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Fused cast refractories

Fused cast refractories

Fused cast refractories are manufactured by electro-fusing and casting process. Carefully selected high-purity raw materials are melted in Heroult type electric arc furnace at 1900 – 2500 ℃ and cooled to solidify after pouring into molds. Fused cast refractories have very high density and strength owing to electro-fusing process compared with ordinary types of refractories such as bonded refractories and stable mineralogical composition contribute to high resistance against corrosion and erosion by molten glass.

ZB-X950 Series  ZB-X9510  ZB-X9540

AGC Ceramics has developed unique, first-class zirconia fused cast refractories by utilizing its years of accumulated fused cast refractories technology. ZB-X950 Series achieved highest level of quality without stone and blister defects in the molten glass. Therefore, it is suitable for the parts that come into contact with glass in fine glass melting furnaces. It has a proven performance in melting furnaces of boro-silicate glass, alumino silicate glass, glass ceramics and display glass.

ZB-X950 Series consists of ZB-X9510 for general use and ZB-X9540 with high electrical resistivity. The latter is suitable for electrode blocks that particularly need high electrical resistivity.

Chemical composition(%)
  ZB-X9510 ZB-X9540
SiO2 4.0 9.3
Al2O3 0.8 1.5
ZrO2 94.5 88
Na2O 0.4 0.02
Others 0.3 1.2


ZB-X950 Series

Zirconite (ZB) Series

Zirconite series is high quality Al2O3-ZrO2-SiO2(AZS) fused cast refractories, consisting of crystallized baddeleyite (ZrO2) and corumdum (Al2O3), and matrix glass. The raw materials are carefully selected and fused in Heroult type electric arc furnaces.

Chemical composition(%)
  ZB-1681 ZB-1681X ZB-1691 ZB-1691X ZB-1711
SiO2 13.5 10.5 12.0 12.5 12.0
Al2O3 52.0 55.3 50.8 50.0 45.8
ZrO2 33 33 35 36 41
Na2O 1.3 1.0 1.9 1.4 1.0
Others 0.2 0.2 0.3 0.2 0.2


Zirconite (ZB) Series

Marsnite (MB) Series

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

Chemical composition(%)
  MB-G MB-C MB-U
SiO2 0.8 0.8 0.2
Al2O3 95.0 96.5 93.0
Na2O 3.5 2.0 6.5
Others 0.7 0.7 0.3

Marsnite (MB) Series

Casting types

Fused cast refractories are manufactured by electro-fusing and casting process. After being poured molten material into molds, shrinkage voids occur in cooling and solidification process. The location of shrinkage voids is important for furnace design and is controlled by casting techniques as the following table.

Casting types

Casting types

Mark Casting type Remark
RC Regular Cast The normal type of product including the shrinkage voids under the casting gate.
VF Void Free The special type of product being removed the shrinkage voids after cooling.
ENC End Cut For side wall blocks, most of the shrinkage voids are removed by the same method as VF.

The products and casting types

  ZB-X950 Zirconite(ZB) Marsnite(MB)
  ZB-X9510 ZB-X9540 ZB-1681 ZB-1681X ZB-1691 ZB-1691X ZB-1711 MB-C MB-G MB-U
RC - - - -
VF
ENC - - - - - -

Non-destructive Inspection Method

Non-destructive Inspection Method imageFused cast refractories, which are used for important portions of glass furnaces should be guaranteed its inner structure.
AGC Ceramics Co., Ltd. is the first company in the world that has begun to inspect all AZS(Al2O3-ZrO2-SiO2) fused cast refractories in glass contact parts, such as side wall, throat, dam wall by non-destructive inspection method in 1994. We have accumulated our experiences more than 20 years and contributed to improve the reliability of glass melting furnaces and extend its life.

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