Zircon Sand
Zircon Sand is a naturally occurring, high-purity mineral (Zirconium Silicate, ZrSiO₄). It is recovered primarily as a co-product of heavy mineral sands mining. Zircon is one of the most chemically stable and refractory raw materials available, valued for its high density, low thermal expansion, and exceptional resistance to chemical attack and high temperatures.
It is the essential ingredient for producing Zircon Refractories and is widely used in the foundry and ceramic industries where high refractoriness, low thermal conductivity, and good dimensional stability are required.
Main Function and Characteristics
Zircon Sand provides a highly stable, inert, and dense aggregate for extreme-temperature applications.
| CHARACTERISTIC | VALUE RANGE | PRIMARY REFRACTORY FUNCTION |
|---|---|---|
| Purity (ZrSiO₄) | >99% | Ensures high refractoriness and chemical stability. |
| Zirconia (ZrO₂) Content | ~66% | The high ZrO₂ content imparts exceptional stability. |
| Density (Specific Gravity) | 4.2 to 4.7 | High density is crucial for resisting liquid metal and slag penetration. |
CLASSIFICATION
- Mineralogy Focus: Zirconium Silicate – Tetragonal Crystalline Structure
- Primary Application Focus: Glass Furnaces, Investment Casting Shells, and Foundry Molds.
Key Performance Metrics
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
|---|---|---|
| Refractoriness (PCE) | VERY HIGH (~2500°C) | Decomposes only at very high temperatures, providing excellent stability. |
| Chemical Inertness | EXCELLENT | Highly resistant to reaction with molten glass, CaO-containing materials, and many slags. |
| Thermal Expansion | VERY LOW | Ensures minimal volume change, providing superior dimensional stability. |
- Decomposition and Stability
Zircon Sand is stable up to very high temperatures, but above approximately 1680°C (3056°F), it slowly decomposes:
ZrSiO₄ → ZrO₂ (Zirconia) + SiO₂ (Silica)
- Refractory Use: This decomposition is slow and manageable. Zircon-based refractories are widely used because the dense ZrSiO₄ structure resists corrosion from Fe and Mn oxides and, critically, from molten glass.
- Dimensional Stability: Zircon’s extremely low coefficient of thermal expansion is a major advantage, minimizing the risk of thermal shock and spalling in highly cyclic operations.
- Applications in Foundries and Furnaces
- Glass Furnaces: Zircon-based bricks are crucial for the paving and sidewall areas of glass tanks due to their exceptional resistance to attack by molten glass melt.
- Investment Casting: Zircon flour is used in the primary coat of the ceramic shell in investment casting (lost-wax process). Its purity and fine particle size ensure a perfect surface finish on the final metal casting.
- Foundry Sand: Zircon Sand is a premium, high-performance alternative to silica sand for molding (cores and molds) when casting high-temperature alloys (e.g., stainless steel, superalloys). Its superior chilling ability and resistance to metal penetration result in higher quality castings.
- Refractory Mortars: Used as a fine aggregate in high-purity mortars for bonding zircon and chrome-containing refractories.
- Technical Guidance
- Cost: Zircon Sand is significantly more expensive than silica or fireclay materials, making it a specialty, high-performance material used strategically in areas of high wear or high chemical exposure.
- Iron Content: Low levels of Fe₂O₃ are essential, as iron acts as a flux that can reduce the high-temperature stability of the final refractory product.
✨ 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. |
