Application of Shrinkage-Free Fused Zirconium Corundum Bricks

In recent years, the advancement of kiln technology has continuously raised the quality requirements for tilt-cast fused zirconium corundum bricks, and their usage has continued to expand. As a manufacturer, the production process of tilt-cast bricks has been updated and improved. The quality of the products has reached a relatively high level, basically reaching the international advanced level of similar products. Application of shrinkage-free fused zirconium corundum bricks. The new process highlights the characteristics of tilt-cast bricks. After strict optimization of the tilt angle, strict quality control was achieved. As a result, the shrinkage hole distribution of the product is very reasonable.

Fused Cast α-β Aluminum Refractory Bricks for Glass Kilns

Fused zirconium corundum brick cast without shrinkage cavity

The demand for fused zirconium corundum bricks cast without shrinkage holes has been increasing day by day in recent years. In addition to the 41# fused zirconium corundum bricks that are almost entirely cast without shrinkage holes, the demand for oxidation method 33# non-shrinkage fused zirconium corundum bricks has also increased significantly. The production cost of this product is high and the production process is relatively complex, so the product sells for a higher price. In recent years, glass-melting furnaces using dense end-cast bricks have also appeared in China. This product is mostly used on the pool wall. From the perspective of manufacturing fused bricks, the process is simpler than shrinkage-free casting, the manufacturing cost is relatively low, and the sales price is of course different. The performance on the pool wall is almost the same as that of non-shrinkage cast bricks.

Basic principles for the application of shrinkage-free fused zirconium corundum bricks

(1) For the pool wall bricks in contact with the molten glass, use the oxidation method 33# to tilt-cast zirconium corundum bricks. This choice is relatively reasonable both technically and economically. If you consider the need for bricks in the later stages of the furnace, it will be even more foolproof if you make slight changes in the brick type. Of course, compared with the traditional bottom-up multi-layer brick construction of the pool wall, this choice of pool wall bricks has more advantages than disadvantages, but there is also the problem of considering one at the expense of the other. Therefore, many furnace designers are still accustomed to traditional tank wall structures. It should be pointed out that it is the best choice to use 20mm thick 44# non-shrinkage AZS bricks for the upper pool wall, while the quality grade of the lower pool wall bricks can be reduced in turn.

It is worth noting that when choosing multiple varieties of pool wall tiles, attention should be paid to the grade gap between adjacent fused bricks and tiles should not be too large. Because from the perspective of the production of various types of refractory materials, there are great differences in physical and chemical indicators, mineral composition, and performance between high- and low-grade materials. It is technically and economically unreasonable to use them adjacently.

(2) The upper structure of the furnace can almost always be made of ordinary cast fused zirconium corundum bricks, and their functions are fully sufficient.

(3) For melting furnaces with kiln bottom insulation, 75mm thick oxidation method 33# non-shrinkage AZS bricks are most suitable for the kiln bottom pavement. Used in conjunction with zirconium corundum ramming material during construction.

(4) The side walls, flat bricks, and inclined bricks of the small furnace are generally made of 33# zirconium corundum bricks made by the reduction method of ordinary casting. The furnace bottom can also be made of 33# zirconium corundum bricks without shrinkage holes or densely cast.

(5) It is best to use ordinary cast α-β alumina bricks for the tank wall of the clarification part. The bottom of the kiln should be made of α-β alumina bricks cast without shrinkage holes. The cost of this choice of kiln is higher, and oxidation method 33# AZS bricks can also be used instead.

High-quality AZS bricks for glass kilns have reliable product quality and can effectively extend the service life of the glass kiln. Rongsheng refractory materials manufacturer.

Tips for Choosing the Right AZS Bricks for Your Glass Furnace

When it comes to constructing a glass furnace, one of the most important decisions is choosing the right AZS bricks. AZS bricks are made of alumina, zirconia, and silica, which make them highly resistant to thermal shock and corrosion, making them the perfect material for use in the harsh conditions of a glass furnace. However, not all AZS bricks are created equal, and choosing the wrong ones can lead to costly mistakes. In this article, we’ll share some tips for choosing the right AZS bricks for your glass furnace.

AZS Bricks for Your Glass Furnace

Know your furnace’s operating conditions

The first step in choosing the right AZS bricks is to understand the operating conditions of your furnace. This includes the temperature range, the type of glass being produced, and the chemical environment. Different types of AZS bricks are designed for different operating conditions, so it’s important to choose the right ones that can withstand the specific conditions of your furnace.

Consider the composition of the AZS bricks

AZS bricks come in different compositions, each with different ratios of alumina, zirconia, and silica. The composition of the bricks can affect their performance in the furnace, so it’s important to choose the right composition for your specific needs. For example, if you’re producing soda-lime glass, you’ll need bricks with a higher silica content to withstand the corrosive effects of sodium oxide.

Choose the right shape and size

The shape and size of the AZS bricks can also impact their performance in the furnace. The bricks should be designed to fit snugly together, without any gaps or spaces that can allow heat to escape. They should also be easy to install and remove so that maintenance and repairs can be done quickly and efficiently.

Consider the quality of the AZS bricks

Not all AZS bricks are created equal, and the quality of the bricks can vary depending on the manufacturer. It’s important to choose a reputable manufacturer that uses high-quality materials and has a proven track record of producing reliable and durable bricks. Choosing a low-quality brick can lead to premature failure, which can be costly and dangerous.

Consult with experts

If you’re not sure which AZS bricks are right for your furnace, it’s a good idea to consult with experts in the field. Glass furnace manufacturers, engineers, and other professionals can provide valuable insights and advice on choosing the right bricks for your specific needs. They can also help you with installation, maintenance, and repairs, to ensure that your furnace operates safely and efficiently.

In conclusion, choosing the right AZS bricks is a critical decision that can impact the performance and safety of your glass furnace. By understanding your furnace’s operating conditions, considering the composition of the bricks, choosing the right shape and size, selecting high-quality bricks, and consulting with experts, you can ensure that your furnace operates at its best, with minimal downtime and maintenance.

How to Improve the Quality of Fused Zirconia Corundum Bricks?

In recent years, with the advancement of technology and the advancement of kiln technology, the quality requirements of obliquely cast fused zirconia corundum bricks have been continuously improved, and the amount has been expanding. How to improve the quality of fused zirconia corundum bricks? As a manufacturing plant, the production process of inclined cast bricks has been updated and improved, which has made the quality of the products reached a relatively large level and basically reached the international advanced level of similar products. The new technology highlights the characteristics of inclined cast bricks. After strict optimization of the inclination angle, strict quality control was realized, so that the shrinkage cavity distribution of the product was very reasonable.

Fused Zirconia Corundum Bricks

Silicon oxide and sodium oxide are the main components of the glass phase of fused brick products. The content of silicon oxide and sodium oxide is the main factor related to the amount of glass phase. Strictly controlling the content of silicon and sodium is an important condition to ensure the production process is stable and the glass phase performance is relatively good.

Composition of fused zirconia corundum brick

The composition of the fused zirconia corundum brick is oblique zircon, corundum, a small amount of mullite, glass phase, and pores. In order to reduce and eliminate residual thermal stress, a certain amount of glass phase is required in the product as an absorbent to buffer thermal stress. However, the glass phase of fused bricks is a weak link in terms of resistance to glass erosion. In the process of corrosion, the first is the exudation of the glass phase and replacement with the high-temperature glass melt, thereby accelerating the corrosion of the crystal phase. Under high-temperature conditions, the glass phase will ooze out and bubbles will be released, which will contaminate the glass melt. The segregation of fused bricks is also manifested in the glass phase. In the 33#, 36#, 41# series of fused bricks with zirconium content, the glass phase content is 20℅-14℅, so the influence of its properties on the quality of fused bricks cannot be ignored.

Rongsheng High-Quality Fused Zirconia Corundum Bricks

How to improve the quality of fused zirconia corundum bricks?

AZS three-element alumina, zirconia, and silica, theoretically, there is no glass phase. Even if there are a small number of impurities, there is little glass phase when no alkaline oxide is added. In production, due to the introduction of alkaline oxide (sodium oxide), most of the silicon oxide is promoted to enter the glass phase.

Sodium oxide (encapsulated potassium oxide) together with silicon oxide and aluminum oxide form the backbone of the glass phase. The content of sodium oxide in the raw material has been reduced from 1.37℅ to 0.65℅, and the amount of glass phase has been significantly reduced, from 21.5℅ to 12℅. Increasing the sodium content obviously reduces the viscosity of the glass phase. When the sodium content is less than 1℅, it is an ideal range.

From the perspective of improving the performance of the glass phase and reducing the pollution of molten glass, the smaller the number of impurities such as iron oxide, titanium, calcium, and magnesium, the better. The increase of these quantities will increase the quantity of the glass phase and reduce the viscosity of the glass phase, which not only pollutes the glass products but also affects the service life of the products. The content of iron oxide and titanium is controlled to be less than 0.2℅.

In the production process of AZS fused bricks, it is necessary to control the impurity content of raw materials and certain specific components. (1) The content of iron and titanium is less than 0.2℅. (2) The sodium content is less than 1℅. (3) Strictly control the silicon content from details. In order to increase the service life of fused bricks and improve the quality of glass fusion products, the key is to master the intrinsic component properties of bricks.

If AZS fused brick products can achieve the lowest degree of pollution to the glass, the service life of the bricks can be maximized. Only high-quality products are the guarantee for increasing market share.