glass engineering - m glass factory...

Head office　Mita NN Building Floor 6, 4-1-23, Shiba, Minato-ku, Tokyo 1080014 JAPANPhone +81-3-5442-9172Fax +81-3-5442-9190

Tokyo officeMita NN Building Floor 6, 4-1-23, Shiba,Minato-ku, Tokyo 1080014Phone +81-3-5442-9184Fax +81-3-5442-9192

Osaka officeRiso Shinosaka Building Floor 7, 4-3-7, Miyahara, Yodogawa-ku Osaka, 5320003Phone +81-6-6391-9210Fax +81-6-6391-9216

West-Japan officesKitakyushu5-1-1, Makiyama, Tobata-kuKitakyushu-shi, Fukuoka 8048520(c/o Asahi Glass Co. Ltd. Kitakyushu Plant)Phone +81-93-882-1955Fax +81-93-882-7241

Singapore office 101 Cecil Street, #14-08 Tong Eng Building,Singapore 069533Phone +65-6223-2052Fax +65-6226-2204

Takasago plantProduction Division5-6-1, Umei, Takasago-shi, Hyogo 6768655(c/o Asahi Glass Co. Ltd. Takasago plant)Phone +81-79-447-7342Fax +81-79-447-3190Development Center5-6-1, Umei, Takasago-shi, Hyogo 6768655(c/o Asahi Glass Co. Ltd. Takasago plant)Phone +81-79-447-7336Fax +81-79-447-2590

AGC Ceramics Co., Ltd.

Glass Engineering

AGC Ceramics Co., Ltd.

Printed in Japan 2010.7

AGC Ceramics Co., Ltd. Glass Engineering

CONTENTS

1. AGC Ceramics at a glance

2. EngineeringFive Activities throughout Furnace Life

3. MaterialFused Cast Refractories

Bonded Refractories

Monolithic Refractories and mortars

4. Data bank

A Century working with Glass

AGC Ceram

ics at a glanceEngineering

Material

Data bank

1 2


1 AGC Ceramics at a glance

A Century working with Glass

For almost a century, AGC Ceramics has cultivated technologies including production/development of ceramics products for glass melting furnaces, evaluation, quality guarantee and a range of technologies in relation to glass melting furnaces. By integrating these technologies to off er a wide-range of solutions, we aim to minimize the life-cycle cost of glass melting furnaces and increase customers’ satisfaction.

Global network of AGC Ceramics

AGC Ceram


Material

Data bank

AGC GroupThe AGC Group, with the Asahi Glass Company at its core, is a global business group. The main industries of the group, such as flat glass, automotive glass, electronics & energy and chemicals, help drive business development worldwide.

Our mission is to provide the best solutions to meet our customers’ needs. While promoting the diversification of our business and developing new technologies and products, the group has launched itself into global market. Capitalizing on such performance and its business foundation, we continue to provide “solutions based on the best materials and technology” on a global scale to the contemporary leading industries. Beginning with the Asahi Glass Company, the AGC Group now has operations in roughly 30 countries for a total of over 200 subsidiaries and approximately 50,000 group employees worldwide.

AGC CeramicsOur refractory business began when AGC Ceramics started producing refractories for the glass production in 1916. Since then, we have been engaged in development and manufacturing of high quality refractories, including fused cast, bonded and monolithic for nearly 100 years.

AGC Ceramics is well known worldwide as a leading supplier of fused cast refractories, which have high resistance against corrosion by molten glass and excellent minimal contamination character. Due to these properties, ZB-X950 series refractories are well suited to the furnace for high quality glass. Now in addition to ZB-X9510, we offer ZB-X9540, which have unique features as high electrical resistivity.

Outline of AGC Ceramics’ BusinessHistory

1916 Started production of bonded refractories1932 Started production of fused cast refractories1969 Started production of monolithic

refractories by buying out theMonolithic Refractories Division of NKK

1993 Setting up of Zibo Asahi Glass Fused Material Co. in China

2002 Spun off from Asahi Glass Co., Ltd.Corporate participation in Zibo GT Industrial Ceramics Co.

Consolidated base (2009)

− Sales volume in the year US$ 260million− Number of employees 1,000− Total capital US$ 35million− Stock holders Asahi Glass Co., Ltd. (100%)

ZIBO ASAHI GLASSALUMINA MATERIALS

AGC HEAD OFFICE

AGCC HEAD OFFICE

AGCC OSAKA BRANCH

AGCC TAKASAGO FACTORY(located in AGC TAKASAGO FACTORY)

ZIBO GT industrial Ceramics

AGC SINGAPOREAGCC SINGAPORE

3 4

AGC Ceramics Co., Ltd. Glass EngineeringAGC Ceram


Material

Data bank

Five Activities throughout Furnace Life

2 Engineering

It is very important to provide the optimum design to meet the needs of customers in the planning of the glass melting furnaces which continue operations for more than ten years.

Utilizing glass melting technologies, operation know-how and expertise in furnace design accumulated as a subsidiary of Asahi Glass Company, AGC Ceramics provides the best solution for glass furnace at any life stage in a wide range of glass production fi elds such as fl at glass, LCD glass, container glass, table ware glass, fi ber glass, sodium-silicate glass and other special glasses.

We summarize our operations to support customers throughout their furnace life into fi ve activities.

Engineering technologies of AGC Ceramics are focused on realization of the best system in terms of Glass Quality, Environment Protection and Reliability. In this sense, AGC Ceramics off ers the unique technologies and solutions.

- Technologies to improve Glass Quality

Glass melting furnace will often continue to operate for more than ten years, once started.The appropriateness of the furnace design, therefore, aff ects the glass quality, energy cost, furnace life etc.

AGC Ceramics proposes best furnace design to satisfy the needs of customers. In order to improve glass quality AGC Ceramics provides several unique technologies. For example, AGC Ceramics utilizes simulation technologies refi ned by the long time experiences in comparing the calculation and observation to predict the glass fl ow and temperature distribution in advance. Furthermore, refractory corrosion test and continuous blister test give the data to predict the refractory performance in the conditions similar to the actual operation.

-Technologies for Energy Saving and Better Environment

AGC Ceramics also provides several unique technologies to protect environment. Among them, we propose oxy-furnace, advanced regenerator, low-NOX burner and waste gas cleaning system (Electrostatic precipitator and bag-fi lter)

DESIGN

FURNACEMATERIAL

CONSTRUCTIONCOMMISSIONING

OPERATIONSUPPORT

COLD REPAIRPLANNING

Activity 1 DESIGN

Double pass regenerator

3D glass fl ow simulation

Electrostatic precipitator

Inspection of bubble from refractory

5 6



Material

Data bank

In AGC Ceramics, maximum use of highly functional furnace materials we developed and of our global material supplier network enables us to provide a wide range of world class materials for customers engaged in various kinds of glass manufacturing. We can provide the best material combination for any kind of glasses, glass products, furnace design and combustion system.

We help our customers solve problems in glass manufacturing based on our accumulated furnace operation technology and knowhow. Unpredictable problems and diffi culties may arise during furnace life time. We provide reliable services to meet various requirements from daily maintenance to urgent trouble shooting.

During cold repair and furnace inspection, very important information will be collected which is useful to plan the future improvement of the furnace. Panorama photographing technology can record the conditions of the furnace effi ciently. The information from analysis of used refractory will be helpful to select the refractory more suitable to the furnace.

In addition to proposing the optimal plan (cold repair and new construction) for our customers, we also apply our longstanding experience in melting work to the on-site operation. We can therefore off er an integrated design and construction work plan to meet requirements such as effi ciency, safety and economy in performing cold repair and new construction

Activity 2 Activity 4

Activity 5 Activity 3

FURNACE MATERIAL OPERATION SUPPORT

COLD REPAIR PLANNINGCONSTRUCTION and COMMISSIONING

Fused cast refractory(Pre-assembled AZS crown)

Bonded refractory(Magnesia bricks)

Monolithic refractory(Castable and mortar)

Furnace inspectionafter campaign

Inside inspection of operating furnace

PLEASUREsoftware Glass defect analysis

Panorama view inside furnaceView from port to melter AZS (fused cast) crown

・Electric fused cast refractories (AZS, alumina, high pure zirconia, etc.)・Bonded refractories (alumina, magnesia, magnesia spinel, sillimanite, zircon, alumina zircon, silica, fi re clay, etc.)・Monolithic refractories (sealing/repairing material, mortar/tamping material and castable refractories)

■ Refractories (Refer to Section 3 MATERIAL for more details)

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Fused Cast Refractories3 Material

AGC Ceram


Material

Data bank

By using our in-house high-functional materials and parts materials, and through a global material supplier network, AGC Ceramics can off er our custmers any type of refractory to best suit their glass components/burning methods/melting furnace design.

It is common to run a glass melting furnace non-stop for more than 10 years. Therefore, it is important to choose a refractory for the furnace that will generate high-quality glass over a long period.

For parts in the glass furnace which are in contact with molten glass or the super-structure of a melter, it is common to apply Fused cast refractories that are corrosion-proof and do not cause glass defects.

Alternatively, for melter crowns, furnace bottoms, super-structure of the forehearth and feeder parts, Bonded refractories (silica bricks, sillimanite bricks, etc) or Monolithic refractories (mortar/tamping material of zircon aluminate, etc) are commonly used.

For regenerator checkers and housing Bonded refractories (magnesia bricks, basic bricks, etc) are widely used.

AGC Ceramics has developed unique, fi rst-class zirconia fused cast refractories by utilizing its years of accumulated fused cast refractories technology. The ZB-X950 Series contains over 88% zirconia thereby achieving the highest quality without stone and blister defects in the molten glass. Therefore, this fused cast refractory is most suitable for the parts of fi ne glass melting furnaces that come into contact with glass. It has a proven performance in melting furnaces that use boro-silicate glass, alumina silicate glass, glass ceramics and TV glass.The ZB-X950 Series consists of the ZB-X9510 for general use and ZB-X9540 with high electrical resistivity. The latter is suitable for electrode blocks in electric furnaces that particularly need high electrical resistivity.

Zirconite series are a high quality Al2O3-ZrO2-SiO2(AZS) fused cast refractories, consisting of crystallized baddeleyite (ZrO2) and corundum (Al2O3), and matrix glass. It is made by melting refi ned raw materials through a Heroult type electric arc method under a thorough quality control process.ZB-1681The AZS fused cast refractory class containing 33% ZrO2. It is unlikely to cause defections of stones, blisters and cords. Therefore, it is most suitable for superstructures of melters, side walls of refi ners, paving blocks, and forehearth channel blocks.ZB-1681XThe AZS fused cast refractory containing 33% ZrO2 with lower contents of Na2O and glass phase compared with ZB-1681.ZB-1681X has lower potential for contamination to molten glass with lower exudation.The new product, ZB-1681X is suitable for superstructure of glass melting furnace.ZB-1691The AZS fused cast refractory class containing 35% ZrO2. It is corrosion resistant and shows minimal contamination against molten glass. It is most suitable for glass contact parts of melters, and has shown considerable results in side walls and paving blocks.ZB-1691XThe AZS fused cast refractory containing 35% ZrO2 with lower content of Na2O and higher SiO2/Na2O ratio compared with ZB-1691. ZB-1691X has minimal contamination and higher corrosion resistance to molten glass.The new product, ZB-1691X is suitable for side walls and paving blocks of glass melting furnace.ZB-1711The high-zirconia AZS fused cast refractory class containing 41% ZrO2. It is highly corrosion resistant against molten glass, and by strengthening matrix glass, it shows minimal contamination to molten glass. It is most suitable for glass melting furnaces; on throats of parts that demand high corrosion resistance, dog house corner blocks, electrode blocks, bubbler blocks and electric furnaces.

An example of an application(end-port type container glass melting furnace)

RegeneratorMelter

Working end

Forehearth

Zirconia fused cast refractories

AZS fused cast refractories

ZB-X950 Series

Zirconite (ZB) Series

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Material

Data bank

Marsnite (MB) series are alumina fused cast refractories whereby highly pure alumina raw material is melted at over 2000℃ and poured into a mold.

MB-GThe MB-G consist of approximately 50% α-alumina and 50% β -alumina, where intertwined crystals of both materials result in a very dense structure. Under 1300℃ , it has a corrosion resistance against molten glass that equals Zirconite, and shows excellent performance against contamination to molten glass, that it is very suitable for paving blocks and forehearth channel blocks.

MB-UThe MB-U refractory comprises of 100% β -alumina, which shows extremely high resistance to alkaline vapor. Moreover, the intersected texture of large β-alumina shows signifi cant resistance against spalling. MB-U refractory is suitable for superstructure where batch scattering is not a problem.

MB-AThe MB-A is a fused cast refractory of over 90% α-alumina. It shows excellent stability under high temperatures. Their crystal structure is completely stable and dense, it is hard, slag erosion resistant and abrasion resistant. It shows high performance for high temperature tunnel kiln interior lining and carbon furnace interior lining.

High alumina raw materials are completely melted at high temperature and poured into an appropriate mold to produce this Alumina-mullite fused cast refractory. Matrix glass is fi lled in the gaps of intertwining crystals of corundum (Al2O3) and mullite (3Al2O3·2SiO2), creating a very hard and dense structure. It is, therefore, highly resistant to corrosion and erosion. It shows high performance on reheating furnaces' beds, skid rails, and for the linings of industrial waste incinerators.

CB-MFor general use, reheating furnaces and skid rails.

Alumina fused cast refractories

Alumina-mullite fused cast refractories

Marsnite (MB) series

CB

Bonded Refractories

PB-G1PB-G1 is direct bonded periclase brick and is produced from carefully selected high-purity magnesia clinkers as the basic ingredient burned at super-high temperature. This product has high corrosion and creep resistance, and is suitable for the crown and the superstructure of regenerator housing and top course of regenerator checkers.

PB-98GDirect bonded periclase brick, PB-98G, is produced by using carefully selected high-purity magnesia clinkers as the basic ingredient and burning them at super-high temperature. This product has improved high temperature strength and creep-resistance, and this brick is suitable for the crown and the superstructure of regenerator housing.

PB-98SDirect bonded periclase brick, PB-98S, is produced by carefully selected high-purity magnesia clinkers as the basic ingredients and burning them at super-high temperatures. This product has high creep-resistance and corrosion-resistance, and is applicable for the top course of regenerator checkers.

G-MG-95SG-MG-95S is standard-type magnesia brick with excellent performance, suitable for the middle-to-upper course of regenerator checkers and housings.

UB-M (Unburned magnesia brick)To produce this brick, an appropriately designed granulation blending is used with special bonding agents. This product has high corrosion resistance and spalling resistance under high temperature.Using magnesia clinkers as the raw ingredients, this product is particularly suited and is widely used for regenerator housing of glass melting furnaces.

AGC Ceramics Co., Ltd. produces a variety of bonded refractories including basic burned/unburned bricks, high-alumina burned/unburned bricks, fi reclay burned/unburned bricks, graphite containing burned/unburned bricks and special bricks for steel refi ning and glass melting furnaces. We produce a variety of mortar according to the bricks used.

There are three types of basic bricks; spinel, highly pure magnesia clinker and dolomite.

Basic bricks

Magnesia bricks

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Material

Data bank

MZ-HGMZ-HG brick is blended with electro-fused magnesia and shows high creep-resistance. This product is most suitable in terms of cost-performance for the crowns, walls and top course of regenerator checkers.

MZ-SGMZ-SG brick is blended with standard-type magnesia. This product has high creep-resistance and high performance against thermal cycle test after impregnation of sodium sulfate. In terms of cost-performance, this product is most suitable for transition zone of solidifi cation/liquefaction of sodium sulfate for checker works.

PSB-A3This is high-quality periclase-spinel refractory, produced from high-purity electro-fused spinel ingredients and magnesia clinkers. This product shows high alkali resistance and excellent performance in glass melting furnaces, particularly in the transition zone of solidifi cation / liquefaction of sodium sulfate for checker works. In addition, it is adherence-resistant to dispersed sodium sulfate and other glass materials, making them particularly suitable for regenerator checkers.

CWK-3CWK-3 is high-alumina refractory made of electro-fused aggregates. This product has low-porosity with high creep and alkali corrosion resistance. This is suitable for melting crowns and superstructure of borosilicate glass furnaces, fl ue linings of recuperators, canal ceiling and other superstructures which are prone to damage by alkaline vapour.

CWR-6CWR-6 high-alumina brick has high spalling resistance and heat resistance. This product is used for parts that require stronger heat resistance than SK-34, such as superstructures of melters, recuperator furnaces and fl ue linings.

CWK-8CWK-8 high-alumina brick has low-porosity with high creep resistance and excellent alkali corrosion resistance. This product is used for superstructures of melters, fl ue linings, canal ceiling and other superstructures which are prone to damage by alkaline vapour.

Magnesia-zircon bricks

Magnesia-spinel bricks

TB-CFor furnace bottoms of glass melting furnaces and parts of the tank block that come into contact with glass, it is common to use AZS fused cast refractories or α/β alumina fused cast refractories. For furnaces with increased thermal insulation, molten glass penetrates through joints in the fused cast refractories. Furnace bottoms and lined bricks of tank blocks come into contact with glass that fl ows in through the joints. Refractories used in these situations must have high corrosion and pollution resistance against molten glass. Most suitable is tank block that is carefully-selected clay-type materials, produced under appropriate condition. Tank block is produced in a large mold to prevent further molten glass penetration.

RG-35This fi reclay brick uses special ingredients which is formed at high pressure and fully sintered, so that it has very low porosity and is highly heat-resistant. It is also highly alkali resistant and creep resistant. It is particularly suitable for the lower parts of regenerator checkers, rider arch and middle and lower parts of regenerators walls.

RG-34This product is fi reclay brick that is dense and highly alkali-resistant. It is suitable for lower parts of regenerator walls.

SK-34, SK-32Using carefully-selected quality ingredients, these stable quality chamotte bricks are produced using a highly quality-controlled system. We off er SK-34 and SK-32, depending on heat-resistance. They are widely used in glass melting furnaces' melter, back-up material for working end walls and walls/furnace bottoms of lower parts of regenerators.

Pure raw materials are carefully selected, and their granulation blending is specifi cally designed to produce these bricks.

Fireclay bricks

Tank block

Super duty chamotte bricks

Standard chamotte bricks

High-alumina bricks consist mainly of corundum or corundum-mullite.

High-alumina bricks

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Material

Data bank

ZM-P, ZM-CUsing high-purity alumina and zircon as the main ingredients, alumina-zircon bricks are produced using a highly quality-controlled system. These refractories have high corrosion resistance and pollution resistance against molten glass, and shows excellent performance in alkaline vapour corrosion and spalling resistance. They are used in glass furnace melters' super structure, such as front and back walls and subpaves. For forehearths, they are used in the super-structures of covers, burner blocks, and in parts which come into contact with glass, such as stirrers, spouts, plungers and the sleeves. We off er ZM-P (press-molded) or ZM-C (cast-molded) depending on the shape.

ZR-UP, ZR-UCA refractory made of high-purity zircon (ZrO2-SiO2), this mineral substance is stable up to 1600℃ , and shows particularly effi cient acid-slag corrosion resistance. They are also stable when in contact with other bricks at very high temperature. These are widely used for the borosilicate glass furnaces at parts which come into contact with glass such as the paves, feeder-parts and walls of the superstructure. For general glass bottle/ fl at glass melting furnaces, they are used as TC blocks of melter crowns, partition brick between silica brick and AZS fused cast refractories bricks, and for sub-pave bricks for melter furnace bottoms. ZR-UP is press-molded, dense and corrosion resistant which can be widely applied from the sub-paves to the super-structures. ZR-UC is cast-molded, suitable for irregular-shaped bricks which are hard to press mold. They are suitable for melter crown TC blocks.

SR-2792N, SR-2782Using high-purity materials as main ingredients, sillimanite refractories are produced in a highly quality-controlled system. These refractories have high corrosion resistance and pollution resistance against molten glass, and show excellent alkaline vapour corrosion and spalling resistance. SR-2792N is particularly excellent against molten glass pollution with high corrosion resisitance and lower-blister potential. It is suitable for the glass-contact parts such as the sleeves, plungers, orifi ces, superstructures of forehearths. SR-2782 is particularly excellent in spalling-resistance and is suitable for superstructures of forehearths and tuyere bricks.

Here are some of our special alumina-zircon, zircon and sillimanite bricks.

Special bricks Bonded and Non-Oxidized AZS fused cast Refractories by Zibo GT Industrial Ceramics

Alumina-zircon bricks

Zircon bricks

Sillimanite bricks

Series Brand Application

Mullite seriesG-M-75 Superstructure and crown for E-glass

G-M-75D is suitable for superstructure and crown for Oxy-fuel furnaceG-M-75D

Sillimanite seriesG-AS-60 Channel, channel cover, burner, feeder,

outside wall, checker and crown of regeneratorG-AS-60J

Tin-bath bottom block G-DX-2 Tin-bath bottom block

Tank bottom block G-TB Tank bottom block

MG seriesG-MG-98

Regenerator checker and wallG-MG-95S

Zirconia brick G-ZR-65 Front wall, back wall, peep hole block and tuckstone

ZM series

G-ZM-BChecker, channel cover, burner, feeder, outside wall, checker and crown of regenerator

G-ZM-BJ

G-AZS-30

Chamotte and low porosity fi reclay

G-SK-32Chamotte: General furnace construction wall＊ Low porosity fi red clay: Regenerator

G-SK-34

G-SK-36

G-RG-34＊

Dense zircon series

G-ZRHD-65Paving block, side wall and electrode block

G-ZRHD-65S

Non-OxidizedAZS fused cast brick G-AZS-33 Port wall, crown, burner, block and checker

brick

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Material

Data bank

Monolithic Refractories and mortars

Zircon patching materialZR-3500

High alumina self-fl ow castableRF-SRC1

Fused silica sealing materialMET-SILCAST

Alumina sealing materialMETPUMP C-190

High alumina sealing materialMETPUMP IPSX

High alumina hot sealing material for jointsCM-12

Castable Refractory for Glass Tank Sub-paveRF-AZS2

Mortar for Glass Tank Sub-paveAZSM

Mortar/tamping materialfor paving General-use mortar

Alumina zircon mortarZMM

High purity alumina mortar for pavingCM-15

High alumina tamping material for pavingCMP-AH

Zircon tamping material for pavingZR-2000

Alumina zircon tamping material for pavingZM-2500

CW mortarCMS

Fireclay mortarOM-SK34, OM-SK36, OM-SK35

Silica mortarGSM

Basic mortarMGM, MMC2000

Zircon mortarZRM-1100, ZRM-1200

Sealing/Repairing materials

Castable Refractory and Mortar for Glass Tank Sub-pave

Mortar/tamping materials

4 Data bank

Fused Cast Refractories ZB-X950 series Zirconite(ZB)　series

ZB-X9510 ZB-X9540 ZB-1681 ZB-1681X ZB-1691 ZB-1691X ZB-1711

Chemical composition(%)

SiO2 4.0 9.3 13.5 10.5 12 12.5 12Al2O3 0.8 1.5 52 55.3 50.8 50 45.8Fe2O3 0.05 0.05 0.1 0.1 0.12 0.1 0.1TiO2 0.15 0.15 0.04 0.04 0.06 0.04 0.05ZrO2 94.5 88 33 33 35 36 41CaO - - - - - - -Na2O 0.4 0.02 1.3 1.0 1.9 1.3 1.0

Mineral composition(%)

Baddeleyite 94 88 33 33 35 36 41α -alumina - - 47 52 47 46 42β -alumina - - - - - - -Glass phase 6 12 20 15 18 18 17

Physicalproperties

True specifi c gravity 5.41 4.96 3.84 3.88 3.92 3.95 4.12 Cold crushing strength(Mpa)

400 400 350 350 350 350 350

Quotation density 5.35 4.90 3.50(RC)3.72(VF)3.72(ENC)

3.51(RC)3.76(VF)3.76(ENC)

3.52(RC)3.80(VF)3.80(ENC)

3.52(RC)3.80(VF)3.80(ENC)

3.70(RC)3.97(VF)3.97(ENC)

Marsnite(MB) series CBMB-G MB-U MB-A CB-M

Chemical composition(%)

SiO2 0.8 0.2 0.3 17Al2O3 95 93 98.5 78Fe2O3 tr tr tr 1.8TiO2 tr tr tr 1.2ZrO2 - - - 2.1CaO 0.3 tr 0.4 -Na2O 3.5 6.5 0.3 0.2

Mineralcomposition(%)

Mullite - - - 30α -alumina 44 0 >94 58β -alumina 55 >99 5 -Glass phase 1 >1 <1 10

Physicalproperties

True specifi cgravity 3.54 3.26 3.90 3.38

Cold crushing strength(Mpa)

200 30 250 300

Quotation density 3.20(RC)3.40(VF)

2.80(RC)3.00(VF)

3.50(RC)3.70(VF)

3.00(RC)3.20(VF)

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Material

Data bank

Bonded refractoriesBasic bricks

Magnesia Bricks Magnesia-zirconbricks

Magnesia-spinel bricks

PB-G1 PB-98G PB-98S G-MG-95S UB-M MZ-HG MZ-SG PSB-A3

Chemicalcomposition

(%)

SiO2 0.4 0.2 0.2 1.2 3.3 7.1 6.7 0.4Al2O3 0.1 0.1 0.1 0.2 0.7 0.2 0.2 15Fe2O3 0.3 0.1 0.1 0.9 0.2 0.3 0.5 -Cr2O3 - - - - - - - -ZrO2 - - - - - 13 12 -CaO 1.1 0.7 0.6 2.1 1.1 0.8 0.8 -MgO 98 98.5 98.5 95 94.6 78 78 84

Physical properties

Bulk density 3.00 3.00 2.93 2.90 2.96 3.22 3.08 2.90 Apparent porosity(%) 15.5 15 16 18 13 13 15 17.5Cold crushing strength

(Mpa) 85 70 60 100 40 90 70 40

Thermal expansion(% , at 1,000℃ ) 1.3 1.3 1.3 1.3 1.2 1.2 1.2 1.0

Hot modulus of rupture(MPa at 1,500℃） 10.0 4.6 3.1 1.0 - 9.0 6.0 2.0

Refractoriness underload (T2, ℃ ) >1,720 >1,720 >1,720 >1,680 - >1,720 1,710 -

Creep test (%)(1,400℃× 720hrs, 0.5MPa) -0.8 -0.8 -1.3 -3.3 - -0.9 -2.3 -2.0

Thermal conductivity(W/m/K)

600℃ 8 8 8 8 8 5.5 5.5 3.4

1,000℃ 6 6 6 6 6 4.6 4.6 2.4

Quotation density 3.00 3.00 2.95 2.90 2.95 3.20 3.10 2.90

Typical applications

Regenerator crown

upper wall, Checker top course

Regenerator crown upper wall

Checker top course

Regenerator upper & middle wallchecker middle course

Regeneratorhousing

Regenerator crown upper wall,

Checker top course

Transition zone of

solidifi cation/liquefaction of Na2SO4

Checker Na2SO4

condensation zone

High alumina bricks CWK-3 CWR-6 CWK-8

Chemicalcomposition

(%)

SiO2 25 37 25Al2O3 69 58 70Fe2O3 1.5 1.5 1.0TiO2 1.1 2.0 1.4

CaO+MgO 0.2 0.3 0.3

Physical properties

Refractoriness (SK) 37 36 38 Bulk density 2.62 2.30 2.75

Apparent porosity(%) 17 23 12.5Cold crushing strength

(Mpa) 100 55 120

Permanent linear change on reheating

(% ,at 1,500 ℃× 2hr)0 -0.1 0.1

Thermal expansion(% , at 1,000℃ ) 0.45 0.44 0.50

Refractoriness under load (T2, ℃ ) 1,590 1,470 1,650

Thermalconductivity(W/m/K)

600℃ 1.7 1.4 1.8

1,000℃ 1.9 1.5 2.0

Quotation density 2.6 2.3 2.75

Typical applicationsCrown and superstructure in boro-silicate glass tank furnace, fl ue lining

Superstructure backup in melter, fl ue lining

Crown and superstructure in boro-silicate glass tank furnace, fl ue lining

Fireclay bricks

Tank block Super duty chamotte bricks Standard chamotte　bricksTB-C RG-35 RG-34 SK-34 SK-32

Chemicalcomposition

(%)

SiO2 47 52 54 52 62Al2O3 49 42 40 42 33Fe2O3 1 1 2 2 2TiO2 - 2 2 2 2

Physical properties

Refractoriness(SK) 34 35 34 34 32Bulk density 2.29 2.33 2.20 2.14 2.12

Apparent porosity(%) 18 13 16 21 23Cold crushing strength

(Mpa) 55 65 55 40 40

Permanent linear change on reheating

(% ,at 1,500 ℃× 2hr)0.56 0 0 -0.2

(at 1,400℃ )-0.3

(at 1,300℃ )

Thermal expansion(% , at 1,000℃ ) 0.6 0.61 0.46 0.5 0.58

Refractoriness under load (T2, ℃ ) 1,430 1,510 1,420 1,420 1,350

Quotation density 2.30 2.35 2.20 2.15 2.10

Typical applications

Paving backup in glass melter, side wall backup, forehearth and canal backup

Regenerator ride arch,wall

Regenerator wall

Melter in glass tank furnace, backup/regenerator lower wall/paving, backup of upper wall of melter in glass tank furnace

Special bricksAlumina-zircon bricks Zircon bricks Sillimanite　bricksZM-P

(press-mold)ZM-C

(cast-mold)ZR-UP

(press-mold)ZR-UC(cast-mold) SR-2792N SR-2782

Chemical composition

(%)

SiO2 10 11 33 33 25 39Al2O3 68 67 0.6 1 73 58Fe2O3 0.2 0.2 0.3 0.4 1 1TiO2 0.2 0.2 0.7 0.6 0.5 1.5ZrO2 21 21 65 65 - -CaO - - - - 0.1 0.1MgO - - - - 0.15 0.1

Physical properties

Refractoriness(SK) 35 35 - - 38 36Bulk density 3.10 2.95 3.48 3.47 2.35 2.30

Apparent porosity(%) 17 19 23.5 24 22 20

Cold crushing strength (Mpa) 115 110 100 90 70 70

Permanent linear change on reheating (% ,at 1,500 ℃ × 2hr)

- - 0.04 0.2 -0.4 -0.4

Thermal expansion(% , at 1,000℃ ) 0.57 0.60 0.36 0.42 0.49 0.47

Refractoriness under load (T2, ℃ ) 1,660 1,660 1,650 1,650 1,630 1,520

Quotation density 3.05 2.95 3.6 3.5 2.3 2.3

Typical applicationsStructure of melter, sub-pave, superstructure of forehearth,

stirrer, spout

Melter crown, partition bricks for crowns skew blocks, TC blocks for sub-paving and

crown

Tube, plunger, orifi ce,

superstructure of forehearth

superstructure of forehearth, tuyere brick

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Material

Data bank

Bonded and Non-Oxidized AZS fused cast Refractories by Zibo GT Industrial Ceramics

SeriesMullite series Sillimanite series

Tin-bath bottom block

Tank bottom block

MG series Zirconia brick

G-M-75 G-M-75D G-AS-60 G-AS-60J G-DX-2 G-TB G-MG-98 G-MG-95S G-ZR-65

Chemicalcomposition

(%)

SiO2 20 25 26 27 55 47 0.4 1.2 32Al2O3 78 73 70 66.5 40 49 0.1 0.2 1Fe2O3 0.5 0.1 0.5 0.6 0.6 1.0 0.6 0.9 0.1CaO - - - - - - 1.1 2.1 -MgO - - - - - - 97.8 95 -ZrO2 - - - - - - - - 65

Na2O+K2O 0.3 0.3 0.2 0.6 1.5 0.3 - - 0.4

Physical properties

Apparent porosity(%) 17 17 18 21 17 17.5 18 18 18

Bulk density 2.65 2.60 2.52 2.45 2.15 2.33 2.90 2.90 3.73Cold crushing Strength (MPa) 100 55 80 50 50 50 60 100 90

Refractoriness under Load (T2 ℃ )

1720 >1720 1700 1600 1530 1430 >1720 1680 1700

Air permeability (nPerm) - - - - 0.9 - - - -

H2 diff usivity (mmH2O) - - - - 50 - - - -

Thermal expansion(%)

at 1000℃0.5 0.5 0.5 0.5 0.47 0.5 1.3 1.3 0.45

SeriesZM series Chamotte and

low porosity fi reclayDense zircon series

Non-Oxidized AZS Fused Cast Brick

G-ZM-B G-ZM-BJ G-AZS-30 G-SK-32 G-SK-34 G-SK-36 G-RG-34 G-ZRHD-65G-ZRHD-65S

G-AZS-33

Chemicalcomposition

(%)

SiO2 20 13 16 60 50 27 50 32.8 32.5 16Al2O3 56 64 50 35 44 67 45 0.2 0.2 47Fe2O3 0.2 0.2 0.1 2.5 2 1.5 1 0.1 0.1 0.1CaO - - - - - - - - - -MgO - - - - - - - - - -ZrO2 21 20 30 - - - - 65.5 66.1 33

Na2O+K2O 0.5 0.4 0.7 - - - - 0.02 0.02 1.4

Physicalproperties

Apparent porosity(%) 15.5 20 17 21 18 21 14 0.3 0.7 -

Bulk density 2.92 3.13 3.28 2.18 2.27 2.45 2.35 4.34 4.34 Quotation Weight RC:3.40 VF:3.65

Cold crushing Strength (MPa) 120 90 150 50 70 70 70 500 500 -

Refractoriness under Load (T2 ℃ )

1650 1650 1680 - - - 1410 >1700 >1700 -

Air permeability (nPerm) - - - - - - - - - -

H2 diff usivity (mmH2O) - - - - - - - - - -

Thermal expansion(%)

at 1000 ℃0.6 0.7 0.65 0.58 0.5 0.44 0.46 0.69 0.49 -

ZMM CM-15 CMP-AH ZR-2000 ZM-2500W(Wet/Dry） RF-AZS2 AZSM

Materials Alumina zircon mortar

Alumina mortar

Alumina tamping Zircon tamping

Alumina zircon tamping

AZS castable for paving

Leveling mortar with RF-AZS2

Quantity required per cubic mater(T/m3) 3 2.4 2.6 3.5 3.2 3.26 3.1

Chemical composition （％）

Al2O3 65 96 95 0.3 60 50 50 ZrO2 21 - - 65 27 30 32 SiO2 13 3 - 32 13 16 17 Fe2O3 0.2 0.1 - 0.1 - - -

Cold crushing strength （MPa）

after 110℃×3hrs - - 20 1 28 110 -

after 800℃×3hrs - - 25 98 73 - -

after 1,300℃×3hrs - 10 35 110 80 - -

after 1,500℃×3hrs - - 40 - 130 370

(after 1450℃） -

Linear shrinkage after heating (％）

after 110℃×3hrs - - 0.4 0 0 0 -

after 800℃×3hrs - - 0.5 0 0.06 - -

after 1,300℃×3hrs 1 3 1 0.05 0.05 - -

after 1,500℃×3hrs - - 1.5 - 1 0.4

(after 1450℃） -

ZR-3500(Wet/Dry) RF-SRC1 MET-SILCAST CM-12

Materials Zircon Ptach Alumina Castable Silica Castable Alumina hot sealing for joints

Quantity required per cubic mater(T/m3) 3.5 3.19 2 2.4

Chemical composition （％）

Al2O3 0.5 91 0.1 95.5 ZrO2 63 - - - SiO2 32 7 99.5 2.5 Fe2O3 0.1 0.2 tr. 0.1

Cold crushing strength （MPa）

after 110℃×3hrs 1 140 25 -

after 800℃×3hrs 70 - 30 -

after 1,300℃×3hrs 90 140 35 15

after 1,500℃×3hrs 110 140 35 -

Linear shrinkage after heating (％）

after 100℃×3hrs 0 0 - -

after 800℃×3hrs 0 0 - -

after 1,300℃×3hrs 0.3 - 0.5 2

after 1,500℃×3hrs 1.5 0.5 0.1 -

Monolithic Refractories

Mortar/Tamping/Castable materials

Sealing/Repairing materials

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kosuke sunahara

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