Introduction
Zirconia corundum ramming mix is an unshaped refractory material with zirconia corundum as the main raw material. Constructed by ramming, it combines the slag resistance of zirconia and the high-temperature strength of corundum. It is widely used in high-temperature, erosive environments such as those found in the glass and metallurgical industries.
Advantage
Extremely High Temperature Resistance and Thermal Stability
Zirconia corundum (primarily composed of ZrO₂-Al₂O₃) has a refractoriness exceeding 1850°C, maintaining structural stability in extreme high-temperature environments (1600–1700°C) without softening or melting. This makes it suitable for high-temperature applications in steel and non-ferrous metal smelting.
Its crystal structure (e.g., the ZrO₂ phase-change toughening mechanism) effectively buffers thermal stress from sudden temperature changes, providing excellent thermal shock resistance that minimizes cracking or spalling.
Strong Slag Erosion Resistance and Chemical Stability
It is highly resistant to both acidic and alkaline slags:
Withstands erosion from CaO-MgO-SiO₂-based alkaline slags in steelmaking, as well as high-nickel slags and matte in non-ferrous metal smelting.
Resists penetration and corrosion from acidic media such as glass melt and cement kiln clinker, demonstrating strong chemical compatibility.
It shows virtually no chemical reaction with molten steel, glass, or other media at high temperatures, preventing contamination of the melt.
Excellent Mechanical Properties and Wear Resistance
Once rammed, it forms a dense structure with room-temperature compressive strength of 80–120 MPa and retains high strength even at 1400°C. This allows it to withstand scouring and abrasion from molten steel and slag.
With a high hardness (7–8 Mohs), it resists mechanical impact, making it ideal for heavily worn areas such as furnace bottoms and slag lines.
Low Thermal Conductivity and Energy-Saving Advantages
Its low thermal conductivity at high temperatures (1.0–1.5 W/(m·K)) helps reduce furnace heat loss and improves thermal efficiency, especially in insulation components such as glass kiln regenerators.
Penetration and Spalling Resistance
Its dense structure effectively prevents slag, glass vapor, and other media from penetrating the material, reducing the risk of spalling and extending service life.
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Raw Materials
Core Material: Zirconia Corundum
Composition: Primarily composed of Al₂O₃ (55%–75%) and ZrO₂ (20%–40%), synthesized from industrial alumina and zircon sand through electrofusion to form an Al₂O₃-ZrO₂ solid solution.
Characteristics:
Refractoriness ≥1850°C with strong high-temperature creep resistance.
ZrO₂ phase-transition toughening gives it excellent thermal shock resistance.
Auxiliary Raw Materials
Aggregate: Electrofused zirconia corundum particles (5–1 mm), zircon sand (ZrSiO₄)
Binders: Silica sol, aluminum dihydrogen phosphate (medium-temperature curing), or phenolic resin (high-temperature curing)
Additives: Metallic silicon powder (anti-explosion), TiO₂ (sintering aid)
Physical and Chemical Specifications
|
Item |
Index |
||
|
AZSD-5 |
AZSD-0.6 |
AZSD-0.4 |
|
|
Maximum Grain Size mm |
5 |
0.6 |
0.4 |
|
ZrO2 % |
≥30 |
||
|
Al2O3 % |
≥48 |
||
|
SiO2 % |
≤20 |
||
|
Bulk Density g/cm3 |
3.2 |
3.1 |
3.1 |
|
Phase Composition |
α-Al2O3,Bshiaddeleyite,Quartz,Glass phase |
||
|
Apparent Porosity % |
≤20 |
||
|
Compression Strength MPa 1400℃×3h |
≥25 |
||
Process
Waste Brick Pre-Treatment
Reclaimed electrofused zirconia corundum bricks are cleaned to remove surface contaminants and impurities, preparing them for further processing.
Crushing
The cleaned bricks are crushed into specific particle sizes using crushers to meet granulometry requirements.
Screening
Crushed materials are screened to separate particles of different sizes, ensuring they meet the specifications for various ramming mixes.
Batching and Mixing
Screened electrofused zirconia corundum particles are proportioned with other refractory materials or additives (e.g., high-alumina cement, zirconia powder, kaolin clay) according to technical specifications. The mixture is homogenized in a mixer to ensure uniform consistency.
Forming and Curing
The mixed ramming material is placed into molds and compacted either manually or mechanically. After compaction, it is cured to develop the required strength and stability.
Post-Processing
After curing, the product may undergo cutting, trimming, or other finishing steps to meet specific dimensional and shape requirements, resulting in the final zirconia corundum ramming mix.
Application
Glass Industry
Application Areas: Glass kiln walls, flow holes, and spouts
Function: Resists erosion from 1500–1600°C glass melt (containing alkaline components such as Na₂O, K₂O), and prevents structural damage from melt infiltration.
Metallurgical Industry
Application Area: Slag line of non-ferrous metal smelting furnaces (e.g., copper smelting)
Advantage: Resists erosion from oxide melts such as Cu₂O and FeO without contaminating the metal.
Other High-Temperature Equipment
Cement Kiln Decomposition Zone: Resists combined erosion from CaO-based clinker and sulfur-alkali compounds.
Ceramic Sintering Furnaces: Used as saggers or furnace linings, resisting glaze volatile erosion.
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