Corrosion Degree in Chemical Furnace (after 12 months) | Minor | Severe |
Let's look at some real - world customer cases. In a large - scale glass manufacturing enterprise, after replacing traditional refractory bricks with zircon mullite bricks in their glass melting furnaces, the furnace life was extended from the original 1 - 1.5 years to over 3 years. This not only reduced the frequency of furnace repairs and replacements but also increased the continuous production time, resulting in a 15% increase in annual production capacity. In addition, the reduction in downtime also saved a significant amount of energy and labor costs.
In conclusion, zircon mullite bricks, with their unique raw material composition, scientific component ratio, and excellent performance, are an ideal choice for high - temperature industrial applications. If you are still in the stage of choosing refractory materials, don't miss this high - performance solution. Click here to learn more about zircon mullite bricks and take the first step towards improving your production efficiency and reducing costs!
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