Fused Mullite Brick
Fused Mullite Brick is a high-purity, synthetic refractory composed primarily of MULLITE 3Al2O3 2SiO2. The fusion process (melting raw materials in an electric furnace) eliminates impurities and maximizes the density of the crystalline phase.
| CATEGORY | AL2O3 CONTENT | KEY FEATURE | PRIMARY ADVANTAGE |
| FUSED MULLITE | 70% to 75% | Fusion-Cast (Very High Density) | Extreme corrosion resistance |
| SINTERED MULLITE | 60% to 75% | High-Fired (High Hot Strength) | Better thermal shock resistance |
Key Properties and Performance
| PROPERTY | TYPICAL PERFORMANCE | VARIATION WITH AL2O3 CONTENT |
| Temperature Under Load (TUL) | EXTREMELY HIGH | MAXIMIZED by the purity and uniform, interlocking crystal structure created during fusion. |
| Apparent Porosity (AP) | NEGLIGIBLE (near 0%) | MINIMIZED by the fusion process, which directly provides resistance to penetration. |
| Corrosion Resistance | OUTSTANDING against molten glass, slags, and metal penetration. | DIRECTLY CORRELATED with the absence of interconnected pores and low impurity levels. |
| Thermal Shock | GOOD TO MODERATE | Density is a trade-off; the absence of pores reduces resilience to rapid temperature changes (better than pure Fused Alumina). |
Fused Mullite Brick
Advantages and Key Characteristics
Fused Mullite bricks are premium refractories defined by their zero-porosity and exceptional resistance to chemical wear, offering the longest service life in the most demanding, corrosive environments.
- Maximum Resistance to Penetration: The fusion-casting process produces an extremely dense, closed-pore structure, virtually eliminating pathways for molten materials (glass, metal, slag) to penetrate and chemically degrade the lining.
- Superior Hot Strength and Creep Resistance: The large, interlocking Mullite crystals that form during controlled cooling provide maximum load-bearing capacity and minimal deformation (creep) at the highest operating temperatures.
- High Purity: Made from carefully selected, high-purity raw materials, minimizing the introduction of fluxing agents Fe2O3 or K2O that can lead to early failure.
Typical Industries and Applications
Fused Mullite is used in areas where high cost is justified by avoiding failure in critical, high-value assets:
- Glass Industry: The primary application, used in critical areas of glass melting tanks (e.g., pavement, metal line, feeders).
- Non-Ferrous Industry: High-corrosion linings for specialty metal melting/refining vessels.
- Petrochemicals/Chemicals: High-temperature reactors and burners where structural integrity and chemical inertness are vital.
Furnace Areas and Service Zones
They are used in zones of continuous chemical and thermal attack:
- Molten Contact Zones: Specifically the tank bottoms, sidewalls, and melter throats that are constantly immersed in or exposed to molten materials.
- Burner Ports and Throats: High-wear areas subject to high-velocity gases and localized overheating.
- Feeder Systems: Used in channels that require precise dimensional stability and zero contamination.
Key Data Sheet Properties to Consider
Selection criteria for Fused Mullite focus heavily on structural integrity and purity:
- Apparent Porosity (AP): THE CRITICAL VALUE. Must be < 1.0% to confirm its fusion-cast nature and true resistance to melt penetration.
- Bulk Density (BD): Must be extremely high (e.g., 2.9 to 3.1 g/cm), reflecting the lack of pores.
- Impurity Content: Low Fe2O3 and alkali content is crucial for glass quality and refractoriness.
- Thermal Expansion: Must be noted, as the material can develop high internal stress if heated too quickly.
Technical Guidance: Fused Mullite is a premium material used for MAXIMUM CORROSION RESISTANCE AND CAMPAIGN LIFE. Due to its density, installation must be performed with great care, ensuring proper joint filling with low-shrinkage mortar. Always conduct a slow, controlled dry-out and heat-up schedule to prevent thermal shock cracking.
✨ 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. |
