Home Brick for Cement/Lime Kiln Anti-spalling High alumina Brick for Cement/Lime Kiln

Anti-spalling High alumina Brick for Cement/Lime Kiln

Anti-spalling high alumina brick, crafted from high-quality high alumina bauxite clinker and zircon-containing materials, are known for their superior resistance to peeling or spalling. Their manufacturing involves adding a specific amount of composite binders and additives. Key to their design is the controlled granulation of the mud material, followed by molding and high-temperature firing​​.

The principle behind their anti-spalling capability lies in enhancing their resistance to crack formation and propagation. This is achieved by incorporating materials with varying expansion coefficients into the mix, creating intentional microcracks post-firing due to thermal expansion mismatch. Commonly used materials for this purpose include andalusite, sillimanite, and zircon. Andalusite decomposes at around 1325-1350°C, expanding by 16-18% by volume; sillimanite decomposes at 1500°C with an 8.4% volume expansion, while zircon’s toughening effect comes from the transformation between tetragonal and monoclinic zirconia phases, as well as the mullite effect. Adding zirconia to high alumina bricks significantly improves their wear resistance and anti-spalling characteristics​​.

In response, the 1990s saw the development of a second generation of anti-spalling high alumina bricks. These utilize high alumina bauxite and zircon powder as additives, along with resin, to enhance the micro-crack “toughening” effect of zirconia. This generation improved upon the high-temperature flexural strength, load softening temperature, and compressive strength compared to its predecessor, particularly in the transition zone of cement rotary kilns​​.

In comparison to high alumina bricks, anti-spalling high alumina bricks have higher strength, better chemical corrosion resistance, a lower thermal expansion coefficient, and reduced thermal conductivity. They offer improved resistance to environmental conditions such as potassium, sodium, sulfur, chlorine, and alkaline salts. Consequently, they are ideal for use in the transition and decomposition zones of cement kilns. Their enhanced thermal shock resistance and adaptability make them suitable for preheating zones in rotary kilns, calciners, and grate coolers​​.

In summary, anti-spalling high alumina bricks are a specialized type of refractory material designed to withstand harsh conditions in various industrial processes, particularly in cement kilns. Their development and refinement over the years underscore the continuous innovation in the field of refractory materials to meet the evolving demands of industrial applications.

Anti-spalling High alumina Brick

rhimagnesita We can produce RHI Magnesita standard Anti-spalling High alumina Brick for Cement/Lime Kiln

Refrateknik1 We can produce Refratechnik standard Anti-spalling High alumina Brick for Cement/Lime Kiln

OSYMEN

Al2O3

ZrO2

Fe2O3

AP

BD

CCS

RUL

TSR

1100°C Water

%

%

%

%

g/cm3

MPa

(Ta)°C

Cycles

CYRS-85

85.0

8-10

1.5

22

2.70

70

1550

30

CYRS-80

80.0

8-10

1.5

22

2.70

60

1550

30

CYRS-75

75.0

8-10

1.5

22

2.55

60

1500

30

CYRS-70S

70.0

6.0

1.5

22

2.55

60

1470

20

CYRS-70

70.0

 

1.5

20

2.55

60

1470

15

AP: Apparent Porosity   |  BD: Bulk Density  |  CCS: Cold Crushing Strength  |  RUL: Refractories Under Load  |  TSR: Thermal Shock Resistance  |  TE: Thermal Expansion

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Last updated: 2024-01-03
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