Sintered Mullite Bauxite Grade
Category:
Product Introduction
Product Details
Sintered mullite is a high-grade refractory material primarily composed of high-purity synthetic mullite as its main phase and primary crystalline phase. It is typically manufactured using high-purity quartz, alumina, kaolin, or industrial alumina as raw materials. These components undergo precise blending, mixing, and shaping before being sintered in high-temperature kilns (generally exceeding 1600°C). Its core mineral component is mullite (3Al₂O₃·2SiO₂), a structurally stable and high-performance aluminosilicate mineral. Due to their exceptional high-temperature performance, stable chemical properties, and excellent thermal shock resistance, sintered mullite products are widely used across various high-temperature industrial applications.
I. Key Characteristics and Advantages
1. High Refractoriness: Mullite's inherently high melting point endows sintered mullite products with exceptional refractoriness, enabling structural stability under extreme temperatures.
2. Superior High-Temperature Volume Stability: The product exhibits minimal shrinkage or expansion during prolonged high-temperature use, featuring an extremely low linear change rate upon re-firing. This is crucial for maintaining dimensional stability in high-temperature kiln linings and extending service life.
3. Superior Thermal Shock Resistance: The low and isotropic thermal expansion coefficient of the mullite crystal structure enables the product to withstand sudden temperature fluctuations without cracking or spalling.
4. Exceptional Creep Resistance: It exhibits strong resistance to slow plastic deformation under high temperatures and sustained loads. This is critical for kiln furniture subjected to heavy loads, such as kiln car bricks and firing shelves.
5. Superior chemical resistance: Exhibits excellent resistance to acidic slags and molten glass, with minimal reactivity to these substances. This makes it widely applicable in glass melting furnaces, metallurgical furnaces, and similar environments.
6. High mechanical strength: Exhibits superior flexural strength at both ambient and elevated temperatures, featuring robust structure and excellent wear resistance.
II. Production Process Overview
1. Raw Material Preparation: Utilizes high-purity industrial alumina, high-purity silica, kaolin, and other raw materials.
2. Batching and Mixing: Precisely blends components according to the target theoretical mullite composition (typically around 72% Al₂O₃ content), followed by fine grinding and thorough mixing.
3. Shaping: Form the mixture into green bodies of desired shapes using methods such as pressing (e.g., friction presses, hydraulic presses), extrusion, or casting.
4. Drying: Dry the green bodies to remove moisture and enhance their strength.
5. High-Temperature Sintering: Sintering occurs in tunnel or shuttle kilns at 1600-1800°C, inducing solid-phase reactions that generate abundant mullite crystals and densify the green bodies.
6. Processing and Inspection: Post-sintering products undergo dimensional machining, visual inspection, and performance testing (e.g., bulk density, apparent porosity, room-temperature compressive strength) to ensure compliance with standards.
III. Primary Application Fields
Sintered mullite products are high-performance refractories primarily used in environments with demanding temperature and operational conditions:
1. Glass Industry:
Glass melting furnaces: The largest application field. Used for furnace upper structures (e.g., furnace roofs, breast walls, small furnaces), regenerators (checker bricks), etc., due to its exceptional resistance to alkali vapor corrosion.
2. Ceramic Industry:
Kiln furniture: Includes ceramic rollers for roller kilns, push plates for push plate kilns, kiln car bricks for tunnel kilns, firing shelves (shelving plates), and crucibles. Its high load-bearing softening temperature and thermal shock resistance enable repeated use and extended service life.
3. Metallurgical Industry:
Refractory linings for thermal equipment including hot blast stoves, blast furnaces, and ladles.
4. Petrochemical Industry:
Lining materials for high-temperature furnaces such as carbon black reactors, gasifiers, and converters.
5. Other Fields:
Support plates for sintering electronic ceramics, refractory kiln furniture, and high-temperature furnace chambers for laboratory use.
Indicator Requirements:
|
Specs\Grade |
M47 | M60 | M70 |
|
Al2O3 |
47%MIN |
59%MIN |
69%MIN |
|
TiO2 |
2%MAX |
3%MAX |
3.5%MAX |
|
Fe2O3 |
1.5%MAX |
1.5%MAX |
1.7%MAX |
|
B.D. |
2.55G/cm3 MIN |
2.6G/cm3 MIN |
2.65G/cm3 MIN |
Keywords:
Sintered Mullite Bauxite Grade
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