In the kiln hot repair industry, operators often face challenges such as poor thermal shock resistance, high expansion rates, and low corrosion resistance of traditional repair materials. These issues can lead to frequent repairs, reduced kiln service life, and increased production costs. Enter zero-expansion silica bricks, a revolutionary product that is rewriting the rules of the game.
Zero-expansion silica bricks are primarily made from fused quartz, which endows them with a range of outstanding properties. First and foremost, they have excellent thermal shock resistance. Tests have shown that they can withstand temperature changes of up to 800°C without cracking, while traditional materials may start to show damage at around 300°C. This high thermal shock resistance is due to the low coefficient of thermal expansion of fused quartz, which allows the bricks to maintain their structural integrity under extreme temperature fluctuations.
In addition, these bricks have high strength. Their compressive strength can reach up to 50 MPa, which is significantly higher than that of many traditional hot repair materials. This strength ensures that the bricks can withstand the mechanical stress and pressure in the kiln environment, reducing the risk of breakage and damage.
Another remarkable feature is their low expansion rate. The linear expansion coefficient of zero-expansion silica bricks is less than 0.1% in the temperature range of 0 - 1000°C, which means they hardly expand when heated. This property is crucial in preventing the formation of cracks and gaps in the kiln lining, which can lead to heat loss and reduced efficiency.
Moreover, they have excellent acid corrosion resistance. In environments where acidic gases are present, such as in glass kilns, zero-expansion silica bricks can resist corrosion for up to 5 years, while traditional materials may need to be replaced within 1 - 2 years.
In glass kilns, zero-expansion silica bricks are used to repair the critical areas such as the crown and sidewalls. Their low expansion rate and high thermal shock resistance ensure that the kiln can operate at high temperatures for extended periods without the need for frequent repairs. This not only improves the production efficiency but also reduces the downtime and maintenance costs.
In coke ovens, these bricks are ideal for repairing the combustion chambers and regenerators. Their acid corrosion resistance helps to protect the oven lining from the corrosive effects of the gases produced during the coking process. As a result, the service life of the coke oven can be extended by up to 30%, leading to significant cost savings for the operators.
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| Properties | Zero-Expansion Silica Bricks | Traditional Hot Repair Materials |
|---|---|---|
| Thermal Shock Resistance | Withstands up to 800°C temperature change | Starts to damage at around 300°C |
| Compressive Strength | Up to 50 MPa | Lower, around 20 - 30 MPa |
| Expansion Rate | Less than 0.1% (0 - 1000°C) | Higher, around 0.5 - 1% |
| Acid Corrosion Resistance | Resists corrosion for up to 5 years | Needs replacement within 1 - 2 years |
"Since we started using zero-expansion silica bricks in our glass kilns, we have noticed a significant improvement in the kiln's performance. The frequency of repairs has decreased by 50%, and the production efficiency has increased by 20%. We are very satisfied with this product." - A glass manufacturer
"In our coke oven, the zero-expansion silica bricks have extended the service life of the oven by 30%. This has saved us a lot of money on replacement and maintenance costs. We highly recommend this product to other coke oven operators." - A coke producer
Zero-expansion silica bricks offer a high-quality solution for kiln hot repair. Their unique combination of excellent thermal shock resistance, high strength, low expansion rate, and acid corrosion resistance makes them superior to traditional hot repair materials. By choosing zero-expansion silica bricks, kiln operators can improve the performance and service life of their kilns, reduce maintenance costs, and increase production efficiency.
If you are looking for a reliable and effective hot repair solution for your kilns, we encourage you to learn more about zero-expansion silica bricks and give them a try. Contact us today to find out how this product can benefit your business.
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