Xintai Refractory manufactures premium Fused Cast AZS Bricks for Glass Furnaces, engineered for high-temperature glass melting applications requiring exceptional corrosion resistance, structural stability, and long service life.
Fused Cast AZS bricks are advanced refractory materials made from high-purity Al₂O₃ (alumina), ZrO₂ (zirconia), and SiO₂ (silica) through an electrofusion casting process. During manufacturing, carefully controlled raw materials are melted at extremely high temperatures and cast into specially designed molds, creating a dense fused structure with excellent resistance against molten glass erosion.
Compared with conventional sintered AZS bricks, fused cast AZS bricks feature a much denser microstructure, lower porosity, higher bulk density, and significantly improved resistance to glass penetration. The combination of zirconia crystals, corundum crystals, and a stable glass phase provides outstanding performance in aggressive glass furnace environments.
Fused Cast AZS bricks are widely used in critical areas of float glass furnaces, container glass furnaces, fiberglass furnaces, and specialty glass production lines, especially where direct contact with molten glass requires maximum corrosion resistance and minimum glass contamination.
Xintai supplies different grades of fused cast AZS bricks, including AZS33, AZS36, and AZS41, with customized dimensions and casting methods available according to furnace design and operating conditions.
Technical Specifications
| Item | AZS33 | AZS36 | AZS41 |
|---|---|---|---|
| ZrO₂, % | ≥32.5 | ≥35.5 | ≥40.5 |
| Al₂O₃, % | ≥50.0 | ≥49.0 | ≥45.0 |
| SiO₂, % | ≤15.0 | ≤13.5 | ≤12.5 |
| Na₂O + K₂O, % | ≤1.30 | ≤1.35 | ≤1.30 |
| Bulk Density, g/cm³ | ≥3.75 | ≥3.85 | ≥4.00 |
| Apparent Porosity, % | ≤1.2 | ≤1.0 | ≤1.2 |
| Cold Crushing Strength, MPa | ≥200 | ≥200 | ≥200 |
| Initial Exudation Temperature, ℃ | ≥1400 | ≥1400 | ≥1410 |
| Bubble Separation Rate (1300℃×10h), % | ≤1.2 | ≤1.0 | ≤1.0 |
| Glass Corrosion Rate (1500℃×36h) | ≤1.4 mm/24h | ≤1.3 mm/24h | ≤1.2 mm/24h |
Key Features
- Excellent Resistance to Molten Glass Corrosion: Fused Cast AZS bricks provide outstanding resistance against molten glass corrosion, chemical erosion, and high-temperature oxidation. The high zirconia content forms a stable crystal structure that effectively protects the refractory lining from aggressive glass melts.
- High Zirconia Content for Superior Performance: The ZrO₂ component is the key factor determining AZS brick corrosion resistance. Higher zirconia content provides stronger resistance against glass dissolution and improves furnace campaign life.
- Dense Fused Cast Structure: The electrofusion casting process creates a highly compact microstructure with very low apparent porosity. The dense structure minimizes molten glass penetration and prevents internal damage caused by chemical reactions.
- Low Glass Contamination: The controlled crystalline structure of fused cast AZS bricks reduces bubble formation, exudation, and refractory particles entering molten glass.
- Excellent Thermal Stability: Fused Cast AZS bricks maintain stable physical properties under repeated heating and cooling cycles. Their excellent thermal shock resistance helps prevent cracking and premature failure during furnace operation.
- Long Service Life and Reduced Maintenance: Due to superior corrosion resistance and mechanical strength, fused cast AZS bricks can significantly extend furnace campaign duration, reduce downtime, and lower overall maintenance costs.
Typical Applications
Fused Cast AZS Bricks are widely used in:
- Glass melting furnace tank bottoms
- Glass melting furnace tank sidewalls
- Melting tank corner blocks
- Furnace throat blocks
- Barrier wall blocks
- Weir blocks
- Electrode blocks
- Doghouse areas
- High corrosion zones of glass furnaces
- Float glass production lines
- Container glass furnaces
- Fiberglass melting furnaces
- Optical glass furnaces
- Specialty glass manufacturing furnaces
- Chemical melting reactors
- High-temperature corrosion-resistant linings
- Molten material processing equipment
Production Details
Xintai follows strict manufacturing procedures to ensure stable quality and reliable performance.
The production process includes:
Raw Material Preparation
High-purity alumina, zirconia, and silica materials are precisely proportioned according to AZS grade requirements.
Electro-Fusion Melting
Raw materials are melted at extremely high temperatures to achieve complete fusion and chemical uniformity.
Precision Casting
The molten material is carefully poured into customized molds to form dense refractory blocks.
Controlled Cooling
A controlled cooling process develops the required crystal structure and minimizes internal stress.
Quality Inspection
Each batch undergoes strict testing, including:
- Chemical composition analysis
- Bulk density testing
- Porosity measurement
- Cold crushing strength testing
- Corrosion resistance evaluation
- Dimensional inspection
Through advanced manufacturing technology and strict quality control, Xintai ensures every fused cast AZS brick meets demanding glass furnace requirements.
Packing and Shipping Details
Xintai uses professional packaging methods to ensure safe transportation of fused cast AZS bricks.
Packing includes:
- Heavy-duty export wooden cases
- Protective foam layers between bricks
- Moisture-proof plastic wrapping
- Reinforced corner protection
- Steel band reinforcement
- Product identification labels
- Detailed packing lists
Before shipment, every package is carefully inspected to ensure product integrity and safe delivery.
Xintai provides global shipping solutions with flexible delivery schedules according to customer requirements.
Frequently Asked Questions (FAQ)
Q1: What is a fused cast AZS brick?
Fused Cast AZS brick is a premium refractory material made from alumina, zirconia, and silica through an electrofusion casting process. It is mainly used in glass furnaces due to its excellent corrosion resistance against molten glass.
Q2: What is the difference between fused AZS brick and sintered AZS brick?
Fused AZS bricks have a denser structure, lower porosity, higher bulk density, and better resistance to molten glass penetration compared with sintered AZS bricks.
Q3. Which AZS grade is best for glass furnaces?
The suitable grade depends on furnace conditions. AZS33 is used for moderate environments, AZS36 is suitable for general glass-contact areas, and AZS41 is recommended for the most aggressive corrosion zones.
Q4: What is the maximum service temperature of fused cast AZS bricks?
Fused Cast AZS bricks can operate continuously in high-temperature glass furnace environments, generally up to approximately 1550–1600℃ depending on furnace conditions.
Q5: Can Xintai provide customized AZS brick sizes?
Yes. Xintai supplies customized fused cast AZS bricks according to furnace drawings, installation requirements, and customer specifications.
