Zircon Brick (ZrO₂‑Rich)
Main Chemical Compositions & Categories
ZrO2-Rich Zircon Bricks are composed mainly of high-purity ZIRCONIA (ZrO2), which is the oxide of Zirconium. They are classified based on the percentage of ZrO2 and its phase stability (monoclinic, tetragonal, or cubic, often stabilized by CaO, MgO, or Y2O3).
| CATEGORY | ZrO2 CONTENT | PHASE STABILITY | PRIMARY ADVANTAGE |
| ZrO2-RICH | 65% to $99% | Partially or Fully Stabilized | Highest service temperature and chemical resistance |
| STANDARD ZIRCON | $65% ZrO2 – SiO2) | Monoclinic Zircon | Excellent resistance to glass melt and low basicity slag |
Key Properties and Performance
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Service Temperature | EXTREME (Up to $\sim 2300^{\circ}\text{C}$) | $\text{ZrO}_{2}$ has one of the highest melting points among common refractory oxides. |
| Thermal Insulation | EXCELLENT | $\text{ZrO}_{2}$ has a low thermal conductivity, making it an excellent high-temperature insulator. |
| Corrosion Resistance | EXCEPTIONAL | Chemically inert to many molten metals, slags, and glasses, especially when stabilized. |
| Thermal Shock | GOOD to VERY GOOD | The inherent micro-cracking mechanism of $\text{ZrO}_{2}$ absorbs thermal stress. |
Advantages and Key Characteristics
ZrO2-Rich Zircon bricks are ultra-premium refractories used in highly specialized, extreme-temperature zones where no other material offers the necessary combination of chemical stability and thermal performance.
- Highest Temperature Stability: The main benefit is the ability to operate continuously at temperatures far exceeding the limits of Al2O3 or standard MgO refractories.
- Chemical Inertness: Zirconia exhibits high resistance to chemical reaction and dissolution, especially against many corrosive glasses, slags, and molten non-ferrous metals. The stabilized variants (PSZ, FSZ) maintain this inertness even under thermal cycling.
- Low Thermal Conductivity: Unlike many dense, high-T refractories, Zirconia acts as a high-performance insulator, minimizing heat loss and increasing process energy efficiency.
- Thermal Shock Tolerance: The crystal phase transformation (monoclinic ↔ tetragonal) in partially stabilized ZrO2 (PSZ) creates controlled micro-cracking that absorbs and dissipates thermal stress, minimizing catastrophic spalling.
Typical Industries and Applications
This brick is used in industries with the most demanding thermal requirements:
- Glass Industry: Critical paving, bottom, and throat areas of specialized, high-temperature glass melting furnaces, particularly those making high-purity or specialty glasses.
- Aerospace/Electronics: Furnace components, hot zones, and supports for manufacturing advanced ceramics, single-crystal materials, and high-purity metal alloys.
- High-Temperature Furnaces: Linings and insulation for UHT (Ultra High Temperature) kilns and vacuum furnaces.
Furnace Areas and Service Zones
They are specified for zones of maximum heat, corrosion, and value:
- ELECTRODE BLOCKS: Used as surrounding or contact refractory for electrodes due to its stability under high localized heat.
- CRITICAL HOT SPOTS: Used as contact material in high-temperature liquid containment (molten metals, glass).
- THERMAL INSULATION: Used as a premium, multi-layer insulating barrier in extreme-temperature environments.
Key Data Sheet Properties to Consider
Selection criteria focus on phase stability and purity:
- ZrO2 Purity/Content: 65% to 99% must be verified. Higher content equals higher service temperature limit.
- Stabilization Type (Y2O3, CaO, MgO): CRITICAL VALUE. Stabilization (Partial or Full) is necessary to control the volume change associated with the monoclinic ↔ tetragonal transformation. PSZ (Partially Stabilized Zirconia) has the best thermal shock resistance; FSZ (Fully Stabilized Zirconia) has the highest hot strength and service temperature.
- Bulk Density (BD) and Apparent Porosity (AP): Must be carefully controlled to balance thermal shock resistance (higher AP can help) with corrosion resistance (lower AP is better).
- Thermal Conductivity: Look for low values, confirming its insulating properties.
Technical Guidance: ZrO2-Rich Zircon bricks are an extremely high-cost investment. They are typically used only where the high cost is justified by the requirement for MAXIMUM OPERATING TEMPERATURE and UNRIVALED CHEMICAL INERTNESS. The phase transition of unstabilized ZrO2 at 1000°C causes a large volume change (7%), which is highly destructive. Always confirm the stabilization method for the intended service 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. |
