Alkali Resistant Brick Formulations

Alkali-activated binder comprising a blend of natural pozzolans and a controlled amount of high-quality slags, which provides enhanced strength and durability through the combination of natural pozzolans and high-quality slags. The binder contains a controlled proportion of natural pozzolans and high-quality slags, with the slags having an X-ray amorphous content below 50 wt.-% and free lime content from 1 to 10 wt.-%, and the natural pozzolans having an amorphous content of at least 30 wt.-%. The binder also contains an activator with a modulus of ≤ 3, specifically designed to facilitate rapid hydration and cross-linking in the presence of natural pozzolans. The binder can be used to manufacture high-performance precast concrete elements with improved mechanical properties compared to conventional alkali-activated binders.

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High-titanium heavy slag sodium water glass concrete with enhanced thermal resistance and acid resistance. The concrete combines high-titanium heavy slag sand, refractory mud, sodium water glass, and high-titanium heavy slag gravel in a specific weight ratio to achieve superior thermal stability and durability. The sodium water glass reacts with the refractory mud to form a stable hydration product, while the high-titanium heavy slag sand and gravel provide excellent mechanical strength. The resulting concrete exhibits exceptional thermal resistance up to 900°C and maintains mechanical properties at high temperatures, making it suitable for applications requiring both thermal and chemical resistance.

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High-alkali erosion-resistant clay bricks comprising a composition of clay, alumina, and phosphoric acid, wherein the clay component comprises 50% to 70% of the total weight, the alumina component comprises 20% to 40% of the total weight, and the phosphoric acid component comprises 5% to 15% of the total weight.

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High-strength alkali-resistant bricks prepared through a novel method that combines the use of acid leaching erbium slag, mixed stone slurry, and specific additives to enhance the brick's alkali resistance. The process involves pretreating the erbium slag with nitric acid to create a more stable iron oxide phase, followed by the incorporation of a precise blend of stone slurry, fine sand, triethanolamine, quicklime, and magnesium nitrate. This combination enables the production of bricks with significantly improved alkali resistance while maintaining their high strength and thermal stability.

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A method for producing high-temperature, heat-insulating, alkali-resistant bricks that combines the benefits of dual-functionality in rotary kiln applications. The bricks incorporate a dual-layer structure comprising a dense, high-temperature refractory core and a lightweight, porous working layer. The core is prepared through a unique process involving acid-leached manganese slag, acidified clay, refined light aggregate, quicklime, sodium lignosulfonate, and triethanolamine, while the working layer is produced through a ball mill process of acid-leached manganese slag mixed with stone slurry, porous fine sand, triethanolamine, quicklime, drill nitrate, and nickel nitrate. The core is pressed into a kiln mold, subjected to high-temperature drying and sintering, and then cooled. The working layer is applied to the core and fired at elevated temperatures. The resulting bricks combine the improved thermal insulation and fire resistance of the core with the lightweight, high-temperature performance of the working layer.

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High-strength alkali-resistant brick produced by using silica powder and preparation method thereof. The brick contains a binding agent of calcium lignosulfonate, which enhances the material's operating performance while reducing water content. The binding agent improves cracking resistance and contributes to improved kiln performance. The brick composition is optimized to achieve superior alkali resistance while maintaining high strength.

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High-strength alkali-resistant castable for cement kilns that combines enhanced corrosion resistance with improved mechanical properties. The castable incorporates silicon-rich electric ceramic flakes, high-silica glass fibers, and silicon nitride fibers, which synergistically enhance its resistance to corrosive substances while increasing its strength and durability.

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A novel binding agent for zeolite-like hydrated zeolites that combines the benefits of aluminosilicate alkali and calcium-based additives for enhanced mechanical properties and corrosion resistance. The binding agent, comprising a calcium-modified aluminosilicate alkaline, exhibits superior performance characteristics compared to traditional zeolites. The modified binding agent achieves its enhanced properties through the incorporation of a calcium-based additive that modifies the zeolite structure while maintaining the same oxide composition. This calcium-modified aluminosilicate alkaline binding agent enables the creation of zeolites with improved mechanical strength, thermal stability, and corrosion resistance under normal operating conditions.

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Ceramic aluminum alkali-resistant brick for dry process cement production, comprising a batch material comprising low alumina bauxite clinker, feldspar-aluminum oxide, calcined kaolin, Suzhou clay, and micro silica powder, with a binder comprising silica sol. The batch material is formulated to achieve a uniform composition and binder content for the brick.

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Anti-alkali insulation wear-resistant fire-resistant material and its preparation method, comprising a zeolite composite powder-based material that prevents alkali leaching and degradation in high-humidity environments. The material comprises zeolite-based powder that is combined with other refractory materials to create a composite that maintains its fire-resistant properties despite exposure to corrosive environments.

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An acid-resistant alkali-resistant clay comprising a unique blend of refractory materials, specifically combining 20-30% coke powder, 20-35% silicon carbide, 25-35% porcelain waste, 15-20% Guangxi mud, 4-8% baby powder, 3-5% boron carbide, 4-8% sodium fluoride, and 40-50% water glass. This composition provides superior thermal stability and resistance to chemical attack in high-temperature applications, making it suitable for cement kiln refractory brick masonry.

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A refractory brick comprising coal gangue, bauxite, fly ash, silica sand, and sulfuric acid pulp waste liquid, produced through a unique composition of 40-60% coal gangue, 30-50% bauxite, 2-15% fly ash, 0-15% silica sand, and 0-1% sulfuric acid pulp waste liquid. This composition provides exceptional thermal shock resistance, including both high-temperature quenching and rapid cooling properties, while maintaining excellent abrasion resistance. The composition enables the production of refractory bricks that meet the requirements of high-temperature applications, particularly in blast furnaces, while minimizing costs and environmental impact.

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Refractory brick for glass kilns with enhanced corrosion resistance, developed through a novel manufacturing process. The brick combines advanced refractory materials with a unique production method that incorporates a specialized ceramic coating process. This coating enhances the brick's resistance to chemical attack from the molten glass and its surroundings, while maintaining its thermal stability. The coating is applied through a controlled chemical reaction that forms a durable, glass-like layer on the brick surface. This proprietary coating provides superior corrosion protection while maintaining the brick's structural integrity.

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Ceramic bricks with enhanced frost resistance and acid resistance, achieved through the incorporation of calcium-containing blast furnace slag with aphanic structure. The slag, which forms a glass phase with rare microlites, provides improved mechanical properties at high temperatures. The incorporation of this slag-based material into clay bricks enhances their durability in extreme environmental conditions.

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Ceramic bricks with enhanced frost resistance and acid resistance through the incorporation of specific clay minerals. The invention involves the use of clay minerals with high refractory properties, particularly those containing calcium, sodium, magnesium, and aluminum oxides, to improve the thermal stability of ceramic bricks. These clay minerals, such as clay from the Obraztsovskaya and Beydellitovaya regions, exhibit enhanced refractory properties and high binding capacities, enabling the production of bricks with improved thermal resistance to frost and acid attack.

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Mass production of bricks with enhanced frost resistance achieved through the incorporation of waste materials from pegmatite ore into clay-based brick compositions. The waste materials, which are typically generated during the mining process of pegmatites, are combined with clay to create a new brick product that retains superior frost resistance compared to traditional clay-based bricks. The waste materials, which may include waste rock and minerals, are processed into a form suitable for incorporation into the clay matrix. This innovative approach enables the production of bricks with improved thermal insulation properties, particularly in cold climates where frost protection is critical.

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A corrosion-resistant foam brick made from waste glass, comprising citric acid, high alumina powder, basalt, boron nitride, sodium dodecyl sulphate, calcium oxide, sodium pyrophosphate, and white mineral oil. The brick is prepared through a process involving the mixing of waste glass, high alumina powder, and basalt, followed by the addition of boron nitride and sodium dodecyl sulphate. The sodium pyrophosphate and calcium oxide enhance the corrosion resistance of the glass matrix, while the sodium dodecyl sulphate improves the foam structure. The resulting brick exhibits excellent thermal insulation properties and is suitable for non-bearing wall applications.

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A novel acid and alkali resistant casting material that combines high strength and excellent resistance to chemical corrosion. The material comprises a magnesium-rich phase that forms through a unique reaction between magnesium oxide and alumina, followed by the formation of magnesium aluminium spinel through ion exchange. This phase is then combined with silicon dioxide, boron carbide, and zirconium oxide to form a refractory material with exceptional resistance to chemical attack. The material exhibits superior performance compared to traditional refractory materials, particularly in applications requiring high-temperature resistance and chemical durability.

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