Fused Magnesia (FM)
Fused Magnesia (FM) is a synthetic refractory raw material produced by melting high-purity (>98.5%) MgO in an electric arc furnace at temperatures exceeding 2800°C (5072°F) and allowing it to solidify into large, crystalline masses. The solidified material is then crushed and sized.
The electric-arc melting process results in exceptionally large periclase crystals and near-zero porosity, making FM the most dense, chemically pure, and highest-performing basic refractory grain available. It is indispensable for refractories used in critical zones of steelmaking and glass production where resistance to slag attack, high temperature, and thermal shock is paramount.
Main Function and Characteristics
FM is valued for maximizing density and crystal size, which directly translates to superior performance in high-wear, high-temperature environments.
| CHARACTERISTIC | VALUE RANGE | PRIMARY REFRACTORY FUNCTION |
|---|---|---|
| Magnesia (MgO) Content | >98.5% | Ensures ultimate refractoriness and chemical stability. |
| Crystal Size | LARGE | Minimizes grain boundaries, reducing pathways for chemical attack. |
| Porosity | VERY LOW | Provides maximum resistance to slag penetration and corrosion. |
CLASSIFICATION
- Structure Focus: Ultra-High-Purity Basic Oxide
- Primary Application Focus: Critical Hot Spots in EAF linings, Glass Tank Crowns, and high-performance Ladles.
Key Performance Metrics
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
|---|---|---|
| Slag Penetration | MINIMAL | High density and low open porosity block liquid slag infiltration. |
| Refractoriness Under Load (RUL) | ULTIMATE | Large, interlocked crystals provide maximum high-temperature mechanical strength. |
| Volume Stability | EXCELLENT | Highest density ensures virtually no shrinkage during service. |
- The Fusing Advantage
While Dead-Burned Magnesia (DBM) is sintered at high temperatures, Fused Magnesia (FM) is melted, which allows for two critical performance enhancements:
- Crystal Growth: Melting allows the periclase crystals to grow to a massive size (>100 μm), far larger than those achieved by DBM. Large crystals minimize the total area of grain boundaries, which are the primary pathways for chemical corrosion by slag.
- Porosity Reduction: The casting process eliminates nearly all porosity (<3% open porosity), directly preventing slag penetration and subsequent corrosive wear.
These factors result in FM-based refractories outperforming DBM refractories in terms of corrosion resistance and hot strength.
- Applications
FM is reserved for the most aggressive environments where service life must be maximized regardless of cost:
- Steel Ladles: Used in the most critical areas, such as the slag line and stirring zones, often in composite Magnesia-Carbon (Mag-Carbon) bricks.
- Electric Arc Furnaces (EAF): Used in the EAF hot spots and tap holes to maximize campaign life.
- Glass Industry: Used in high-temperature zones of glass melting furnaces, particularly in Magnesia-Zirconia refractories, for their resistance to glass melt attack.
- Technical Guidance
FM is significantly more expensive than DBM. Therefore, it is typically used selectively, often mixed with DBM or carbon (as in Mag-Carbon bricks) to achieve the necessary balance of performance and cost. The final FM product must be crushed and sized accurately to meet the precise particle size distribution required by the brick press or castable formulation.
✨ 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. |
