Chrome Corundum Precast Shapes
Chrome Corundum (Al2O3 – Cr2O3) Precast Shapes are high-performance refractory components made from a dense, sintered composite of Alumina (Al2O3) and Chromium Oxide (Cr2O3). These shapes are hydraulically pressed or cast into specific, ready-to-install geometries (e.g., impact blocks, nozzles, flow channels). They are highly valued for their exceptional slag and chemical corrosion resistance, very high hot strength, and superior abrasion resistance at extreme temperatures.
Main Chemical Compositions & Categories
Chrome Corundum refractories are characterized by the solid solution formed between Al2O3 (Corundum) and Cr2O3, which enhances the properties of both oxides. The level of Cr2O3 dictates the performance, particularly the corrosion resistance.
| CATEGORY | Cr2O3 Content | TYPICAL DENSITY | PRIMARY ADVANTAGE |
| Standard Chrome Corundum | 10% to 25% | 3.0 g/cm3 to 3.8 g/cm3 | Excellent hot strength and volume stability. |
| High Chrome | 30% to 90%+ | 3.9 g/cm3 to 4.5 g/cm3 | Maximum chemical inertness and slag resistance. |
Key Properties and Performance
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Slag Resistance | EXTREME | Cr2O3$ is highly inert and resists dissolution by most acidic, neutral, and some basic slags. |
| Hot Strength/Creep | MAXIMUM | The solid solution crystal structure provides outstanding resistance to deformation (creep) at high T. |
| Abrasion Resistance | SUPERIOR | High density and the hardness of Corundum/Chrome phases resist mechanical erosion. |
| Metal Non-Wetting | GOOD | Resists wetting and penetration by various molten metals. |
Advantages and Key Characteristics
Chrome Corundum Precast Shapes provide a specialized, high-integrity lining for the most aggressively corrosive and high-wear zones in high-temperature furnaces, offering significantly longer life than traditional Alumina or Magnesia materials.
- Superior Slag Line Protection: The Cr2O3 forms a very stable, high-viscosity interface layer with molten slags. This interface minimizes the reaction and erosion rates, making these shapes ideal for slag contact areas in reactors and furnaces.
- Maximum Wear Life: Used in zones subject to severe erosion from fast-flowing process materials (liquid or gas/solids), their high hardness and density ensure minimal material loss over the campaign life.
- Pre-Fabricated Consistency: Being precast and fired, these shapes offer superior dimensional accuracy and guaranteed material properties compared to site-installed castables. This is crucial for flow control elements or parts requiring precise fit.
- High Thermal and Structural Stability: They maintain high structural integrity and dimensional stability up to 1850°C, making them suitable for load-bearing and critical flow applications.
Typical Industries and Applications
This specialized refractory is essential in processes with highly corrosive environments:
- Petrochemical/Chemical: Linings for coal gasifiers, black liquor gasifiers (highly corrosive process environment), and FCC (Fluid Catalytic Cracking) cyclones/nozzles.
- Metallurgy: Tap hole blocks, impact pads, and slag line zones in EAF and LF steelmaking where corrosive slags are present; specialized flow control components.
- Waste Incineration: Linings in high-temperature incinerators exposed to aggressive, complex fly ash and corrosive vapors.
Furnace Areas and Service Zones
They are specified for structural, chemical-wear, and flow control areas:
- SLAG/METAL INTERFACE: The most corrosive zone in many metallurgical vessels.
- IMPACT BLOCKS/EROSION ZONES: Used to withstand high-velocity material flow.
- CRITICAL FLOW ELEMENTS: Nozzles, weir blocks, and pouring channels requiring high dimensional precision and wear life.
Key Data Sheet Properties to Consider
Selection criteria focus intensely on chemical and mechanical stability:
- Cr2O3 Content: CRITICAL VALUE. Specify the minimum content (e.g., 15% or 25%) based on the severity of the corrosion. Higher content usually means higher cost and performance.
- True Porosity/Bulk Density: Look for high Bulk Density (> 3.6 g/cm3) and low Apparent Porosity (< 15%) to minimize slag penetration.
- Slag Corrosion Index: Look for supplier-specific test data showing the corrosion rate against the target slag (e.g., basic, acidic, high FeO).
- Cold Crushing Strength (CCS): Must be exceptionally high, confirming the dense, sintered structure.
Technical Guidance: Due to the material’s cost, these shapes are typically only installed in the highest wear or most chemically corrosive zones. When used in precast form, the joints between the shapes must be sealed with a chemically compatible Al2O3 mortar to prevent localized attack. Note that Chromium-containing refractories require special handling and disposal procedures due to environmental regulations.
✨ 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. |
