Low-porosity Clay Brick

Introduction

 

Low-porosity clay bricks are made from low-alumina mullite as the primary raw material, formed under high pressure and sintered at high temperatures. They primarily consist of mullite phases and exhibit excellent high-temperature physical properties and resistance to chemical erosion. Low-porosity clay bricks offer good stability and do not experience sudden changes in erosion levels, with a service life 2 to 3 times longer than that of ordinary clay bricks. Their porosity ranges from 12% to 22%, with lower porosity bricks being more difficult to produce and thus more expensive.

Although the pressing and firing temperatures are generally the same for both standard clay bricks and low-porosity bricks, the formulation process differs. Low-porosity bricks contain a certain proportion of fused corundum, which is absent in standard clay bricks. The addition of fused corundum results in low-porosity bricks-also known as dense clay bricks-and commonly referred to abroad as High Duty Fireclay Brick and Super Duty Fireclay Brick. These bricks offer low porosity, high strength, and enhanced erosion resistance. They effectively protect materials such as steel and glass from oxidation or deformation at high temperatures.

 

Advantage

 

Low Porosity and High Density: By incorporating ruby and other raw materials, optimizing grading, and increasing firing temperatures, the porosity of these bricks is significantly reduced-typically below 17%-which enhances density and compactness.

Good Dimensional Stability: In high-temperature or long-term service, low-porosity bricks resist deformation and maintain their original shape and size, contributing to overall structural stability.

High Mechanical Strength: Their dense structure gives them high compressive and flexural strength, enabling them to withstand significant pressure and external forces without cracking.

Strong Abrasion Resistance: These bricks maintain surface integrity under friction and impact, showing minimal wear and preserving their functional and visual qualities.

Strong Erosion Resistance: The low porosity prevents slag, gas, and liquid from penetrating the brick, offering resistance to both acidic and alkaline environments.

Good Oxidation Resistance: Under high-temperature oxidative conditions, the components are less susceptible to chemical degradation.

High Fire Resistance: Capable of withstanding 1770°C to 2000°C, they maintain strength and stability at high temperatures without softening or melting.

Good Thermal Shock Stability: Internal microporosity helps relieve thermal stress during rapid temperature changes, minimizing cracking and spalling.

Good Thermal Insulation Performance: Lower porosity reduces air circulation within the brick, increasing the heat conduction path and lowering thermal conductivity-improving insulation.

 

Zinfon Refractory Technology Co.,Ltd.

 

We provide one-stop services from technical consultation to design, production, and after-sales support.

Manufacturer Direct

Factory Prices

Premium Service

Customization Available

Raw Materials

Clay minerals as the main

 

Physical and Chemical Specifications

 

Item	Specification
	YXLP-45	YXLP-42	YXLP-42L	YXLP-40
Al2O3 %	≥45	≥42	≥42	≥42
Fe2O3 %	≤1.2	≤1.5	≤1.8	≤1.7
P2O5 %	/	/	≥5	/
Apparent Porosity, %	≤12	≤15	≤14	≤17
CCS, MPa	≥80	≥70	≥70	≥55
0.2MPa RUL, ℃	≥1500	≥1460	≥1450	≥1420
PLC, %	1450℃×3h -0.2~0.1	1450℃×3h -0.2~0.1	1450℃×3h -0.2~0.1	1400℃×2h -0.4~0

strength

 

1.Penetration resistance:The low-porosity structure effectively blocks slag infiltration (e.g., CaO, Fe₂O₃ in cement kilns), extending service life.

2.High temperature strength:High bulk density (≥2.2 g/cm³) provides superior compressive and creep resistance under heat.

3.Erosion resistance:The dense structure reduces chemical reaction penetration from gases like SO₃ and Na₂O.

 

Process

 

Raw Material Selection
Use high-purity clay with Al₂O₃ content ≥35% and low impurity content (e.g., Fe₂O₃, TiO₂) to reduce sintering shrinkage. Add 2%–5% SiO₂ or CaO as sintering aids.

Particle Size Optimization
Use multi-grade mixing (coarse:medium:fine = 30%:40%:30%) to reduce porosity. Add 0.5%–2% organic binders (e.g., calcium lignosulfonate) to enhance compactness during molding.

High-Pressure Molding
Apply ≥150 MPa using a friction or hydraulic press to achieve bulk density ≥2.2 g/cm³.

High-Temperature Sintering
Sinter at 1350–1450°C (compared to 1300–1400°C for standard clay bricks) for 6–8 hours to promote mullite crystal formation.

 

Choose low-porosity clay bricks when the application involves:

High-temperature, highly erosive environments (e.g., cement kiln firing zones).

Long-term resistance to infiltration (e.g., heat storage chambers in glass furnaces).

DN-10 Type: Apparent porosity <10%. Very high density and strength; used in extremely harsh erosion environments.

DN-12 Type: Porosity ≈12%. Suitable for demanding kiln lining applications.

DN-15 Type: Porosity ≈15%. Balances high densification with cost efficiency; widely used in general high-temperature kilns.

DN-17 Type: Porosity >17%. Suitable for less demanding conditions.

01/Customized dimensions and shapes

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Customized Brick Shape

Provide Sample Sheets--Mold Opening & Quotation--Mold Opening & Sample Making--Bulk Production Quotation--Contract Signing--Bulk Production

02/Delivery cycle and logistics

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Sea freight, land freight. Determine the mode of transportation according to the needs

About 30 days, customized products delivery time depends on the actual situation.

03/Customized packaging

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Customize your brand

Logo customization, custom fonts, taglines and messages for packaging, signage, websites or printed materials.

Take your brand to the next level, contact us today to discuss your project!

04/Purchase ZINFON refractory Bricks at Reasonable Prices

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The price of refractory bricks is a known key factor influencing customers' purchasing decisions. Therefore, we offer affordable refractory bricks for sale. Here are several reasons why ZINFON provides refractory bricks at competitive prices:

It is worth noting that while price is an important factor, it should not be the sole determinant of your purchasing decision. When buying refractory bricks from ZINFON, quality, reliability, and technical support are equally important considerations.

By choosing ZINFON as your supplier, you can access high-quality refractory bricks, a wide range of other refractory materials, and comprehensive support. Contact ZINFON Refractories immediately to discuss your specific requirements and obtain customized solutions!

How To Cooperate With Us?

7*24 hours online response

Provide professional after-sales protection‬

Our address

Qinghua Management Dist., Dashiqiao City, Yingkou City, Liaoning, China

Phone Number

+8613700131695

+8618540210631

E-mail

info@zinfon-refractory.com

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