Precision-engineered refractories powering the global glass industry’s evolution.
Table of Contents
- Introduction
- Kerui’s Glass Industry Leadership
- Critical Glass Furnace Zones & Material Innovations
- Case Studies: Revolutionizing Glass Production
- Next-Generation Technologies
- Certifications & Quality Excellence
- Sustainable Glass Manufacturing
Introduction
Modern glass furnaces demand refractory systems capable of withstanding 1,600°C+ temperatures, alkali vapor corrosion, and glass melt erosion while maintaining exceptional thermal efficiency. Kerui Refractories has pioneered 23 specialized solutions for glass production, supporting over 180 global projects since 2012. Our ISO 9001-certified fusion-cast products and 14 patented formulations enable 8-12 year campaign lives, reducing energy consumption by 15-22% compared to conventional materials.
Kerui’s Glass Industry Leadership
- 3.2 Million Ton Annual Glass Production Supported: Solutions for 100-800 TPD furnaces
- Comprehensive Glass Compatibility:
- Soda-lime glass
- Borosilicate/Pharmaceutical glass
- E-glass/Fiberglass
- Ultra-clear solar glass
- Global Footprint: 32 countries including USA, Germany, India, and Saudi Arabia
- Technical Milestones:
- 40% lower bubble defects vs industry standards
- 0.5% annual corrosion rate in melting zones
- Performance Guarantees:
- 10-year warranties for fusion-cast blocks
- ≤0.1% Fe₂O₃ contamination assurance
Critical Glass Furnace Zones & Material Innovations
1. Melting Tank (1,500-1,600°C)
Challenges: Molten glass erosion + alkali vapor attack
| Material | ZrO₂ | Al₂O₃ | Corrosion Rate | Key Innovation |
|---|---|---|---|---|
| KFC-95 AZS Fusion Cast | 41% | 50% | 0.8 mm/year | Gradient phase optimization |
| KER-92 Electrocast | 33% | 63% | 1.2 mm/year | Low-exudation formulation |
2. Refining Zone (1,450-1,550°C)
Challenges: Gas bubble formation + thermal gradients
| Material | Al₂O₃ | SiO₂ | Thermal Stability | Bubble Rating |
|---|---|---|---|---|
| KGR-99 High-Alumina | 99% | 0.3% | 1,650°C | Class A1 |
| KZS-85 Zirconia-Mullite | 85% | 12% | 1,700°C | Class AA |
3. Working End (1,200-1,400°C)
Challenges: Thermal cycling + batch dust erosion
| Material | Al₂O₃ | Cr₂O₃ | Thermal Shocks | Conductivity |
|---|---|---|---|---|
| KWC-80 Chrome-Corundum | 80% | 15% | 100+ | 2.8 W/m·K |
| KIS-70 Insulating Layer | 70% | – | – | 0.5 W/m·K |
4. Feeder Channels (1,000-1,300°C)
Challenges: Glass cord formation + thermal fatigue
| Material | ZrSiO₄ | Al₂O₃ | Wear Rate | Thermal Expansion |
|---|---|---|---|---|
| KFS-90 Zircon-Enhanced | 90% | 8% | 0.1 mm/h | 4.5×10⁻⁶/°C |
| KLC-65 Low-Reactivity | 65% | 30% | 0.3 mm/h | 5.2×10⁻⁶/°C |
See more about Fused AZS Bricks
Case Studies: Revolutionizing Glass Production
Case 1: High-Performance Borosilicate Furnace (Germany)
Client: Leading pharmaceutical glass manufacturer
Challenge:
- 14-month crown replacement cycles
- 3.2% defect rate in vial production
Kerui Solution:
- KFC-95G Gradient AZS Blocks with zirconia-enriched surface
- Anti-Reactive Coating KAC-3000 reducing Na₂O attack
- AI-Driven Thermal Equalization System
Results:
- Crown lifespan extended to 7 years
- Defect rate reduced to 0.8%
- Achieved USP <660> compliance
Case 2: Ultra-Clear Float Glass Upgrade (USA)
Client: Global architectural glass producer
Challenge:
- 0.015% Fe₂O₃ contamination limiting clarity
- 18% energy loss through furnace walls
Kerui Solution:
- KGR-99HP Ultra-Pure Alumina (Fe₂O₃ <0.03%)
- KHI-50 Hybrid Insulation System
- Laser-Aligned Brickwork Technology
Results:
- Light transmittance increased to 91.5%
- Energy consumption reduced by 22%
- Achieved EN 572-1 Class 1 clarity
Case 3: Solar Glass Production Breakthrough (China)
Client: 2 GW photovoltaic glass facility
Challenge:
- 0.4 mm/year bottom paving erosion
- 0.12% bubble content exceeding specs
Kerui Solution:
- KZS-88 Zirconia Superstructure
- Vacuum-Impregnated KVB-2000 Blocks
- Ultrasonic Bubble Detection System
Results:
- Campaign life extended to 10 years
- Bubble content reduced to 0.03%
- Production yield increased by 15%
Next-Generation Technologies
Material Science Advancements
- Nano-Zirconia Inclusions: Enhance corrosion resistance by 50%
- Self-Healing Glass Contact Layer: Automatic surface regeneration
- Phase-Engineered Bonding Matrix: Reduces crack propagation
Digital Integration
- Furnace Digital Twin: Predictive corrosion modeling
- RFID-Enabled Blocks: Real-time wear monitoring
- Robotic Installation System: ±0.1 mm alignment accuracy
Certifications & Quality Excellence
- Global Standards:
- ASTM C862 (Fused cast testing)
- EN 993-15 (Thermal shock resistance)
- GB/T 17912 (Chinese AZS standards)
- Quality Protocols:
- X-ray fluorescence batch analysis
- 3D laser scanning for dimensional accuracy
- 72-hour thermal cycling tests
Sustainable Glass Manufacturing
Kerui’s Green Glass Initiative delivers:
- Energy Efficiency: 0.85 GJ/ton glass energy consumption
- Emission Control: 98% NOx reduction systems
- Material Circularity: 95% spent refractory recycling rate
- Water Conservation: Closed-loop cooling systems
Elevate Your Glass Production – Consult Kerui’s Glass Technology Team:
- 📞 +86 153 7871 8880
- 📧 info@krefractory.com
Illuminating the future of glass manufacturing through refractory innovation since 2012.
