In modern industrial high-temperature equipment, the performance of refractories plays a vital role in the stable operation and service life of equipment. As a kind of high-performance refractory, low porosity clay brick is widely used in many fields because of its excellent physical and chemical properties, and has become one of the key materials to ensure the normal operation of high-temperature equipment.

I. Characteristics of clay brick with low porosity

Low porosity clay brick is a kind of refractory material made of super-calcined flint clay and calcined bauxite by high pressure forming and high temperature sintering. Its unique production technology endows it with a series of excellent properties.

(1) Low porosity and high bulk density

Low porosity is one of the core characteristics of this clay brick. Its porosity is extremely low, and the porosity of DN-10, DN-12 and DN-15 is less than 10%, 12% and 15% respectively. Low porosity means high compactness inside the brick, which can effectively block the penetration of high-temperature gas and liquid, reduce heat loss, and enhance the resistance of the brick to aggressive substances. Complementing the low porosity is its high bulk density, with the bulk densities of DN-10, DN-12 and DN-15 reaching 2.40 g/cm³, 2.35 g/cm³ and 2.30 g/cm³ respectively. The high bulk density further improves the mechanical strength and wear resistance of the brick, so that it can maintain the structural integrity in the harsh high temperature environment.

(2) High cold compressive strength

The cold compressive strength of clay brick with low porosity is extremely high, and the cold compressive strength of DN-10, DN-12 and DN-15 reaches 80 Mpa, 68 Mpa and 58.8 Mpa respectively. This characteristic means that even in the unheated state, the brick can bear greater mechanical pressure and will not easily break or deform. In practical application, this high cold compressive strength makes the brick body more stable during installation and transportation, and reduces the risk of damage caused by external force.

(3) softening temperature under high load

The softening temperature under load is a key index to measure the structural stability of refractories at high temperature. The load softening temperature of clay brick with low porosity is extremely high, and the load softening temperatures of DN-10, DN-12 and DN-15 (under the condition of 0.2 Mpa) reach 1550°C, 1500°C and 1470°C respectively. This means that even under a certain load in a high temperature environment, the brick body will not easily soften or deform, thus ensuring the structural stability of high temperature equipment. For example, in glass kilns, blast furnaces and other high-temperature equipment, this high-load softening temperature makes low-porosity clay bricks withstand the double tests of high temperature and heavy load for a long time, and prolongs the service life of the equipment.

(4) Good corrosion resistance

Low porosity clay brick has good resistance to all kinds of aggressive substances. Its main components include high alumina (Al₂O₃) content, with the alumina content of DN-10 and DN-12 reaching 45% and DN-15 42%. The high alumina content enables the brick to form a stable oxide film at high temperature, effectively resisting the corrosion of acidic and alkaline substances and molten metal. At the same time, the low porosity also reduces the passage of corrosive substances into the brick body, further enhancing its corrosion resistance. This characteristic makes the clay brick with low porosity perform well in high-temperature equipment in metallurgy, chemical industry and other industries, and can effectively protect the equipment from corrosive substances.

II. application of low porosity clay brick

The excellent performance of low porosity clay brick makes it widely used in many fields, especially in high temperature equipment.

(1) Metallurgical industry

In metallurgical industry, clay brick with low porosity is the key refractory for blast furnace, metal mixer and hot metal mixer. Blast furnace is one of the core equipments in iron and steel production, its internal temperature is extremely high, and it also bears the erosion of molten iron and slag. The high load softening temperature and good corrosion resistance of low porosity clay brick enable it to form a solid protective layer on the inner wall of blast furnace, effectively prevent the lining from being corroded and prolong the service life of blast furnace. In metal mixer furnace and hot metal mixer tank, the brick body needs to bear the impact and stirring of high-temperature molten metal. The high cold compressive strength and high bulk density of low porosity clay brick enable it to bear these mechanical forces, and its corrosion resistance can also prevent the corrosion of molten metal to the brick body and ensure the normal operation of the equipment.

(2) Glass industry

Glass kiln is the core equipment of glass production, and its internal temperature is usually above 1500 C. At the same time, the molten glass is very corrosive to refractories. The high load softening temperature and good corrosion resistance of low porosity clay brick make it an ideal refractory for glass kiln. Brick can keep its structure stable at high temperature, and its low porosity can effectively prevent glass liquid from penetrating into the brick, reduce heat loss and improve the thermal efficiency of glass kiln. In addition, the high cold compressive strength of clay brick with low porosity can also bear the static pressure of molten glass, ensuring the normal operation of glass kiln.

(3) Chemical industry

Low porosity clay brick also plays an important role in high temperature reaction furnace, cracking furnace and other equipment in chemical industry. There are usually complex environments of high temperature, high pressure and chemical erosion in these equipments. The high load softening temperature and good corrosion resistance of low porosity clay brick make it stable under these harsh conditions and prevent equipment from being eroded and damaged. At the same time, its high bulk density and high cold compressive strength can also bear the mechanical pressure during the operation of the equipment, ensuring the safe operation of the equipment.

(4) Building materials industry

Clay bricks with low porosity are also widely used in high-temperature equipment such as cement kilns and lime kilns in building materials industry. The internal temperature of cement kiln is high, and it also bears the wear and chemical erosion of clinker. The high corrosion resistance and wear resistance of clay brick with low porosity enable it to form a solid protective layer on the inner wall of cement kiln and prolong the service life of kiln lining. In the lime kiln, the brick body needs to withstand the chemical erosion caused by high temperature and limestone decomposition. The high load softening temperature and good erosion resistance of the clay brick with low porosity can effectively resist these erosions and ensure the normal operation of the lime kiln.

III. Quality control, packaging and transportation of clay bricks with low porosity

The quality control of low porosity clay brick is the key link to ensure its performance and service life. As a professional refractory manufacturer, Zibo Zhuoyue Refractory Co., Ltd. has a perfect quality control system. The company is equipped with professional quality inspectors to sample all products to ensure that each brick meets strict quality standards. Quality inspection items include chemical analysis, physical performance testing and appearance inspection. Chemical analysis can accurately determine the content of main components such as alumina and iron oxide in the brick body, and ensure that it meets the design requirements. The physical performance test includes the detection of bulk density, porosity, cold compressive strength, load softening temperature and other indicators to ensure that the physical performance of the brick meets the standard. Appearance inspection mainly focuses on the dimensional tolerance, deformation, cracks, corner defects, melting holes and colors of the brick body to ensure that the appearance of the brick body is complete, the size is accurate and there are no obvious defects.

In packaging and transportation, Zibo Zhuoyue Refractory Co., Ltd. has also taken scientific and reasonable measures. Refractory bricks are packed in pallets, fixed with PET tape and covered with plastic film to prevent the bricks from being damaged during transportation. The size of the standard export pallet is 1000×1000mm, and the loading weight of each pallet is 1.0-2.0 tons. During transportation, the containers should be loaded reasonably according to their sizes. A 20-foot container can load 24 tons and a 40-foot container can load 28 tons. This scientific packaging and transportation method can not only effectively protect the brick body, but also improve the transportation efficiency and reduce the transportation cost.

IV. After-sales service of clay bricks with low porosity

Zibo Zhuoyue Refractory Co., Ltd. provides customers with comprehensive after-sales service to ensure that customers can use low porosity clay bricks with confidence. The company can provide customers with photos of every link in the production process, so that customers can intuitively understand the production process of products and enhance their confidence in product quality. At the same time, the company can also provide authoritative product inspection reports to further prove the performance and quality of products. In terms of after-sales service, the company provides customers with comprehensive support, including product quality consultation, construction scheme design and usage guidance. If customers find product quality problems during use, the company will negotiate with customers and compensate them according to the actual situation to effectively protect the interests of customers.

V. Development prospect of low porosity clay brick

With the continuous development of modern industry, the operating conditions of high-temperature equipment are more and more demanding, and the performance requirements of refractories are also higher and higher. As a kind of high-performance refractory, low porosity clay brick has broad prospects in the future development with its excellent physical and chemical properties.

(1) Technological innovation promotes performance improvement.

With the continuous progress of material science and engineering technology, the production technology and performance of low porosity clay brick will be further improved. For example, by optimizing raw material formula and production process, the porosity of brick can be further reduced, and its bulk density and load softening temperature can be improved. At the same time, new additives and modification technology can also enhance the corrosion resistance and wear resistance of brick, so that it can maintain stable performance in more harsh environment. In addition, the application of intelligent manufacturing technology will improve the production efficiency and quality stability of low porosity clay bricks, and further enhance their market competitiveness.

(2) Application expansion in emerging fields

With the development of new energy, aerospace, marine engineering and other emerging fields, the demand for refractories is also increasing. Clay bricks with low porosity are expected to be widely used in these emerging fields because of their excellent properties. For example, in the battery thermal management system of new energy vehicles, clay bricks with low porosity can be used as high-temperature insulation materials to protect the safe operation of batteries in high-temperature environment. In the aerospace field, clay bricks with low porosity can be used for high-temperature components of engines to improve the performance and reliability of engines. In marine engineering, clay bricks with low porosity can be used in high-temperature equipment of offshore platforms to resist the corrosion of seawater and the test of high-temperature environment.

(3) the demand of sustainable development

Under the background of global sustainable development, energy conservation and environmental protection have become the important direction of industrial development. Low porosity and high bulk density of low porosity clay brick can effectively reduce heat loss and improve energy utilization efficiency in high temperature equipment, which meets the requirements of energy saving. At the same time, its good corrosion resistance and long service life can reduce the replacement frequency of refractory materials, reduce resource consumption and waste discharge, and have good environmental benefits. Therefore, low porosity clay brick will be more in line with the needs of sustainable development in the future development, and will be more widely used and popularized.

VI. Conclusion

As a kind of high-performance refractory, low porosity clay brick has been widely used in high-temperature equipment in metallurgy, glass, chemical industry, building materials and other industries because of its excellent characteristics such as low porosity, high bulk density, high cold compressive strength, high load softening temperature and good corrosion resistance. Zibo Zhuoyue Refractory Co., Ltd. relies on its perfect quality control system, scientific and reasonable packaging and transportation mode and comprehensive after-sales service to provide customers with high-quality clay brick products with low porosity, so as to ensure that customers can use them with confidence. With the promotion of technological innovation, the application expansion of emerging fields and the demand of sustainable development, low porosity clay bricks will have broad prospects in the future development and continue to provide reliable protection for high-temperature equipment in modern industry.

The production and application of low porosity clay brick not only reflects the progress of material science, but also shows the urgent demand for high performance refractories in modern industry. In the future development, we have reason to believe that low porosity clay brick will continue to play an irreplaceable role in high-temperature equipment with its excellent performance and wide application fields, and make greater contributions to the stable operation and sustainable development of industrial production.