Carbon Brick – Pitch Bonded
Main Chemical Compositions & Categories
Pitch-Bonded Carbon Bricks are composed of high-purity CARBON (C) materials, such as petroleum coke, anthracite, or graphite, held together by a COAL TAR PITCH binder. The brick is typically baked at low-to-medium temperatures to carbonize the pitch.
| COMPONENT | CONTENT | KEY FEATURE | PRIMARY ADVANTAGE |
| CARBON (C) | 90% to 99% | High thermal conductivity | Extremely low slag/metal wetting |
| ASH CONTENT | < 1% | High purity | Minimal contamination of molten metal |
Key Properties and Performance
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Non-Wetting | OUTSTANDING | High carbon content prevents molten metal and slag from adhering to the surface. |
| Thermal Conductivity | VERY HIGH | Carbon efficiently transfers heat, which is essential for cooling the hearth lining. |
| Thermal Shock Resistance | EXCELLENT | Low thermal expansion and high conductivity dissipate thermal stress effectively. |
| Refractoriness | EXTREMELY HIGH | Carbon has no melting point and remains stable up to sublimation temperature. |
Advantages and Key Characteristics
Pitch-Bonded Carbon Bricks are critical for the structural integrity and longevity of the hearth and bottom of primary metallurgical furnaces due to carbon’s unique combination of properties.
- Corrosion Resistance: Carbon is virtually inert to iron, steel, and many non-ferrous metals. The non-wetting property ensures that corrosive agents cannot easily infiltrate the brick structure.
- Safety and Campaign Life: The high thermal conductivity allows for efficient cooling of the furnace hearth (usually via water or air), solidifying a protective “skull” of metal/slag on the surface, which drastically extends the campaign life and prevents breakouts.
- High Purity and Stability: The low ash and low impurity levels ensure minimal contamination of the molten charge. The brick remains structurally stable under load at extreme temperatures.
- Wear Resistance: The dense, rigid carbon structure resists mechanical erosion and abrasion from the movement of the molten metal bath.
Typical Industries and Applications
This brick is essential for primary metal production where large volumes of molten material are contained:
- Ferrous Industry (Iron): The absolute standard for Blast Furnace hearth and bottom linings (the crucible that holds the molten iron and slag).
- Non-Ferrous Industry: Cathode and sidewall blocks for Aluminum reduction cells (electrolysis pots).
- Chemical Industry: Specialized linings for furnaces involving highly corrosive chemical reactions.
Furnace Areas and Service Zones
They are specified for the permanent structures in contact with the melt:
- BLAST FURNACE HEARTH AND BOTTOM: The most crucial application, where the brick must withstand tremendous load, extreme heat, and constant chemical attack.
- ALUMINUM REDUCTION CELL: Used as the cathode block which conducts electricity and contains the molten aluminum.
Key Data Sheet Properties to Consider
Selection criteria focus on thermal performance, structural integrity, and purity:
- Bulk Density (BD): Must be high (e.g., > 1.55 g/cm3) to minimize porosity and maximize thermal conductivity.
- Thermal Conductivity: THE CRITICAL VALUE. Must be high (often reported in W/(m·K)) to ensure effective hearth cooling.
- Apparent Porosity (AP): Must be low (e.g., < 10%) to resist penetration by molten metal.
- Ash Content: Must be minimized to ensure high carbon purity.
Technical Guidance: Pitch-Bonded Carbon Bricks are susceptible to OXIDATION (burning) if exposed to oxygen at high temperatures (above 400°C). They must be installed within a sealed environment or protected by a hot face layer of inert gas or other refractory material. The installation requires specialized carbonaceous mortar.
✨ Customization Services
We offer product customization services, allowing you to tailor the appearance, dimensions, or specific markings of items like refractory shapes or bricks. This includes options for incorporating specific geometric requirements to ensure seamless integration into your process systems.
🔬 Sampling for Testing & Validation
Free product samples are available for thorough testing and validation. This allows you to confirm the quality, compatibility, and performance of our materials—such as specific bricks, castables, or raw materials—before committing to a full order.
💡 Expertise in Refractory Solutions
Leverage our deep expertise to receive detailed, application-specific refractory solutions. We move beyond just selling products by providing comprehensive plans that encompass material selection, installation guidance, and performance optimization to maximize the lifespan and efficiency of your high-temperature processes.
Rabatec products are exclusively manufactured in facilities that have achieved rigorous ISO certifications across Quality (ISO 9001), Environmental Management, and Occupational Health & Safety. This commitment ensures every product, from refractory bricks to specialized equipment, meets the highest global benchmarks for performance, sustainability, and workplace safety.
📦 Logistics Excellence: Shipping, Packaging, and Marking
Minimizing Risk: We manage all logistics to minimize handling touchpoints and transit shock. Our carriers are pre-vetted for their experience in transporting heavy, fragile, and sensitive industrial materials.
Traceability: Every shipment includes comprehensive documentation and tracking information, providing end-to-end visibility and ensuring precise delivery coordination for your site.
Protection is Paramount: Our packaging strictly follows industry standards to prevent damage, corner chipping, and moisture absorption—especially critical for materials like Basic Refractory Bricks and Refractory Mortars & Mixes.
Robust Palletization: Products are secured on fumigated, high-strength export pallets (e.g., 1100x950mm or similar sturdy dimensions) using heavy-duty strapping and durable protective wrapping (polyethylene sheeting, cardboard, etc.) to withstand long-distance travel and multiple loadings.
Moisture Control: Sensitive materials are protected with appropriate sealing and, where necessary, desiccants or moisture-vapor proof enclosures to maintain the product's integrity until installation.
Clear Identification: All outer packaging is clearly marked on multiple sides with large, legible text for immediate identification and safe handling.
Full Traceability: Markings include all essential data points: Product Name, Quality Grade, Batch Number, Quantity, Net/Gross Weight, Order Number, and the Final Destination/Construction Area. This ensures every pallet can be accounted for and correctly staged upon arrival.
Safety & Compliance: We adhere to all regulatory requirements for marking, labeling, and placarding—especially for any items classified as Dangerous Goods—to ensure full compliance with international and domestic transport regulations.
❓ Frequently Asked Questions (FAQ)
Question | Elaborated Answer |
Q: What is the Refractoriness Under Load (RUL) of your refractories? | A: Refractoriness Under Load (RUL) is a critical property that defines the maximum temperature our materials can withstand while under compressive stress before deforming (softening). Since we offer a wide range of materials—from Alumina-Silicate Bricks to high-performance Silicon Carbide Bricks—the RUL varies significantly. For specific product data, please refer to the product data sheet or submit a quote request for the material you are interested in. |
Q: Where are the Rabatec refractories and materials produced? | A: Our products are primarily sourced from specialized manufacturing plants in China. Crucially, these facilities have all undergone rigorous audits and achieved comprehensive ISO certifications (Quality, Environment, and Safety), ensuring that production adheres to the highest global standards for consistency and performance. |
Q: What refractory materials does the company offer? | A: We supply a comprehensive portfolio of advanced refractory solutions, including: Shaped Products: Alumina & Silica Bricks, Basic & Specialized Bricks (e.g., Magnesia), SiC & Structural Ceramics, and Precast Shapes. Monolithic Products: Refractory Castables, Mixes & Mortars. Insulation: Insulation Fibre and High-Performance Insulation Products. |
Q: How should I choose the appropriate refractory material for my application? | A: Selecting the correct refractory is paramount to process efficiency. The choice depends on three key factors: 1. Operating Environment: Maximum process temperature and thermal cycling (shock). 2. Chemical Attack: Type of slag, molten metal, or corrosive gas being handled (acidic, neutral, or basic). 3. Mechanical Stress: Abrasion, erosion, and static load requirements. We recommend utilizing our detailed refractory solutions service to consult with our engineers for an optimized, application-specific recommendation. |
Q: Which monolithic material should I choose when patching an existing lining? | A: For patching and minor repairs, the ideal monolithic material depends on the parent lining material, the patching depth, and the need for a rapid return to service. Common choices include: Refractory Mortars & Mixes (for minor joints/surfaces) or Plastic Refractories (for areas requiring physical compaction). Always choose a patch material chemically compatible with the existing lining to ensure proper bonding and service life. |
Q: Can I receive product samples before placing a major order? | A: Yes. We gladly provide product samples for your internal testing and validation purposes. This ensures you can confirm the quality, composition, and fit of the material—such as our Refractory Castables or Alumina-Silicate Bricks—in your specific operational environment before committing to a bulk purchase. |
Q: Do you provide certifications to verify material quality? | A: Absolutely. We provide product-related inspection certificates and quality assurance documentation upon request. This verifies that your order has passed all internal quality control checks and meets the required material specifications and industry standards. |
Q: What measures are taken for product protection during transport? | A: We ensure quick, reliable transport by using robust, industrial packaging that strictly follows industry standards. This includes high-strength palletization, heavy-duty strapping, and weather-resistant wrapping to protect fragile items like bricks and mixes from corner chipping, mechanical damage, and moisture during transit. |
