Compared with traditional processes, modern glass production technology has made a qualitative leap, and is constantly developing towards higher efficiency, lower energy consumption and better product quality. As the core equipment for glass production, the kiln is also constantly improving in terms of technology, and widely adopts new technologies such as improving combustion intensity, enhancing heat transfer effect, reducing heat loss, and reducing pollution to products and the environment.
My country's glass industry has developed rapidly and has long become the world's largest glass producer. The rapid development of the glass industry has naturally promoted the development and technological progress of refractory materials for glass kilns in my country. Compared with traditional processes, modern glass production technology has made a qualitative leap, and is constantly developing towards higher efficiency, lower energy consumption and better product quality. As the core equipment for glass production, the kiln is also constantly improving in terms of technology, and widely adopts new technologies such as improving combustion intensity, enhancing heat transfer effect, reducing heat loss, and reducing pollution to products and the environment. The technological progress of kilns requires a variety of high-quality refractory materials as a guarantee condition, requiring refractory materials to withstand higher temperatures, more rapid temperature changes, stronger chemical erosion, and more severe stress damage. Only by matching the application of a variety of high-quality refractory materials, the advantages of high efficiency, energy saving, and low pollution of new kiln technologies can be realized. High-quality refractory materials are not only consumable materials for modern high-temperature technology, but also functional materials necessary for the realization of new high-temperature technologies.
Refractory materials for foreign glass kilns
1. AZS and high zirconia bricks
The main production process for fused AZS bricks is to improve their corrosion resistance and wear resistance. In addition to adopting oxidation melting to reduce the carbon content of the product to 0.005 and increase the glass phase precipitation temperature to 1450℃. The casting and annealing processes have also been improved. Now, fused AZS with very small or even no shrinkage cavities and high zirconia bricks with a ZrO2 content of more than 90% have been produced. Their thermal shock resistance is very good. For example, high zirconia bricks with ZrO295, SiO21.4, and stabilizer 3.7 have a volume density of 4.7g/cm3, a porosity of 18.4, and thermal shock resistance from room temperature to 1400℃ (15-minute intervals) can reach 15 to 20 times. Japan has produced a fused zirconia brick with a zirconium oxide content of 90, called ZFC brick. Its corrosion resistance is better than that of AZS bricks with a ZrO2 content of 40. At 1500~1600℃, no glass phase is precipitated after 16 hours, and the pollution to the glass is minimal. There is no crack after 40 thermal shock tests at 800~1250℃.
2. Chrome bricks and chrome-containing bricks
The dense chrome oxide bricks formed by isostatic pressing are used for the side walls, necks or other severely corroded parts of E glass and C glass tank kilns, and their service life can reach 6 to 7 years. In recent years, there have been new developments in chromium-containing products, such as adding Cr2O3 to AZS bricks to form Al2O3-ZrO2-SiO2-Cr2O3 refractory materials. At high temperatures, Cr2O3 forms a solid solution with Al2O3 on the one hand, and on the other hand, because Cr2O3 is a high melting point substance, it enters the glass phase of the brick to increase the viscosity of the glass phase, thereby increasing the seepage temperature of the glass phase, which greatly improves the glass corrosion resistance of glass products. A US company has produced a recombined melt-cast AZS/Cr2O3 refractory material with superior chemical composition and physical properties. Compared with the original Al2O3/Cr2O3 material, it reduces power consumption by 4% per year, increases output by 15%, and reduces costs by 3.75%. The quality of the glass is not affected. This type of brick can be formed by machine pressing, manual ramming or isostatic pressing, and then sintered at high temperature.
3. Alkaline bricks
High-purity direct-bonded alkaline bricks fired at 1800℃ are widely used in regenerator walls and arches. Germany has launched a new material, the trade name is RUBINAIEZ, its chemical composition is MgO75, ZrO213.5, SiO29.5, it is a periclase brick bonded with zircon. In the early stage of sintering, the zirconium silicate in the brick structure reacts with magnesium oxide to form a protective layer of forsterite and zirconium oxide around the periclase particles. This structure greatly improves the brick's resistance to alkali and sulfate corrosion, and it has a good effect as a checkerboard brick in the middle of the regenerator.
4. Olivine magnesia brick
Olivine binder phase has particularly strong corrosion resistance. By increasing the forsterite content in the binder phase of magnesia brick, the corrosion resistance of magnesia brick can be improved. For this reason, 20% forsterite fine powder is added to the ingredients of magnesia brick to form a forsterite binder matrix that can protect magnesia particles and reduce corrosion. This brick is relatively cheap and has been widely used in the middle of the lattice body of the glass kiln regenerator abroad.
5. Barium feldspar olivine brick
In view of the good corrosion resistance of olivine and the insufficient thermal shock resistance, the introduction of barium feldspar in its binder phase can significantly improve the thermal shock resistance of the brick. Barium feldspar is formed during the firing process and only exists in the binder matrix phase. When the content of barium feldspar is 15, the performance of silicon is the best and the use temperature is about 1250℃. Studies have shown that barium feldspar can resist the corrosion of alkali and sulfate.
6. Amorphous refractory materials
The application of amorphous refractory materials in glass kilns is also a development trend. The UK uses refractory concrete prefabricated blocks to build heat storage chambers, checker brick bottom arches, flues, small furnace support plates, burners, etc., which greatly reduces the joints of the kiln structure, increases the speed of furnace construction and shortens the cold repair time. ERSOL of Sip, France, is an amorphous refractory material series made of ER1681 fused particles as the main component. It is used in conjunction with fused bricks on the bottom of the pool. It has excellent resistance to glass erosion and has a weak tendency to precipitate bubbles and form stones. Some Japanese glass kiln pools have all used ER2SOL series amorphous materials. The theoretical research on refractory materials for glass kilns abroad focuses on how to further improve the resistance to glass erosion and improve the mechanical properties, in order to further extend the life of the kiln.
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