Phosphate Bonded Composite Brick is a type of composite refractory brick manufactured using phosphates as a binder. They leverage the chemical reaction between phosphoric acid and refractory aggregates (such as high-alumina, corundum, silicon carbide, etc.) to form phosphate bonds, which bind the aggregate particles together, imparting excellent properties to the brick.
The Main Raw Material Systems
1).High Alumina Materials: Including high alumina clinker, corundum, mullite, etc., providing high refractoriness and mechanical strength, with Al₂O₃ content typically between 60-90%.
2).Siliceous Materials: Such as quartz, sillimanite, andalusite, etc., improving thermal shock resistance and reducing thermal expansion coefficient.
3).Special Functional Materials:
Silicon carbide: Enhancing thermal conductivity and thermal shock resistance
Zirconia: Strengthening resistance to basic slag corrosion
Spinel: Improving slag resistance and thermal stability
Kyanite group minerals: Providing volume stability
Binder System: Phosphoric acid and aluminum phosphate salts, with addition amounts adjusted according to raw material characteristics, typically 4-10%
Technical Data of Composite Brick
|
Item |
Standard |
Enhanced |
High-purity |
|
Al₂O₃ ,(%) |
≥65 |
≥75 |
≥85 |
|
Fe₂O₃, (%) |
≤2.1 |
≤1.8 |
≤1.8 |
|
P₂O₅,(%) |
2-8% |
2-8% |
2-8% |
|
Bulk density (g/cm³) |
≥2.7 |
≥3 |
≥3.2 |
|
Cold crushing strength, (MPa) |
≥50 |
≥60 |
≥80 |
|
Refractoriness under load (0.2MPa), (℃) |
≥1350 |
≥1520 |
≥1520 |
|
Refractoriness (℃) |
≥1750 |
≥1800 |
≥1850 |
|
Thermal shock resistance (1100℃,water cooling) |
≥20 times |
≥25 times |
≥30imes |
|
Apparent porosity (%) |
18% |
15% |
≤12% |
Manufacturing Process of Composite Bricks
Raw Material Pretreatment
Various materials require separate processing to control particle size distribution, impurity removal, and activation. Some materials need pre-calcination treatment.
01
Mixing Process
Multi-stage mixing process, first mixing dry materials uniformly, then adding phosphate binders, with precise control of mixing time and intensity.
02
Forming Technology
Selecting press forming, isostatic pressing, or casting forming based on product requirements, with forming pressure typically 150-300MPa.
03
Curing and Drying
After forming, curing in controlled humidity environment for 12-24 hours, followed by gradient drying.
04
Heat Treatment
Heat treatment at 500-800°C to achieve full reaction of components and form stable composite structure.
05
Characteristics
Phosphate-bonded composite bricks possess the following characteristics:
Excellent High-Temperature Resistance: Through composite design, refractoriness can reach 1700-1900°C while maintaining good refractoriness under load.
Excellent Thermal Shock Resistance: Good Slag Resistance: Composite phase compositions designed for specific working conditions can resist various types of slag corrosion.
High Strength
Perfect Wear Resistance
Perfect Erosion Resistance
Good Corrosion Resistance: They have a certain resistance to acidic or basic slags, especially strong resistance to acidic slags.
Volume Stability: Rational phase composition design reduces volume changes at high temperatures.
Environmental Friendliness: Chromium-free (no Cr⁶⁺), meeting environmental requirements.
Application
Phosphate bonded refractory bricks are widely used as lining materials in various high-temperature industrial kilns and furnaces, including:
1.Steel Industry:
1).Blast furnace hearth and bottom composite bricks
2).Converter and electric furnace composite linings
3).Composite functional bricks for refining furnaces
4).ladles, tundishes, hot metal pretreatment equipment
2.Non-ferrous Metal Smelting:
1).Composite brick linings for copper flash furnaces
2).Composite materials for aluminum electrolytic cells
3).Slag-resistant composite bricks for lead ,zinc smelting furnaces
3.Petrochemical Industry:
1).Composite linings for catalytic cracking units
2).Composite support bricks for petrochemical furnace tubes
3).Composite brick linings for coal gasification furnaces
4.Cement Industry:
1).Composite bricks for rotary kiln burning zones
2).Composite materials for calciners
3).Composite brick linings for coolers
5.Glass Industry:
1).Composite brick materials for glass melting furnaces
2).Composite structural bricks for horseshoe flame furnaces
6.Power Industry: circulating fluidized bed boilers.
Packaging and Shipping of Phosphate Bonded Composite Brick
1.Packed on wooden pallets with moisture-proof film or wooden box to prevent damage.
2.Keep in dry, ventilated areas.
Our Company
FAQ
Hot Tags: phosphate-bonded composite brick, China phosphate-bonded composite brick manufacturers, suppliers, factory, Phosphate-bonded Corundum Brick, Phosphate-bonded Composite Brick, High Aluminium Phosphate Bonded Abrasion Resistant Brick, Phosphate-bonded High Alumina Brick, phosphate-bonded brick, Ceramic Brick
