At Glasstec 2022, we reported on the introduction of two innovative new materials from PSR’s Research and Development department, PSR-930 and PSR-925. These refractory materials have now established themselves amongst PSR’s range of industry leading solutions for feeder expendables, satisfying many customers’ requirements in their drive for longer production runs, fewer machine stoppages and improved operational and environmental efficiencies.
PSR Refractory Developments go from Strength to Strength.
PSR-930, developed as part of a PhD research project with the University of Leeds, combines a higher zircon content (24.9%) with a significantly increased particle packing density, providing a porosity as low as 13% and bulk density as high as 3200 kg/m3. These properties imbue the material with enhance glass corrosion resistance whilst maintaining the thermal shock resistance inherent in our traditional refractory compositions.
Since Glasstec 2022, consistent operation has confirmed the expected increase in operating life of 30-50% compared with our standard refractory compositions. In some cases, significantly better results than this have been reported. One such example saw a 10” tube operating for 18 months (570 days) on a forehearth producing amber glass at a load of 100-110 tonnes per day, with a gob temperature of 1175-1210°C. This surpassed even our expectations.
PSR-925, was developed specifically as a spout material as an alternative to chrome-oxide inserted spouts. Using Zirconia, a highly refractory material, as the base (as opposed to Zircon, more accurately known as Zirconium Silicate) and adding only alumina grains and powders, we successfully achieved exceptionally high corrosion resistance.
By manufacturing the material ourselves, using our usual slip-casting method, we are able to cast PSR-925 as a single piece ‘uninserted’ spout. This eliminates the joint between a spout insert and spout body. It ensures the entire spout bowl is highly resistant to glass corrosion and eliminates any potential drawbacks of Chromium containing refractories (such as glass discolouration and environmental considerations). PSR-925 spouts have proven to operate for in excess of four years in some typical soda-lime container glass applications, matching or even surpassing the life expectancy of a chrome-oxide inserted spout.
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This article features in the latest issue of PSR Review 2024 which we have produced for Glasstec 2024 where you find us on Stand A63 in Hall 13. Please come and see us.