In the glass manufacturing industry, the choice of refractory materials significantly impacts production efficiency, equipment lifespan, and overall operational costs. Zirconia - mullite bricks have emerged as a high - performance solution to the common problem of refractory material erosion. This article delves into the composition, manufacturing process, and performance of zirconia - mullite bricks, aiming to provide glass production enterprises with valuable insights for their refractory material procurement and technical selection.
Zirconia - mullite bricks are characterized by their high density and purity. Their unique composition includes over 70% corundum phase, more than 19% baddeleyite, and at least 7% mullite. These components are carefully selected and combined through advanced manufacturing processes.
The raw materials are first crushed and milled to achieve a uniform particle size. Then, they are mixed in precise proportions to ensure the desired chemical composition. The mixture is then formed into bricks using high - pressure molding techniques. After that, the bricks undergo a high - temperature firing process at around 1700°C, which enhances their density and strength.
One of the outstanding features of zirconia - mullite bricks is their excellent thermal shock resistance. In glass production, the refractory materials are often exposed to rapid temperature changes. Zirconia - mullite bricks can withstand these temperature fluctuations without cracking or spalling. Tests have shown that they can endure temperature changes of up to 1000°C without significant damage, which is much higher than many traditional refractory materials.
Spalling is a common problem in refractory materials, which can lead to the loss of material and reduced equipment lifespan. Zirconia - mullite bricks have a dense structure and strong internal bonding, which gives them high spalling resistance. They can maintain their integrity even under mechanical stress and thermal cycling, ensuring long - term stable operation in glass furnaces.
The resistance of zirconia - mullite bricks to molten glass is remarkable. Molten glass is highly corrosive, and traditional refractory materials may be quickly eroded, leading to contamination of the glass product and frequent replacement of the refractory lining. Zirconia - mullite bricks, with their unique chemical composition, form a protective layer on the surface when in contact with molten glass, effectively reducing the erosion rate. Studies have indicated that the erosion rate of zirconia - mullite bricks in contact with molten glass is only about 1/3 of that of ordinary refractory bricks.
A leading glass manufacturing company in Europe was facing frequent refractory material failures in its glass furnaces. The traditional refractory bricks were suffering from severe erosion and spalling, resulting in frequent furnace shutdowns for maintenance and replacement. After switching to zirconia - mullite bricks, the situation improved significantly.
The service life of the refractory lining in the glass furnace increased from an average of 1 year to more than 3 years. The production stability was greatly enhanced, with a reduction in unplanned downtime by over 80%. Moreover, the quality of the glass products improved, as the contamination caused by refractory material erosion was minimized.
"Since we started using zirconia - mullite bricks, we have seen a remarkable improvement in our production efficiency and product quality. The long - term cost savings are also significant," said the technical director of the company.
Zirconia - mullite bricks offer a comprehensive solution to the challenges of refractory material erosion in the glass industry. Their high thermal shock resistance, spalling resistance, and erosion resistance against molten glass make them an ideal choice for glass production enterprises.
If you are a glass production enterprise looking to improve your production stability, extend the service life of your equipment, and enhance the quality of your products, zirconia - mullite bricks are the answer. Don't miss this opportunity to revolutionize your refractory material selection. Contact us today to learn more about zirconia - mullite bricks and request a free sample. Click here to take the first step towards a more efficient and profitable glass production process.
