Introduction
High-zirconia bricks are special refractory materials primarily composed of ZrO₂ (zirconia), Al₂O₃ (alumina), and SiO₂ (silica). They are formed by high-temperature melting, during which crystals transform into a ceramic phase. After cooling, the material is crushed into micron-scale powder and then sintered or extruded at high temperatures, forming main crystals of Z-AS corundum and mullite. These bricks feature uniformly developed micro-glass phases with an even distribution, ensuring high structural strength and excellent thermal shock resistance.
Fused high-zirconia bricks are cast refractory materials made by high-temperature melting of high-purity raw materials, followed by casting and crystallization. Their main crystalline phase is plagioclase zircon, which endows them with:
Exceptional resistance to molten glass erosion
Low foam generation and stone inclusion rates
Minimal contamination to molten glass
These bricks are primarily used in special glass furnaces, including high-quality applications such as liquid crystal substrate glass furnaces, high-alumina glass furnaces, borosilicate glass furnaces, microcrystalline glass furnaces, and glass fiber furnaces.
Advantage
Refractoriness
Up to 1750–2600°C (proportional to ZrO₂ content), exceeding that of traditional fireclay or high-alumina bricks.
Superior Corrosion Resistance
Glass Industry: Resists erosion from molten silica, borosilicate, and high-alumina glass melts.
Chemical Environments: Stable in acidic and alkaline slags, outperforming silica bricks in alkali-rich atmospheres.
Outstanding Thermal Shock Stability
Microstructure Advantage: ZrO₂'s tetragonal-to-monoclinic phase transition absorbs thermal energy, reducing crack propagation.
Cycling Performance: Maintains integrity after over 1000 thermal cycles between 20–1200°C, making it ideal for furnaces with frequent startups and shutdowns.
Low Glass Infiltration & Contamination
Density: Dense microstructure (apparent porosity <5%) prevents molten glass penetration.
Purity: High ZrO₂ content minimizes leaching of iron and magnesium ions, critical for low-defect glass production.
Mechanical Strength at Elevated Temperatures
Compressive Strength: Retains 80% of its room-temperature strength (150–200 MPa) at 1400°C.
Load-Bearing Capacity: Supports heavy furnace loads without creep deformation in high-temperature zones.
Service Life: Extends furnace relining intervals by 2–3 times compared to standard refractories.
Chemical Stability in Aggressive Media
Metallurgical Applications: Resists corrosion from molten zinc, aluminum, and their alloys.
Waste Incineration: Withstands attack from chlorine and hydrochloric acid in flue gas treatment systems.
Physical and Chemical Specifications
|
Item |
Specification |
|
High Zirconia Brick |
|
|
ZrO2 % |
≥93 |
|
SiO2 % |
≤5 |
|
Al2O3+TiO2+Fe2O3+K2O+Na2O % |
≤2.0 |
|
Bulk Density, g/cm3 |
≥5.3 |
|
CCS, MPa |
≥400 |
|
0.2MPa RUL ℃ |
≥1700 |
raw materials
Zircon (ZrSiO₄)
Composition: Mainly ZrO₂ (~67%) and SiO₂ (~33%), the most common natural raw material for high-zirconia refractories.
Properties: High refractoriness (~1750°C), but pure zircon bricks have poor thermal shock resistance and require blending. Cost-effective, widely used in bricks with medium ZrO₂ content (50–70%).
Applications: Non-critical components in glass kilns, ceramic kilns, etc.
Baddeleyite (ZrO₂)
Composition: Predominantly ZrO₂ (purity ≥90%). Natural baddeleyite is scarce; industrially produced via zircon calcination or electrofusion (e.g., desilication to form stable ZrO₂).
Properties: High purity approaching theoretical ZrO₂ purity, refractoriness up to 2600°C, excellent erosion resistance. Premium cost; primarily used in high-zirconia bricks (60–85% ZrO₂) or specialized refractories (e.g., electrofused high-zirconia bricks).
Applications: Highly corrosive zones such as glass kiln throats and metallurgical furnace linings.
Electrocast Zirconia-Corundum (ZrO₂·Al₂O₃)
Composition: Synthetic composite mineral produced via electrofusion, containing ZrO₂ (30–60%) and Al₂O₃ (40–70%), with primary crystalline phases of baddeleyite (ZrO₂) and corundum (Al₂O₃).
Properties: High density (low porosity), exceptional abrasion resistance, and superior resistance to molten glass erosion compared to natural zircon. Premium cost, used in high-end refractories (e.g., electrocast high-zirconia bricks with ≥80% ZrO₂).
Applications: Critical zones in glass kilns, including melting zones and hot spots.
Process
Crushing and grading: Raw materials such as zircon and baddeleyite are crushed into different particle sizes (e.g., coarse, medium, and fine powders) and mixed according to a specific gradation to optimize brick structure.
Molding: Dry molding (press forming) or wet molding (slurry casting) is used to ensure uniform brick density.
Firing: High-temperature calcination (1500–1800°C) promotes mineral reactions to form stable crystalline phases (e.g., zirconium corundum, baddeleyite), enhancing high-temperature performance.
By rationally combining zirconium-containing raw materials and auxiliary components, high-zirconia bricks can meet the stringent requirements of refractory materials in diverse industrial applications.
Performance Comparison: Differences with other refractory materials
Typical application scenarios and performance matching
Application
High zircon bricks are widely used in high-temperature and highly aggressive industrial environments due to their excellent resistance to heat, erosion, abrasion, and thermal shock. Below is a detailed description of their core application areas and typical scenarios:
ⅠGlass Industry: The Most Important Application Area
High-zircon bricks serve as refractories in critical parts of glass production kilns, especially in areas of high erosion and temperature that directly affect kiln life and glass quality.
1.Glass Kiln Melting Section
Scenario: Glass raw material melting area (1500–1650°C), exposed to highly viscous glass liquids and volatiles (e.g., Na₂O, K₂O).
Applications:
Pool wall bricks: Electrofused high-zirconium bricks (ZrO₂ ≥ 80%) resist washout and chemical erosion from glass liquids.
Kiln floor bricks: Laid using high-zirconium or zircon bricks to prevent molten glass penetration and mechanical abrasion.
2.Liquid Flow Hole and Ear Pool
Scenario: Passage where glass liquid flows from melting to cooling sections at temperatures up to 1600°C; flow is rapid and highly erosive.
Applications: Electrofused zirconium corundum bricks or high-zirconium bricks (ZrO₂ 60–85%) with high density and strong penetration resistance.
3. Chest Wall and Small Furnace Opening
Scenario: Kiln side wall (breast wall) and fuel burning area, subject to high-temperature flame washout and dust erosion.
Applications: Zircon bricks with low to medium zirconium content (ZrO₂ 50–70%) or high zircon bricks, balancing cost and corrosion resistance.
4.Glass Fiber Kiln
Scenario: Production of glass fibers where melt contains high fluoride concentration (e.g., NaF), which is highly aggressive.
Application: Electrofused high-zirconium bricks to prevent fluoride corrosion and glass fiber contamination.
Ⅱ Metallurgical Industry:Resistance to High Temperatures and Metal Slag Erosion
Used in non-ferrous metal smelting and critical parts of iron and steel industries to resist erosion by molten metal and slag.
1.Copper, Aluminum, Zinc Smelting Furnace
Scenario: Linings in contact with molten metal and slag (e.g., copper slag containing FeO, SiO₂; aluminum slag containing Al₂O₃, Na₂O).
Applications: High-zirconium bricks (ZrO₂ 60–70%) or zircon bricks for furnace walls and bottoms to extend service life.
2.Auxiliary Equipment for Steel Industry
Scenario: Steel pretreatment furnaces, iron ladle linings, exposed to high-temperature iron (>1500°C) and alkaline slag.
Applications: High-zirconium or zirconium-aluminum composite bricks to resist erosion from CaO-MgO-SiO₂ slags.
Ⅲ Ceramics Industry:High-Temperature Furnaces and Wear Parts
Used in ceramic firing to withstand high temperatures and material scouring.
1. High-Temperature Kiln Lining
Scenario: Daily-use ceramics, special ceramics sintering kilns (shuttle kiln, tunnel kiln) with temperatures of 1200–1600°C.
Applications: Zircon or medium-zircon bricks (ZrO₂ 50–60%) for kiln walls and roofs, resistant to dust scouring and thermal shock.
2. Kiln Furniture and Saggers
Scenario: Kiln furniture carrying ceramic billets must withstand high temperatures (1300–1500°C) and repeated rapid heating and cooling.
Applications: Saggers or sheds made from high-zirconium bricks with excellent thermal shock resistance, reducing cracking and breakage.
Ⅳ Chemical and Energy Industry:Corrosion Resistance and High Temperature Environments
1. Chemical Reactor Lining
Scenario: High-temperature crackers in petrochemical industries, coal chemical gasifiers exposed to corrosive gases (CO₂, H₂S) or molten salts.
Applications: High-zirconium bricks or electrofused zirconium corundum bricks to resist chemical corrosion and high-temperature oxidation.
2. Waste Incinerators
Scenario: Acidic gases (e.g., HCl, SO₂) and fly ash generated during incineration erode furnace linings.
Applications: High-zirconium bricks in corrosion-prone furnace parts to extend maintenance cycles.
Ⅴ Other High Temperature Fields
1. Refractory Kilns
Scenario: Tunnel or shuttle kilns for refractory brick production, with linings to withstand temperatures above 1700°C.
Applications: High-zirconium or zircon bricks used for kiln car tables and vaults to reduce structural changes at high temperatures.
2. Nuclear Industry and Special Fields
Scenario: High-temperature components of nuclear reactors and aerospace industry linings requiring resistance to radiation and extreme temperatures.
Applications: Special high-zirconium bricks (e.g., pure ZrO₂ bricks), leveraging their high melting point and chemical stability.
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