Zirconium-Containing Microsilica for Refractory Castables
Zirconia-Containing Microsilica
Zr-102 is an off-white, ultrafine zirconia-bearing silica fume developed for refractory formulations. Its fine particles fill microscopic voids between alumina, silicon carbide, refractory aggregates and other fine powders, helping optimize particle packing, reduce matrix porosity and improve the compactness of monolithic refractories.
Product Overview
In refractory formulations, Zr-102 fills microscopic voids between particles, improving packing density, reducing water demand and porosity, and creating a denser, more uniform matrix.iform matrix.
Product Advantages
A laser-measured average particle size of approximately 1.0 μm allows the powder to fill fine voids between larger refractory particles. Proper dispersion can improve packing density, matrix uniformity and the compactness of the finished refractory body.
Typical impurity data include low levels of alkalis, iron oxide, calcium oxide and magnesium oxide. This makes Zr-102 suitable for formulations where chemical consistency and impurity control are important. Final acceptance limits should be confirmed against the batch Certificate of Analysis.
By optimizing the fine-powder portion of the formulation, Zr-102 can help reduce open porosity and limit the penetration of slag, molten metal and other corrosive media into the refractory matrix.
Chemical composition, moisture, loss on ignition, particle-size distribution and crystalline phases can be reviewed through batch COA data, XRF analysis, XRD analysis and laser particle-size testing.
Technical Data
| Test Item | Typical Value | ASTM C1240 |
|---|---|---|
| SiO₂ + ZrO₂ | 94.17 % | 85.0 % Minimum |
| Moisture content | 0.45 % | 3.0% Maximum |
| Loss on ignition | 0.95 % | 6.0% Maximum |
| Specific surface area | 15,000 m²/Kg | 15,000 m²/Kg Minimum |
| Bulk density | 280-400 Kg/m³ | Supply condition |
| Average particle size | 1.0 um | Laser particle-size analysis |
| 45 µm sieve residue | 1.507 % | 10.0 % Maximum |
| ZrO₂ | 2.81 % | XRF analysis |
| Na₂O + K₂O | 0.51 % | XRF analysis |
| Fe₂O₃ | 0.55 % | XRF analysis |
| MgO | 0.33 % | XRF analysis |
| CaO | 0.32 % | XRF analysis |
| Al₂O₃ | 0.41 % | XRF analysis |
| pH | 2.5 – 5.0 | Aqueous suspension |
| Major silica phase | Amorphous SiO₂ | XRD phase identification |
| Zirconia-bearing phases | ZrO₂ and zirconia–silica composite phases | XRD phase identification |
The data listed above is for reference only and does not constitute factory control specifications or acceptance criteria. Customers should conduct trials within their own systems to confirm product suitability.
Performance Comparison
Based on existing formulation tests, this section shows reference performance improvement from the micro-filling effect and pozzolanic reaction of silica fume. Actual results vary with matrix type, mix design, dosage, dispersion and process conditions, so sample testing is recommended.
Silica Fume Applications
Suitable for high-alumina, corundum and mullite castables where fine-particle packing, low water demand, controlled impurities and consistent matrix densification are required.
Zr-102 can be incorporated into the fine-powder system to help balance particle packing, flowability and water demand. Compatibility with the selected calcium aluminate cement and dispersant should be confirmed through laboratory trials.
Can be evaluated in Al₂O₃–SiC–C and related trough formulations exposed to molten iron, slag, thermal cycling and mechanical abrasion. Complete-formulation testing should focus on oxidation resistance, slag penetration, hot strength and thermal-shock performance.
Suitable for burner blocks, kiln components, injection lances, prefabricated linings and complex refractory shapes requiring repeatable flow, stable forming and controlled dimensional change after firing.
The zirconia-bearing composition makes Zr-102 a suitable candidate for refractory formulations containing zirconia, zircon or other zirconium-based raw materials.
The off-white color and ultrafine particle size allow Zr-102 to be evaluated as a functional filler in selected inorganic coatings, ceramic bonding systems and wear-resistant composites. Dispersion, bonding strength and thermal-cycle stability should be verified before commercial use.
Quality Control
Packaging and Logistics
Suitable for samples, laboratory evaluation, pilot trials and production processes requiring controlled manual dosing.
Suitable for refractory plants and commercial-scale production. Moisture-resistant inner liners can be provided according to handling and storage requirements.
Pallet configuration, inner liners, shipping marks, labels and export documents can be customized according to the destination, transportation route and unloading method.
FAQ
Answers to common purchasing questions about packaging, export documents, sample trials, loading and delivery.
Zr-102 is an off-white, ultrafine silica fume containing a controlled zirconia component. It is developed primarily for refractory castables and other high-temperature material systems requiring fine-particle packing, controlled chemistry and batch consistency.
The main difference is its documented zirconia-bearing composition, off-white appearance and suitability for zirconia-containing refractory systems. It should be selected when these characteristics provide a specific formulation benefit rather than treated as a universal replacement for every conventional silica fume grade.
Typical applications include low-cement castables, ultra-low-cement castables, self-flow castables, blast-furnace trough materials, precast refractory shapes, zirconia or zircon refractories, high-temperature ceramics and selected inorganic composites.
Its ultrafine particles can improve the fine-powder packing system and contribute to matrix densification. However, final performance also depends on carbon content, antioxidants, calcium aluminate cement, dispersants, water addition and firing conditions. Oxidation resistance, slag penetration and hot strength should therefore be evaluated through comparative testing.
There is no universal dosage suitable for every formulation. Zr-102 should initially be compared with the existing microsilica or fine-powder package while keeping all other raw materials and process conditions unchanged. The comparison should include flowability, water demand, setting behavior, apparent porosity, bulk density, fired strength, slag penetration and permanent linear change.
It may be used as a full or partial replacement in selected formulations, but a direct one-to-one replacement should not be assumed. Differences in chemistry, particle-size distribution, surface area, pH and dispersant compatibility may affect flow and setting behavior.
Supply Capacity
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