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Fused Zirconia Mullite | Professional High-Performance Refractory Material
1. Product Overview
Fused Zirconia Mullite (FZM) is a premium fused refractory raw material manufactured by melting high-purity industrial alumina and superior zircon sand in high-temperature electric arc furnaces. Through precise electrofusion and controlled cooling, it forms a stable composite crystalline structure interwoven by mullite matrix and evenly distributed zirconia dendrites, creating a unique two-phase co-crystal system that combines the strengths of both mullite and zirconia refractory materials.
Different from sintered mullite refractories, the electrofusion process delivers ultra-dense internal texture, low apparent porosity, uniform chemical composition and minimal impurity content. The standard chemical composition features Al₂O₃ at 44–48%, ZrO₂ at 35–39%, and SiO₂ at 15.5–19.5%, with iron oxide controlled below 0.2% to avoid high-temperature performance degradation. Available in lump, graded granular and fine powder forms, FZM can be processed into finished refractory bricks, sliding plates, nozzles, castables and precast blocks for diversified high-temperature industrial scenarios.
2. Core Advantages & Key Physical-Chemical Properties
Superior High-Temperature Stability
- Refractoriness reaches above 1750°C, with a high refractoriness under load above 1650°C. It maintains structural integrity under long-term high temperature and mechanical pressure, featuring ultra-low high-temperature creep rate and zero soft deformation during continuous kiln operation.
- Low reversible thermal expansion coefficient (only 0.45% within service temperature range), delivering outstanding volume stability under repeated heating and cooling cycles.
Excellent Thermal Shock Resistance
The dispersed zirconia crystals inside the mullite matrix utilize phase transformation toughening to absorb thermal stress rapidly. Standard 1100℃ water cooling thermal shock tests sustain over 25 cycles without cracking or spalling, perfectly adapting to furnaces with frequent temperature fluctuations such as shuttle kilns and steel rolling heating furnaces.
Powerful Corrosion & Erosion Resistance
- Zirconia phases greatly enhance resistance against alkaline vapors, molten glass, metal slag and molten salt erosion. The material shows extremely low wettability by glass liquid, effectively blocking melt penetration into the brick body; the erosion reaction layer depth stays under 0.5mm in harsh corrosive environments.
- Resists both acidic and weak alkaline atmospheres, outperforming conventional high-alumina and pure mullite refractories by 28–41% in anti-corrosion performance.
High Mechanical Strength & Wear Resistance
Dense fused crystal interlocking structure provides remarkable mechanical performance: bulk density ≥3.6g/cm³, room-temperature compressive strength exceeding 120MPa, and high-temperature bending strength ≥15MPa at 1400℃. It withstands long-term friction, material impact and mechanical scouring, extending service life in high-wear furnace zonesMade-in-Ch….
Low Glass Phase Content & High Chemical Inertness
Strictly limited glass phase (≤5%) eliminates softening risks at elevated temperatures. The stable ZrO₂-Al₂O₃-SiO₂ three-phase system rarely reacts with most high-temperature media, preventing polluting discoloration for glass and ceramic production lines.
3. Main Application Fields
Glass Manufacturing Industry
The most widely adopted application scenario. Fused zirconia mullite bricks serve glass melting furnace tank walls, superstructure, feeder channels and regenerator linings. Its anti-glass-erosion property prevents glass liquid contamination and reduces kiln maintenance frequency for soda-lime glass, borosilicate glass and cosmetic glass production linesMade-in-Ch….
Metallurgy & Continuous Casting
As core raw material for alumina-zirconia-carbon sliding gate plates, submerged nozzles and long casting nozzles. It resists molten steel and slag erosion, improves thermal shock resistance of casting functional refractories, and guarantees stable continuous casting operation for carbon steel, alloy steel and silicon steel production. It also lines steel rolling heating furnaces and intermediate ladles.
Cement & Thermal Power Industry
Used in the transition zone and smoke chamber lining of cement rotary kilns to counter alkali vapor corrosion. It also fits the high-temperature combustion chambers of waste incinerators and petrochemical cracking furnaces that contain complex corrosive flue gas components.
Ceramic & New Energy Kilns
Suitable for high-temperature roller kilns, shuttle kilns and lithium battery sintering furnaces. It supports both direct flame contact working layers and backup insulation layers, lowering kiln energy consumption thanks to balanced thermal conductivity and long service cycle.
Special Refractory & Castable Production
Processed into various particle sizes and fine powder as aggregate for high-performance castables, ramming mixes and precast blocks, used in high-temperature industrial furnaces across electronics, non-ferrous metal and advanced ceramic sectors.
4. Production & Quality Control Standard
Our Fused Zirconia Mullite adopts low-impurity Australian zircon sand and 98.5% high-purity calcined alumina as raw materials, melted in large tilting electric arc furnaces at over 1900℃. After natural slow cooling to form complete crystalline blocks, we conduct crushing, magnetic separation and multi-stage screening to remove iron impurities, then grade into customizable particle sizes from 0–1mm up to 5–3mm as customer requests.
Strict full-process inspection covers raw material chemical analysis, fused block mineral phase detection, physical performance testing of finished particles, and finished product sampling before delivery. We support customized ZrO₂ content, particle gradation and finished brick forming to match different furnace temperature and erosion working conditions, and provide free technical parameter matching guidance for clients.
5. Why Choose Our Fused Zirconia Mullite
- Stable chemical indicators with low impurity iron, avoiding kiln product discoloration and early refractory failure.
- Complete fused crystal structure, no loose internal pores, consistent performance in large-batch kiln lining construction.
- Balanced cost-performance: higher service life than ordinary mullite refractories, lower procurement cost than full fused AZS blocks.
- Flexible supply forms: raw fused lumps, granular aggregates, fine powder and pre-fabricated standard/irregular bricks are all available.
- Professional refractory technical team to offer furnace lining scheme optimization, material matching and installation suggestions.
- Stable monthly production capacity, on-time shipment with moisture-proof and shock-resistant export packaging for sea and land transportation.
6. Conclusion
Fused Zirconia Mullite fills the performance gap between standard mullite refractories and high-cost fused zirconia corundum materials. It balances high temperature resistance, thermal shock stability and anti-corrosion capacity, becoming a cost-effective universal refractory solution for medium-to-high temperature industrial kilns under moderate and severe erosion conditions. Whether you need raw fused mineral aggregate or finished refractory bricks for furnace lining, our customized FZM products can fully meet your long-term high-temperature production operation demands.
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