PRODUCT DESCRIPTION

► Fused Cast AZS SR-AZS41

Description

Fused Cast AZS 41 is the highest-grade material in the fused cast AZS refractory series, engineered specially for the most demanding and aggressive environments in glass melting furnaces. Featuring over 40% zirconia (ZrO₂) content, it delivers exceptionally dense, interlocking crystalline structure with minimal vitreous phase. It stands as the definitive industry standard for high-wear zones where maximum resistance to molten glass corrosion, high-velocity liquid erosion, and extreme thermal loads is critical.

This product is available in large-size straight bricks, approximate bricks, and complex custom shapes tailored via advanced precision machining.

Casting Methods

Fused cast AZS blocks are classified and selected not just by their chemical composition, but primarily by their casting methods. During the cooling process, liquid AZS contracts significantly, leaving a huge shrinkage cavity inside the block.

To manage this cavity, we use four distinct casting methods, each offering specific operational advantages.

  Normal Casting (PT)

The liquid batch is poured directly into the mold and cooled as-is. The shrinkage cavity forms naturally in the middle of the non-working face.

Advantages:

Lowest Cost: The most economical manufacturing process with zero material waste.

Excellent Thermal Shock Resistance: The internal void provides space for thermal expansion, reducing the risk of cracking during furnace heat-up.

Best Used For: Areas completely out of contact with liquid glass and under low erosion, such as the superstructure of the furnace or crown walls.

Tilt Casting (QX)

The mold is tilted during the casting and cooling process. This forces the shrinkage cavity to shift away from the center and into one specific rear bottom side of the block. One complete dense zone forms at the opposite end.

Advantages:

Cost-Effective Defense: Cheaper than completely void-free blocks, but offers a perfectly dense working face.

Targeted Longevity: By installing the dense side facing the molten glass and the cavity side facing outward, it delivers excellent erosion resistance.

Best Used For: Furnace sidewall or upper sidewalls where only one face encounters aggressive chemical attacks.

 End Casting (ZWS)

An extra riser is attached to the top of the mold. The shrinkage cavity forms entirely within this riser. Once cooled, this top portion is sawed off, leaving shallow shrinkage cavity at the very edge where it was cut.

Advantages:

High Structural Density: Over 90% of the block is completely solid, offering massive resistance to physical and chemical wear.

Extended Furnace Life: Prevent the block from breaking too early when melted glass erodes through to an shrinkage cavity inside.

Best Used For: Glass-contact sidewalls, and areas experiencing heavy liquid currents.

 Void-Free Casting (WS)

Similar to End casting, but uses a much larger riser. The top riser is cut off completely, leaving no shrinkage cavity in bricks.

Advantages:

Maximum Corrosion Resistance: No voids or loose crystal structures for molten glass to penetrate.

Zero Joint Leakage: Can be machined and diamond-ground to extreme tolerances for tight, leak-free joints.

Best Used For: The most critical and aggressive zones of the furnace, including the throat, doghouse corners, dam blocks, and bubbler blocks.

Advantages

l  Ultimate Corrosion Resistance
Packed with premium ZrO₂ content to form an impenetrable barrier of baddeleyite and corundum crystals, offering unmatched durability against chemical attack by molten glass.

l  Superior Erosion Resistance to High-Velocity Glass Flow

Maximum structural density withstands intense mechanical wear and shearing forces in areas with high-velocity glass liquid flow.

l  Minimized Glass Contamination

Engineered with a highly stable crystalline matrix and low glass phase exudation to prevent stone, cord, or blister defects, ensuring crystal-clear glass output.

l  Superior High-Temperature Strength
Maintains excellent structural integrity, high load-bearing capacity, and superb electrical resistivity even under prolonged exposure to temperatures above 1550°C.

l  Maximized Furnace Campaign Lifespan
Provides ultimate protection to the furnace's most vulnerable hot spots, preventing premature failures and significantly extending overall campaign life.

Applications

AZS 41 blocks are strategically deployed in the absolute critical "hot spots" and high-wear zones of float glass, container glass, special borosilicate, and premium electronic glass furnaces:

l  Melting Tank Sidewalls (Flux Lines & Hot Spots)
Installed at the flux lind and furnace hot spots where chemical corrosion and temperature fluctuations are most severe.

l  The Entire Throat Assembly
Applied in throat cover blocks, submarine throats, and sleeper blocks where molten glass passes through under extreme thermal and velocity pressure.

l  Doghouse Corners & Joint Blocks
Deployed in doghouse areas to resist the severe combined impact of raw material abrasion, intense thermal shock, and corrosive chemical vapors.

l  Dam Blocks & Fluid Weirs
Used as mechanical barriers within the melting tank where high-velocity currents accelerate refractory wear.

l  Electrode Blocks (Electric Boosting Zones)
Surrounding boost electrodes where intense localized currents demand the highest material density and electrical resistance.

l  Flow Channels & Distributors
Critical blocks in conditioning and distribution channels that require zero erosion to maintain pristine glass purity before forming.

   TECHNIQUE DATA

 Technical Data