High Alumina Brick – Low Creep
MAIN CHEMICAL COMPOSITIONS AND CATEGORIES
Low Creep bricks are a specialized grade of High Alumina, characterized by ULTRA-HIGH PURITY ALUMINA (AL2O3) and extremely low impurity content (FE2O3, K2O, NA2O). The low creep rate is achieved through maximum densification during firing.
- CATEGORY: LOW CREEP ALUMINA
- AL2O3 CONTENT: 70% TO 95%
- KEY RAW MATERIAL: HIGH-FIRED BAUXITE or SINTERED/TABULAR ALUMINA
- PRIMARY ADVANTAGE: EXTREME RESISTANCE TO DEFORMATION UNDER LOAD AT HIGH TEMPERATURES
KEY PROPERTIES AND PERFORMANCE
- PROPERTY: TEMPERATURE UNDER LOAD (TUL)
- TYPICAL PERFORMANCE: EXTREMELY HIGH
- VARIATION: DIRECTLY CORRELATES WITH AL2O3 PURITY. HIGHER PURITY YIELDS A HIGHER TUL AND EXCELLENT CREEP RESISTANCE.
- PROPERTY: CREEP IN COMPRESSION (CISC)
- TYPICAL PERFORMANCE: EXTREMELY LOW
- VARIATION: DECREASES AS PURITY AND FIRING TEMPERATURE INCREASE, ELIMINATING GLASSY OR WEAK PHASES.
- PROPERTY: CORROSION
- TYPICAL PERFORMANCE: VERY GOOD TO EXCELLENT RESISTANCE TO ACIDIC AND NEUTRAL SLAGS
- VARIATION: IMPROVES SIGNIFICANTLY WITH AL2O3 CONTENT AND LOW POROSITY. POOR AGAINST HIGHLY BASIC SLAGS.
- PROPERTY: VOLUME STABILITY
- TYPICAL PERFORMANCE: EXCELLENT
- VARIATION: HIGH FIRING ELIMINATES RESIDUAL SHRINKAGE, PROVIDING A HIGHLY STABLE LINING.
ADVANTAGES AND KEY CHARACTERISTICS
Low Creep High Alumina bricks are engineered for STRUCTURAL LONGEVITY in the hottest, highest-loaded sections of a furnace, where traditional High Alumina might deform over time.
- Exceptional Hot Strength and TUL: The key feature is the maintenance of structural integrity over long periods (months or years) under continuous heat and compression.3 This prevents catastrophic collapse or geometry changes.
- Minimal Creep (CISC): Creep is the slow, permanent deformation of the material under constant load at high temperatures.4 Low Creep bricks minimize this, ensuring the lining geometry remains constant throughout the campaign.
- High Density and Purity: Achieved by selecting high-purity raw materials (e.g., Tabular Alumina) and firing them at very high temperatures, resulting in a dense product with low porosity and high resistance to wear and penetration.
- Extended Campaign Life: By eliminating creep as a failure mechanism, these bricks dramatically extend the service life of critical assets, offering a substantial return on investment (ROI).
TYPICAL INDUSTRIES AND APPLICATIONS
These are premium refractories used exclusively in the most critical, high-load, and long-campaign applications:
- FERROUS INDUSTRY: High-temperature zones of Hot Blast Stoves (HBS) (dome, upper checkers, top structure), Continuous Annealing Furnaces, and large Reheat Furnace crowns.5
- GLASS INDUSTRY: Glass Tank Regenerator crowns, burner ports, and upper setting courses, where stability under load at very high temperatures is paramount.6
- PETROCHEMICALS: Hydrogen and Ammonia Reformers, where precise geometry and long-term thermal cycling stability are required.
FURNACE AREAS AND SERVICE ZONES
They are used in zones demanding the highest combination of temperature and structural stability:
- STRUCTURAL ARCHES AND CROWNS: Areas supporting immense load in large furnaces (e.g., large arch spans or dome roofs).
- UPPER HOT BLAST STOVE CHECKERS: The topmost layers that bear the full weight of the stack while cycling through extreme temperatures.
- HIGH-LOAD PERMANENT LININGS: Zones where the brick must serve as the primary structural component behind the working lining for decades.
KEY DATA SHEET PROPERTIES TO CONSIDER
The performance metrics for Low Creep bricks are specialized:
- CREEP IN COMPRESSION (CISC): THE CRITICAL VALUE. Must be exceptionally low (e.g., less than 0.05% change after 50 hours at $1500^{\circ}C$). This data differentiates a true Low Creep brick from standard High Alumina.
- REFRACTORINESS UNDER LOAD (TUL): Must be high, but the creep rate is a better long-term indicator than TUL.
- APPARENT POROSITY (AP) and BULK DENSITY (BD): Low AP (typically under 18%) and high BD are essential, indicating a densely sintered structure necessary for creep resistance.
- FE2O3 and Alkali Content: Must be minimized, as these impurities form low-melting glassy phases that accelerate creep.7
TECHNICAL GUIDANCE: Low Creep bricks justify their higher cost through MAXIMUM UPTIME and EXTENDED CAMPAIGN LIFE. When specifying this product, always demand the CISC data for the specific service temperature and load, as TUL alone is insufficient to predict long-term stability in these high-stress environments.
✨ 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. |
