High Alumina Checker Brick
- MAIN CHEMICAL COMPOSITIONS AND CATEGORIES
- High Alumina checkers are composed mainly of ALUMINA (AL2O3) with a balance of SILICA (SIO2). The high AL2O3 content minimizes glass phase formation, improving refractoriness.
- ALUMINA CONTENT: 50% to 80% (typically 50-60% for checker applications).
- KEY FUNCTION: Efficient, high-temperature heat storage and transfer.
- PRIMARY ADVANTAGE: Superior structural stability and resistance to fluxing compared to Fireclay checkers.
- KEY PROPERTIES AND PERFORMANCE
- PROPERTY: TEMPERATURE UNDER LOAD (TUL)
- TYPICAL PERFORMANCE: HIGH. TUL is significantly higher than SK34 Fireclay.
- VARIATION: TUL INCREASES as ALUMINA content rises, making it ideal for high-stacked structures.
- PROPERTY: ALKALI RESISTANCE
- TYPICAL PERFORMANCE: GOOD TO VERY GOOD.
- VARIATION: IMPROVES as ALUMINA content increases and porosity is controlled, reducing reaction with alkali vapors (e.g., K2O, NA2O).
- PROPERTY: HEAT CAPACITY / BULK DENSITY (BD)
- TYPICAL PERFORMANCE: HIGH.
- VARIATION: BD is often controlled to be high to maximize heat storage mass for thermal efficiency.
- PROPERTY: VOLUME STABILITY
- TYPICAL PERFORMANCE: EXCELLENT.
- VARIATION: High firing and AL2O3 content result in low residual shrinkage or expansion, crucial for maintaining stack geometry.
- PROPERTY: TEMPERATURE UNDER LOAD (TUL)
- ADVANTAGES AND KEY CHARACTERISTICS
- HIGH STRUCTURAL STABILITY: The high AL2O3 content ensures superior TUL and resistance to creep, preventing deformation or collapse of the checker stack in the hottest zones.
- CORROSION RESISTANCE: Offers much better resistance to chemical attack and subsequent blockage (plugging) caused by carry-over dust and condensed alkali vapors (K2O, NA2O) than Fireclay.
- OPTIMIZED HEAT TRANSFER: Used in custom geometries (like Fireclay checkers) but is capable of withstanding the higher operating temperatures required for maximum thermal efficiency.
- TYPICAL INDUSTRIES AND APPLICATIONS
- GLASS INDUSTRY: Used in the upper, hottest layers of glass furnace regenerators to withstand high temperatures and severe alkali attack.
- FERROUS INDUSTRY: Hot Blast Stoves (HBS) upper dome and upper checker courses where temperatures can exceed 1350 degrees Celsius.
- ANY HIGH-TEMPERATURE REGENERATOR: Used where the waste gas temperature makes Fireclay refractories inadequate.
- FURNACE AREAS AND SERVICE ZONES
- UPPER CHECKER SETTINGS: Placed in the top 3-5 courses of the checker stack to handle the peak incoming gas temperatures and the heaviest thermal and chemical load.
- CRITICAL STACK SUPPORT: Used as the primary structural material in the highest-load areas of the regenerator chamber.
- KEY DATA SHEET PROPERTIES TO CONSIDER
- ALUMINA CONTENT: Should be verified (e.g., 50% or 60%) as the key indicator of refractoriness and chemical stability.
- REFRACTORINESS UNDER LOAD (TUL): MUST be confirmed to be well above the maximum anticipated operating temperature and stack load.
- BULK DENSITY (BD): Look for high BD to ensure maximum thermal mass and minimal porosity.
- APPARENT POROSITY (AP): Low AP is essential to minimize the absorption and subsequent reaction of alkali fluxes, which causes premature failure via plugging.
- TECHNICAL GUIDANCE
- High Alumina checkers provide maximum thermal efficiency by allowing for higher pre-heat temperatures and extending the life of the checker setting against severe fluxing.
- The additional cost is justified by EXTENDED CAMPAIGN LIFE and IMPROVED ENERGY EFFICIENCY. The choice between High Alumina and even higher-performance Magnesia checkers depends on the severity of the alkali load and maximum temperature.
✨ 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. |
