Mullite Brick – Cast Mullite
- MAIN CHEMICAL COMPOSITIONS AND CATEGORIES
- Cast Mullite is a fusion-cast, high-purity product composed predominantly of the synthetic mineral MULLITE (3AL2O3 $\cdot$ 2SIO2).
- ALUMINA CONTENT: 70% to 75%.
- KEY FEATURE: Fusion-cast production method ensures maximum density and zero apparent porosity.
- PRIMARY ADVANTAGE: Excellent resistance to glass and molten metal penetration and corrosion.
- KEY PROPERTIES AND PERFORMANCE
- PROPERTY: POROSITY
- TYPICAL PERFORMANCE: ZERO Apparent Porosity (AP).
- VARIATION: Achieved through the fusion casting process. This is the main difference from sintered bricks.
- PROPERTY: TEMPERATURE UNDER LOAD (TUL)
- TYPICAL PERFORMANCE: EXTREMELY HIGH. Retains shape and strength near its melting point.
- VARIATION: TUL is maximized by the purity of the synthetic Mullite phase.
- PROPERTY: CORROSION RESISTANCE
- TYPICAL PERFORMANCE: OUTSTANDING against molten glass, slags, and metal penetration.
- VARIATION: Directly proportional to DENSITY and absence of interconnected pores.
- PROPERTY: THERMAL SHOCK
- TYPICAL PERFORMANCE: GOOD TO MODERATE.
- VARIATION: Density is a trade-off; the absence of pores reduces resilience to rapid temperature changes.
- PROPERTY: POROSITY
- ADVANTAGES AND KEY CHARACTERISTICS
- MAXIMUM DENSITY AND ZERO POROSITY: Eliminates pathways for molten materials (glass, metal, slag) to penetrate the brick matrix, preventing fluxing and corrosion wear. This leads to the longest campaign life in corrosive environments.
- SUPERIOR HOT STRENGTH: The interlocking crystalline structure formed during cooling of the molten material provides exceptional load-bearing capacity and creep resistance at extreme operating temperatures.
- HIGH PURITY: Made from high-purity raw materials, ensuring minimal contamination of the molten product (e.g., glass or specialty metals).
- TYPICAL INDUSTRIES AND APPLICATIONS
- GLASS INDUSTRY: The primary application, used in critical contact zones of glass melting furnaces.
- NON-FERROUS INDUSTRY: Linings for copper or other specialty metal melting/refining vessels where high corrosion resistance is mandatory.
- SPECIALTY CHEMICALS: High-temperature reactors involving corrosive fluxes.
- FURNACE AREAS AND SERVICE ZONES
- GLASS TANK BOTTOMS AND SIDEWALLS: Used in the immediate contact zone with the molten glass (metal line) due to its resistance to upward drilling and horizontal wear.
- BURNER PORTS AND THROATS: High-wear, high-temperature zones where erosion from high-velocity gases and melt-flow is severe.
- SLAG LINE: Used where the lining is continuously attacked by the corrosive slag layer floating on the melt.
- KEY DATA SHEET PROPERTIES TO CONSIDER
- APPARENT POROSITY (AP): THE CRITICAL VALUE. Must be reported as near zero (typically <1.0%) to confirm the fusion-cast nature and corrosion resistance.
- BULK DENSITY (BD): Must be extremely high (e.g., 2.9 to 3.1 g/cm3), reflecting the lack of pores.
- EROSION RATE: Look for supplier data showing a dramatically lower erosion rate compared to sintered refractories in glass or slag corrosion tests.
- IMPURITY CONTENT (FE2O3, ALKALIES): Must be minimized to ensure high glass quality and maximum refractoriness.
- TECHNICAL GUIDANCE
- Cast Mullite is a premium, high-cost solution justified only in zones of EXTREME CORROSION and EROSION where campaign life is the primary driver.
- CAUTION: Due to its density, Cast Mullite has POOR THERMAL SHOCK RESISTANCE. Care must be taken during the initial heat-up and any subsequent repairs to ensure slow, controlled temperature changes to prevent cracking. Use specialized, low-shrinkage mortar for joints.
✨ 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. |
