Silicon Mullite Brick
Silicon Mullite bricks are composed primarily of high-purity ALUMINA (Al2O3) and SILICA (SiO2) (forming Mullite), along with a supplementary source of Silicon which may be in the form of free Si (in a Reaction-Bonded matrix) or Silicon Carbide (SiC).
| COMPONENT | CONTENT | KEY FEATURE | PRIMARY ADVANTAGE |
| Mullite | 70% – 90% | High refractoriness, low CTE | Excellent thermal shock resistance and hot strength |
| Silicon (Si) / SiC | 5% – 20% | High density, non-wetting agent | Enhanced creep resistance and low porosity |
Key Properties and Performance
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Creep in Compression (CISC) | VERY LOW | Mullite’s crystalline structure, coupled with the dense, high-melting silicon phases, minimizes deformation under load. |
| Volume Stability | EXCELLENT | Fully formed Mullite and stable silicon phases result in minimal shrinkage and high dimensional consistency. |
| Slag Penetration | VERY GOOD | The dense microstructure and the presence of low-porosity, non-wetting silicon phases inhibit the infiltration of molten materials. |
| Hot Strength (TUL) | HIGH | High Al2O3 content and the strong ceramic matrix ensure structural integrity at elevated temperatures. |
Silicon Mullite Brick
Advantages and Key Characteristics
Silicon Mullite bricks are premium materials chosen when the superior creep resistance and chemical stability of Mullite must be combined with enhanced density and resistance to slag infiltration.
- Enhanced Creep Resistance: The unique composition, particularly the fine matrix, helps suppress the formation of low-viscosity liquid phases at grain boundaries, which are the main cause of creep (sagging) in standard Alumina-Silicate bricks. This allows use under high structural load.
- Superior Volume Stability: The high proportion of fully crystalline Mullite and stable silicon compounds ensures the brick maintains its dimensions even through prolonged heating, preventing shifting or cracking in the lining structure.
- Improved Slag Resistance: The low open porosity achieved by the dense matrix and the non-wetting properties of SiC (if present) or free Si make the brick highly resistant to the penetration and subsequent corrosion by most acidic to neutral slags.
- Excellent Thermal Shock Resistance: Inherited from the Mullite phase, the material resists cracking when subjected to rapid or extreme temperature changes, common during cyclic operations.
Typical Industries and Applications
This brick is used in structural, high-temperature, and chemically demanding environments:
- Glass Industry: Checkerwork and structural supports in regenerators, particularly in the middle and lower courses where temperature and load are high.
- Metallurgical Industry: Hot blast stove domes, checkerwork, and high-load supports where minimal creep is required.
- Chemical Industry: Linings for reaction vessels and incinerators handling complex, corrosive atmospheres and residues.
Furnace Areas and Service Zones
They are specified for structural zones that bear load and require chemical stability:
- HOT BLAST STOVE CHECKERS: Used as the structural elements (the ‘bones’ of the checkerwork) to maintain integrity under the massive weight of the overlying brickwork.
- REGENERATOR PACKING/CROWNS: Used in the transition zones of glass furnaces where load and high temperature combine.
- CRITICAL SUPPORT ARCHES: Structural elements in the hot zone of large furnaces.
Key Data Sheet Properties to Consider
Selection criteria focus on structural stability and purity:
- Al2O3 Content: Typically 65% – 75% (indicative of high Mullite content).
- Creep in Compression (CISC): CRITICAL VALUE. Must demonstrate exceptional performance (very low creep rate at the highest service T to confirm its structural suitability.
- Bulk Density (BD) and Apparent Porosity (AP): High BD (e.g., > 2.6 g/cm3) and low AP (e.g., < 15%) are desired for maximum infiltration resistance.
- SiO2 / Fe2O3 Fluxes: Must be minimized to ensure the high hot strength properties are not compromised by early liquid phase formation.
Technical Guidance: Silicon Mullite is a preferred material over standard high-alumina bricks when the operating condition requires exceptional resistance to deformation (creep) under structural load at high temperatures. The inclusion of Silicon or SiC components slightly limits its suitability in strongly oxidizing atmospheres above 1400°C unless the material is glazed or otherwise protected.
✨ 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. |
