In the critical industries such as glass manufacturing, steelmaking, and ceramics production, high - performance zircon bricks play an irreplaceable role. For instance, in a large - scale glass factory, the use of high - performance zircon bricks in the melting furnace has significantly extended the service life of the furnace from an average of 3 years to 5 years, reducing the frequency of furnace repairs and greatly improving production efficiency.

Analysis of Raw Materials

High - performance zircon bricks are mainly made from α - Al2O3, partially stabilized zirconia, and zircon corundum clinker. Each raw material contributes uniquely to the performance of the zircon bricks.

α - Al2O3

α - Al2O3 has high hardness, good wear resistance, and high refractoriness. Its hardness can reach Mohs 9, which can effectively resist the abrasion of high - temperature materials in the furnace. In the zircon bricks, α - Al2O3 forms a strong skeleton structure, improving the overall strength and thermal shock resistance of the bricks. When the temperature in the furnace fluctuates by about 1000°C, the zircon bricks with α - Al2O3 can still maintain good integrity.

Partially Stabilized Zirconia

Partially stabilized zirconia has excellent high - temperature stability and phase - change toughening properties. At high temperatures, it can transform from a monoclinic phase to a tetragonal phase, absorbing a large amount of energy and improving the toughness of the zircon bricks. In practical applications, the addition of partially stabilized zirconia can increase the fracture toughness of zircon bricks by about 30%.

Zircon Corundum Clinker

Zircon corundum clinker has a dense structure and good chemical stability. It can improve the corrosion resistance of zircon bricks. In glass melting furnaces, zircon bricks containing zircon corundum clinker can effectively resist the erosion of glass melt, and the corrosion rate can be reduced by about 20% compared with ordinary bricks.

Analysis of Manufacturing Processes

The manufacturing process of high - performance zircon bricks includes mixing, forming, drying, and high - temperature firing in a shuttle kiln.

Mixing

During the mixing process, the raw materials are evenly mixed to ensure the uniformity of the chemical composition and physical properties of the bricks. Through advanced mixing equipment, the mixing time can be controlled within 30 - 60 minutes, ensuring that each raw material is fully dispersed.

Forming

Forming is to shape the mixed raw materials into the desired brick shape. High - pressure forming technology can make the bricks have a higher density. The forming pressure can reach 100 - 200 MPa, which is conducive to improving the strength and compactness of the bricks.

Drying

Drying is to remove the moisture in the formed bricks. The drying temperature and time need to be strictly controlled. Usually, the drying temperature is about 100 - 150°C, and the drying time is 24 - 48 hours. This can prevent the bricks from cracking during the subsequent high - temperature firing process.

High - temperature Firing in a Shuttle Kiln

High - temperature firing in a shuttle kiln is a key step to form the final performance of the zircon bricks. The firing temperature can reach 1600 - 1700°C. During the firing process, the raw materials undergo a series of physical and chemical reactions, forming a stable crystal structure and improving the high - temperature performance of the bricks.

Relationship between Raw Materials, Processes, and Brick Performance

The combination of raw materials and processes determines the excellent performance of high - performance zircon bricks. The appropriate proportion of α - Al2O3, partially stabilized zirconia, and zircon corundum clinker, combined with scientific mixing, forming, drying, and high - temperature firing processes, enables the zircon bricks to have high strength, good thermal shock resistance, excellent corrosion resistance, and high - temperature stability.

Practical Application Cases

In a steelmaking plant, after using our high - performance zircon bricks in the ladle lining, the service life of the ladle has been extended from 80 heats to 120 heats, reducing the cost of refractory materials and improving the production efficiency. In a ceramics factory, the use of zircon bricks in the kiln has improved the quality of ceramic products and reduced the defect rate by about 15%.

Our high - performance zircon bricks are carefully designed and manufactured through strict processes. We are confident in the reliability and practicality of our products. If you want to know more about our high - performance zircon bricks or have any cooperation intentions, please feel free to contact us. We look forward to establishing long - term and stable cooperative relationships with you.