When it comes to selecting refractory materials, many global buyers often find themselves in a quandary. The market is flooded with a variety of options, each claiming to be the best. However, understanding the classification and characteristics of these materials is crucial for making an informed decision. Among the many refractory materials, mullite bricks stand out for their excellent performance. In this article, we will take you on a journey to understand the unique features of fused mullite bricks by comparing them with sintered mullite bricks.

Sintered Mullite Bricks: An Overview

Sintered mullite bricks are made from high - alumina bauxite, kaolin, and other raw materials. The raw materials are first crushed and milled into fine powder. Then, they are mixed with appropriate binders and additives. After that, the mixture is formed into brick shapes through processes like pressing. Finally, the green bricks are sintered at high temperatures (usually around 1600 - 1800°C) in a kiln. This high - temperature sintering process enhances the density and strength of the bricks.

These bricks have good thermal stability and chemical corrosion resistance. They can withstand temperatures up to 1700°C. In terms of performance, sintered mullite bricks have a relatively uniform structure, which gives them stable physical and chemical properties. They are widely used in industries where moderate temperature resistance and general corrosion protection are required.

Fused Mullite Bricks: A Closer Look

Fused mullite bricks use high - purity alumina and silica as the main raw materials. The raw materials are placed in an electric arc furnace and melted at extremely high temperatures (around 2000 - 2200°C). Once the raw materials are completely melted, the molten liquid is poured into molds and cooled slowly. This process forms a dense and homogeneous structure.

The performance of fused mullite bricks is outstanding. They have a high melting point, usually above 1800°C, and excellent thermal shock resistance. Their dense structure also makes them highly resistant to chemical erosion, especially in harsh environments with strong acids or alkalis. In addition, fused mullite bricks have low porosity, which reduces the penetration of harmful substances.

Comparison between Sintered and Fused Mullite Bricks

Application Scenarios

In the metallurgical industry, sintered mullite bricks are often used in the lining of intermediate frequency furnaces and ladles for general steel - making processes. They can effectively resist the erosion of molten steel and slag at moderate temperatures. On the other hand, fused mullite bricks are preferred in high - temperature areas of blast furnaces and electric arc furnaces, where temperatures can reach over 1800°C.

In the glass industry, sintered mullite bricks are used in the side walls of glass melting furnaces, providing basic insulation and corrosion resistance. Fused mullite bricks are used in the critical parts of the furnace, such as the throat and the regenerator, due to their high - temperature resistance and excellent chemical stability.

In the ceramic industry, sintered mullite bricks are suitable for the kiln furniture and the lining of low - to medium - temperature kilns. Fused mullite bricks are used in high - temperature firing kilns for special ceramics, where high - quality products require a stable and high - temperature - resistant environment.

Conclusion

In conclusion, both sintered and fused mullite bricks have their own unique features and application scenarios. Sintered mullite bricks are cost - effective and suitable for general industrial applications with moderate temperature requirements. Fused mullite bricks, with their superior high - temperature resistance and chemical stability, are ideal for harsh industrial environments. Understanding these differences is essential for global buyers to choose the most suitable mullite bricks for their specific needs.

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