Mullite Brick – Corundum Mullite
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Main Chemical Compositions & Categories
Basic bricks contain high levels of MAGNESIA (MgO) and/or CALCIUM OXIDE (CaO). They are essential for handling basic slag environments.
CATEGORY PRIMARY COMPOSITION MAX SERVICE TEMP. SLAG RESISTANCE MAGNESIA (MgO) 90% to 98% MgO UP TO 1850°C EXCELLENT BASIC SLAG MAGNESIA-CHROME MgO + CHROMITE (Cr2O3) UP TO 1800°C EXCELLENT BASIC SLAG DOLOMITE CaO + MgO UP TO 1700°C GOOD BASIC SLAG Key Properties and Performance
PROPERTY TYPICAL PERFORMANCE VARIATION WITH MgO CONTENT Temperature Under Load (TUL) HIGH TO VERY HIGH INCREASES significantly as MgO purity rises. Pure MgO has superior hot strength. Thermal Shock POOR TO MODERATE IMPROVES with the addition of Chrome or Carbon. Pure MgO is vulnerable to shock. Corrosion EXCELLENT RESISTANCE to BASIC SLAGS INCREASES with MgO content. Reacts POORLY with HIGHLY ACIDIC slags (high SiO2). Mechanical Strength/Wear VERY GOOD at high temperatures INCREASES with BULK DENSITY (BD) and firing temperature, maintaining rigidity.
Advantages and Key Characteristics
Basic refractories are mandatory for any operation involving basic slag—the most aggressive chemical environment in steel and non-ferrous refining.
- Slag Resistance: They are chemically stable against high concentrations of CALCIUM OXIDE (CaO) and MAGNESIA (MgO), which characterize basic slags.
- High Refractoriness: Magnesia has a very high melting point, ensuring stability at the extreme temperatures of steelmaking.
- Corrosion Mechanism: Magnesia minimizes corrosion by forming a solid solution interface layer with the slag, rather than dissolving catastrophically.
Typical Industries and Applications
Basic bricks are primarily concentrated in the metallurgical industries:
- Ferrous Industry (Steel): Electric Arc Furnaces (EAFs), Basic Oxygen Furnaces (BOFs), Ladle Refining Furnaces (LRFs), and Vacuum Degassers.
- Non-Ferrous Industry: Copper converters and lead refining furnaces.
- Cement & Lime: Rotary kiln burning zones where the high CaO content of the clinker is stabilized by MgO brick.
Furnace Areas and Service Zones
Basic refractories are specified for the hottest, most chemically aggressive zones:
- Slag Line: In steel furnaces (EAF/BOF/LRF), the area of maximum chemical attack. Magnesia-Carbon (MgO-C) bricks are often used here for enhanced thermal shock and corrosion resistance.
- Permanent Lining: The high-purity MgO acts as the permanent backing and structural support in severe zones.
- Cement Kiln: The high-temperature burning zone, often utilizing Magnesia-Spinel or Dolomite grades.
Key Data Sheet Properties to Consider
Selection must balance chemical resistance with thermal stability and integrity:
- Chemical Analysis: High purity MgO (over 95%) offers maximum hot strength. Low SiO2 content is essential.
- Bulk Density (BD): CRUCIAL. Must be high (e.g., above 3.0 g/cm³) to minimize porosity and prevent slag penetration.
- Apparent Porosity (AP): Should be low (under 15%) to prevent corrosive media infiltration.
- Refractoriness Under Load (TUL): Must be exceptionally high, often exceeding 1650°C, to ensure structural stability under load in steelmaking.
Technical Guidance: Never use basic refractories in contact with high-silica, ACIDIC slags, as this leads to rapid chemical destruction. When thermal cycling is severe (like in LRFs), look for Magnesia-Carbon grades, as the added carbon improves resistance to thermal spalling and metal/slag wetting.
✨ 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. |
