Fast brick wear and unstable coating were solved by zone-matched magnesia-alumina spinel brick and spalling-resistant high-alumina brick, lengthening coating stability and boosting burning-zone life by about 30%.
The burning zone operated above 1400°C with alkali-salt attack; brick wore fast and coating would not hold, requiring brick replacement about every 8 months with heavy kiln downtime.
Zones were matched to temperature and atmosphere: magnesia-alumina spinel brick for the burning and transition zones for erosion resistance and coating, spalling-resistant high-alumina brick for the front transition zone for thermal-shock stability, with a bricklaying plan and on-site guidance.
Coating stability improved markedly; burning-zone life rose from about 8 months to 10–11 months (about +30%), with fewer annual stoppages and lower overall operating cost.
Magnesia-alumina spinel brick (MgO≥88%, Al₂O₃ 6-10%) is a chrome-free, environmentally friendly alternative to magnesia-chrome. Thermal-shock stability ≥8 cycles, resistant to cement clinker and alkali condensation.
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Spalling-resistant high-alumina brick introduces ZrO₂ (3-6%) for transformation and microcrack toughening. Al₂O₃≥70%, thermal-shock stability ≥15 cycles, greatly improved resistance to structural spalling under frequent temperature cycling.
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High-alumina brick LZ-65 (Al₂O₃≥65%, refractoriness ≥1790℃) has a higher corundum/mullite phase ratio for stronger slag resistance, higher temperature rating and better hot load-bearing capacity.
Learn More →For damaged checker bricks and blocked passages in the high-temperature zone, low-creep high-alumina brick, silica brick and shaped checker tiles were supplied to drawing, improving blast temperature stability.
AZS blocks and silica brick were supplied zone by zone for the tank walls and breast wall, with shaped bricks CNC-machined to drawing and numbered; third-party physical tests passed with zero defects.
Door and door-frame special bricks were custom-made to drawing with ±1mm CNC precision and rapid small-batch delivery, improving joint tightness and reducing door leakage.
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