Low-Sodium Electrofused AZS Refractories in Float Glass Furnaces: 30%+ Life Extension and Defect Reduction Case Study

2025-12-08

Sunrise

Customer Cases

In float glass furnace operations, refractory material performance directly impacts glass quality and equipment longevity. This case study explores how low-sodium electrofused AZS (e.g., TY-AZS36D), with Na₂O content maintained below 1.35%, enhances glass phase stability and crystallization resistance—extending furnace life by over 30% and significantly reducing glass defects. Real-world application data from a major glass plant demonstrates measurable improvements in side wall and floor brick durability, supported by ISO-certified technical parameters (Al₂O₃ ≥50%, ZrO₂ ≥35.5%, glass phase析出 temperature ≥1400°C). Designed for engineers and procurement decision-makers, this analysis provides a data-driven approach to refractory selection, minimizing unplanned downtime and production loss.

https://shmuker.oss-accelerate.aliyuncs.com/data/oss/20250714/20178be6db0eb8062765664db700a511/098654e2-7dd1-403c-be3a-6de4faa4f3f5.jpeg

How Low-Na₂O Electrofused AZS Refractories Extend Float Glass Furnace Life by 30%+

In the high-stakes world of float glass production, even minor fluctuations in refractory performance can lead to costly downtime and defective products. That’s why more than 70% of leading global glass manufacturers now prioritize low-sodium electrofused AZS (Alumina-Zirconia-Silica) materials—specifically those with Na₂O content below 1.35%—for critical lining applications.

Why Sodium Content Matters More Than You Think

Traditional AZS bricks often contain up to 2.0% Na₂O, which accelerates glass phase formation at operating temperatures (typically 1100–1350°C). This leads to increased crystallization, spalling, and eventual erosion of the furnace lining. By contrast, our TY-AZS36D formulation maintains Na₂O levels at just 1.2%, resulting in:

Up to 30% longer service life in side walls and bottom bricks
Reduction in glass defects by over 45% due to minimized bubble and seed inclusion
Lower maintenance frequency—fewer unplanned shutdowns per year

Parameter	Standard AZS (Na₂O >2%)	TY-AZS36D (Na₂O ≤1.35%)
Glass Phase Stability (°C)	~1250	≥1400
Average Service Life (months)	18–24	28–36+
Defect Rate Reduction	Negligible	45–60%

Customer Case – Middle East Float Line Upgrade
A major Egyptian glass producer replaced their standard AZS bricks with TY-AZS36D in the side wall area of a 400 tpd float line. After 32 months of continuous operation, they reported zero unplanned outages related to refractory failure—and a measurable drop in surface defects from 3.2% to 1.1%. “This isn’t just better material,” said the plant manager. “It’s smarter engineering.”

Smart Selection Based on Real-World Conditions

Choosing the right refractory isn’t about generic specs—it’s about matching chemistry to process. Our engineers recommend using this simple decision matrix based on:

Glass composition (especially alkali oxide levels)
Temperature gradient across different zones
Expected run cycle duration (short vs. long-term operations)

For example, if your glass contains higher K₂O or MgO, we suggest going beyond TY-AZS36D to our specialized TY-AZS38D variant, which offers enhanced resistance to alkali attack while maintaining excellent thermal shock performance.

With ISO 9001 certification and consistent compliance with ASTM C71 and EN 1868 standards, our materials are trusted by plants in Europe, North America, and Asia Pacific—including clients who have reduced annual refractory replacement costs by up to 35%.