Lightweight Insulation Brick Made of Clay 0.8
Main Types of Lightweight Insulating and Refractory Bricks Lightweight insulating and refractory bricks can be classified into five major categories based on their material composition and operating temperature: 1. Lightweight Clay Bricks: Made primarily from clay, these bricks contain 30%–48% Al₂O₃, with a bulk density ranging from 0.3 to 1.5 g/cm³. They operate at temperatures between 900°C and 1,400°C, exhibiting a thermal conductivity of 0.15–0.35 W/m·K. These bricks are suitable for use as insulation layers in most industrial kilns. 2. Lightweight Silica Bricks: With SiO₂ content ≥91%, these bricks have a bulk density of 0.8–1.2 g/cm³ and exhibit excellent acid resistance. They are commonly used in the arches of glass furnaces and hot blast stoves, boasting a thermal conductivity of 0.2–0.4 W/m·K. 3. High-Alumina Lightweight Bricks: Containing ≥65% Al₂O₃ and a bulk density of 0.8–1.5 g/cm³, these bricks offer high-temperature resistance up to 1,450°C, with a thermal conductivity of 0.18–0.3 W/m·K. They are employed for thermal insulation in high‑temperature zones within industries such as metallurgy and ceramics. 4. Aluminum Oxide Hollow Sphere Bricks: Featuring Al₂O₃ content ≥90%, these bricks have a bulk density of 1.0–1.8 g/cm³ and can withstand firing temperatures as high as 1,800°C. Their thermal conductivity ranges from 0.08 to 0.15 W/m·K, making them ideal for specialized applications such as aerospace and nuclear power. 5. Lightweight Mullite Bricks: Comprising 60%–75% Al₂O₃ and boasting a bulk density of 0.6–1.0 g/cm³, these bricks can be directly exposed to flames (1,200–1,700°C). They are commonly used in cracking furnaces and ceramic roller hearth kilns. Production Processes The core production process for lightweight bricks involves reducing density through a porous structure. The primary methods include: – Burnout Additive Method: Combustible materials such as wood chips or carbon powder are added to the raw clay body; after firing, these materials burn away, leaving behind air pores. – Foam Method: Foaming agents like rosin soap are incorporated into the mix, followed by mechanical foaming before shaping and firing. – Chemical Method: Gases—such as CO₂—are generated through reactions between dolomite and sulfuric acid, creating porosity within the brick. – Hollow Sphere Method: Hollow alumina/mullite spheres serve as aggregate, which is then directly pressed and sintered. For ultra‑lightweight bricks (density <0.4 g/cm³), fly ash-derived cenospheres are often used as lightweight aggregates. Application Scenarios Industrial Kilns: Used as insulation layers or backings in hot blast stoves, soaking furnaces, and cracking furnaces, reducing heat loss by 24%–45%. Chemical and Metallurgical Industries: Employed as linings for petrochemical heaters and blast furnaces—resistant to high temperatures yet not directly exposed to molten slag. Building Materials Industry: Served as thermal insulation layers in cement kilns and glass furnaces, helping to reduce kiln weight. Specialized Fields: Aluminum oxide hollow sphere bricks are used in nuclear power plants; perlite bricks (density 0.26–0.3 g/cm³) are utilized for fire‑resistant partition walls in construction. Performance Advantages Energy‑Efficient and Highly Effective: With low thermal conductivity (0.07–0.6 W/m·K), lightweight bricks minimize heat loss from furnace walls, resulting in fuel savings of 20%–60%. Lightweight: With densities only 1/4 to 1/3 those of heavy bricks, they simplify kiln designs and reduce structural loads. Rapid Heating and Cooling: Due to their small heat capacity, lightweight bricks are well suited for intermittent kiln operations. Environmentally Friendly and Safe: Free from asbestos and formaldehyde (as seen in perlite bricks), these bricks meet Class A1 fire‑resistance standards. Physical and Chemical Specifications Typical Range | Test Standard ————|—————— Bulk Density: 0.4–1.5 g/cm³ (Lightweight Bricks) | GB/T 2997–2000 Compressive Strength: 0.2–8.1 MPa | GB/T 5072–2008 Thermal Conductivity (at 350°C): 0.07–0.6 W/(m·K) | GB/T 10294–2008 Operating Temperature: 600–1,800°C (depending on type) | GB/T 3994–2005 Thermal Shock Resistance: 25 cycles (water quench at 1,100°C) | GB/T 30873–2014 Note: Aluminum oxide hollow sphere bricks and mullite bricks deliver the best high‑temperature performance but come at a higher cost; clay bricks offer the greatest economic efficiency, though their temperature resistance is relatively lower.
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Description:
Main Types of Lightweight Insulating and Fire‑Resistant Bricks
Lightweight thermal insulation firebricks can be divided into five major categories based on their material and operating temperature:
- Lightweight clay brick Made primarily from clay, Al₂O₃ content: 30%–48%; bulk density: 0.3–1.5 g/cm³; operating temperature: 900–1400℃; thermal conductivity: 0.15–0.35 W/m·K; suitable for use as the insulation layer in most industrial kilns.
- Lightweight silica brick ： SiO₂ content ≥ 91%, bulk density of 0.8–1.2 g/cm³, excellent acid resistance; commonly used for arches in glass melting furnaces and hot blast stoves, with a thermal conductivity of 0.2–0.4 W/m·K.
- High-alumina lightweight bricks ： Al₂O₃ ≥ 65%, bulk density of 0.8–1.5 g/cm³, high-temperature resistance (1450°C), thermal conductivity of 0.18–0.3 W/m·K, used for thermal insulation in high‑temperature zones in industries such as metallurgy and ceramics.
- Alumina hollow sphere bricks ： Al₂O₃ ≥ 90%, with a bulk density of 1.0–1.8 g/cm³, a refractoriness of up to 1800°C, and a thermal conductivity of 0.08–0.15 W/m·K, making it suitable for specialized applications such as aerospace and nuclear power.
- Lightweight mullite brick ： Al₂O₃ content: 60%–75%; bulk density: 0.6–1.0 g/cm³; can be directly exposed to flames (1200–1700℃), and is used in cracking furnaces, ceramic roller hearth kilns, and similar applications.
Production Process
The core technology of lightweight bricks involves reducing density through a porous structure, with the main methods including:
- Complete Combustion Method Adding combustible materials such as wood chips and charcoal powder to the clay body creates pores after firing.
- Foam Method Add foaming agents such as rosin soap, then form and fire after mechanical foaming.
- Chemical Method : Utilizing the reaction between dolomite and sulfuric acid to generate gases (such as CO₂) Porosity generation.
- Hollow Sphere Method : Aluminum oxide Mullite hollow spheres are used as aggregate and directly pressed and sintered.
Ultra-lightweight bricks (density (<0.4 g/cm³) Fly ash (a byproduct of coal combustion) is often used as a lightweight aggregate.
Application Scenarios
- Industrial Kilns Insulation or backing for hot blast stoves, soaking furnaces, and cracking furnaces to reduce heat loss. 24%–45%.
- Chemical Engineering and Metallurgy : Petrochemical heating furnaces and blast furnace linings—high-temperature resistant but not in direct contact with molten slag.
- Construction Materials Industry Insulation layers for cement kilns and glass kilns to reduce kiln body weight.
- Specialized Fields Alumina hollow sphere bricks are used in nuclear power plants; perlite bricks (density (0.26–0.3 g/cm³) is used for fire‑resistant partition walls in construction.
Performance Advantages
- Energy-saving and efficient : Low thermal conductivity ( (0.07–0.6 W/m·K), reducing furnace heat loss and saving 20%–60% on fuel consumption.
- Lightweight : Its density is only that of heavy bricks. 1/4–1/3, simplifying the kiln structure.
- Rapid heating and cooling : Low heat capacity, suitable for batch kilns.
- Environmental protection and safety : Asbestos‑free, formaldehyde‑free (such as perlite bricks), compliant with… Class A1 fire‑resistance rating.
Physicochemical Indicators
Indicator
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Typical range
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Test standards
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Bulk density
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0.4–1.5 g/cm³ (lightweight brick)
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GB/T 2997-2000
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Withstand Voltage Strength
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0.2-8.1MPa
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GB/T 5072-2008
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Thermal conductivity (350℃)
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0.07–0.6 W/(m·K)
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GB/T 10294-2008
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Operating temperature
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600–1800℃ (classified by type)
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GB/T 3994-2005
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Thermal Shock Stability
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25 times (water-cooled at 1100℃)
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GB/T 30873-2014
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Note: Alumina hollow sphere bricks and mullite bricks offer the best high-temperature performance, but they come at a higher cost; clay bricks are the most economical, but their temperature resistance is relatively low.
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Lightweight Insulation Brick Made of Clay 0.8
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