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Fused Cast Refractories

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Fused cast refractories are a type of refractory product that features excellent corrosion and erosion resistance and is used as lining material in industrial furnaces and kilns. The most common use of fused cast refractory brick is in glass furnaces, owing to their properties. They are processed by the fusion-casting process with ceramic materials. Electric arc furnaces are usually applied to melt the ceramic materials first. Then the fusion material is cast in the molds. After solidification and cooling, the fused cast refractories are obtained with high density.

AGRM has also developed sintered refractories to meet the demands of customers.

Fused Cast Refractories Series

fused cast azs brick supplier

Fused Cast AZS Brick

Glass Application: working end, feeder, spout, superstructure, crown, sidewall, refining

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Low-exudation Electrofused Brick

Glass Application: working end, feeder, spout, superstructure, crown

electro-fused high zirconium brick supplier

Fused cast high zirconia brick

Glass Application: Throat, weir wall, sidewall, feeder, superstructure

fused cast corundum brick supplier

Fused Cast Corundum Brick α-β

Glass Application: Throat, weir wall, sidewall, feeder, superstructure

fused cast mullite brick manufacturer

Fused Cast Mullite Brick

Application: Metallurgy, steel, waste incineration, glass

fused cast refractory making process

Fused refractory bricks are a high-grade refractory material. The production process of fused refractory bricks requires fine control of multiple links, including raw material selection, ingredient mixing, drying, smelting, shaping, sintering, and inspection to ensure the quality of the final product meets the requirements. The production process of fused refractory bricks mainly includes the following steps:

1. Raw material selection: The raw materials of fused refractory bricks mainly include alumina, silica sand, carbon, silicon nitride, and other materials. These raw materials need to be strictly screened and proportioned to ensure the quality of the final product.

2. Mixing of ingredients: Mix raw materials in different proportions evenly according to a certain formula. Dry or wet methods can be used to mix to ensure the uniformity and stability of the mixed raw materials.

3. Drying: Place the mixed raw materials into a drying chamber for drying to remove moisture and volatile matter and ensure the stability of the raw material components.

4. Smelting: Put the dried raw materials into an electric furnace for smelting processing, usually using direct electric heating or electro slag remelting. At high temperatures, the raw materials melt and form glass liquid, which is then cooled and crystallized to form hard-fused refractory bricks.

5. Molding: Pour the molten material into the molding machine and form fused refractory bricks of various specifications and sizes through extrusion or mold molding.

6. Baking: Put the formed refractory bricks into a high-temperature oven for sintering to make them denser and stronger.

7. Inspection and packaging: Inspect the finished product to check whether its appearance, size, physical properties, chemical composition, and other indicators meet the requirements, and then package and store it for subsequent use.

Fused cast refractories vs. sintered refractories

Compared with sintered refractory materials, the characteristics of fused cast refractories are as follows:

(1) The porosity is low, generally less than 4% or even less than 2%. The pores are isolated, closed pores that are surrounded by extremely dense materials to prevent the intrusion of slag.

(2) High volume density and heavy volume The volume density of the world’s most advanced seawater magnesia is 3.4–3.85 g/cm3. The volume density of this grade of natural magnesia in China is 3.3–3.35 g/cm3, while the same grade of fused MgO is above 3.50 g/cm3.

(3) High mechanical strength. Because their crystals are fully developed and have interlocking characteristics, fused-cast refractory materials generally have higher high-temperature strength and are more difficult to grind than chemically bonded or sintered refractory materials. But there are exceptions. P. T. Berlrahd et al. from the United States measured the room temperature strength of single particles of two kinds of molten and two kinds of flake alumina under pressure, used the Weibull statistical method to conduct data analysis, and concluded that flake alumina contains small bands. Polycrystalline aggregate particles are crystal-sized and contain only fine intergranular pores. In contrast, fused alumina particles are large single crystals and contain large intergranular pores. According to Griffith’s formula, the strength of flaky orthopedic particles with smaller crack sizes and larger fracture toughness is greater than that of molten particles. When studying magnesia for MgO products, there are also reports that high-purity sintered magnesia has better high-temperature strength than high-purity fused magnesia products.

(4) Good volume stability at high temperatures Electric-fused refractory materials have the characteristics of a high load softening point, small re-burning shrinkage, and small high-temperature creep. However, the thermal shock stability is not ideal. Generally, semi-bonded fired bricks are better than fused cast bricks.

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