Zircon mullite brick is made by mixing,, molding, drying and sintering high quality mullite sand and zircon powder with addition of the binding agent under high pressure and high temperature. The sintering process is considered a promising technology for preparing Zircon mullite brick because it has some advantages such as using cheap raw materials, simple production technology and low manufacturing cost. 

 

With the introduction of ZrO2 into the mullite brick, the mechanical properties of the mullite brick at high temperature has been improved greatly. ZrO2 has a promoting role for the sintering of mullite brick. By adding ZrO2, materials with low melting point and vacancies are formed, which can accelerate the densification sintering of ZTM. The sintering temperature determines the degree of decomposition of zircon particles. 

 

The formation process of the Zircon mullite brick includes the decomposition of zircon and the mullitization process. As the reaction and the sintering process happen at the same time, the manufacturing process is difficult to control. Generally, after sintered, the product is insulated at 1450℃ to be densified. Then increase the temperature to 1600℃. ZrSiO4 will decomposed into ZrO2 and SiO2 above 1535℃. SiO2 will react with Al2O3 and produce mullite. Some liquid phase will be produced with the decomposition of ZrSiO4, which can refine the grains, increase the specific surface area and promote the sintering. 

 

The zircon mullite brick has such advantages as high bulk density, high strength, good thermal shock resistance, high temperature erosion resistance and good slag resistance. It is mainly used in long-life orifice rings, tank bottom, tank superstructure, perfume-bottle feeder, covers for working tanks and soda lime glass.

 

The zircon mullite brick is mainly used in long-life orifice rings, tank bottom, tank superstructure,  electrode blocks, perfume-bottle feeder, covers for working tanks and soda lime glass, etc. Recently, with the development of the glass industry and refractory industry, the silica brick has been replaced by the zircon mullite brick used in the front wall.