Complete Refractory Contractor · Non-Ferrous Metals
From aluminum smelting furnaces and copper flash smelters to zinc roasting furnaces and nickel refining reactors — Highland delivers fully engineered, equipment-matched refractory lining packages. One contractor. One quality standard. One point of accountability for your entire facility.
Three structured phases — every commitment confirmed in writing before work begins.
Non-ferrous metal production involves multiple furnace types with radically different thermal, chemical, and mechanical demands. Using the wrong refractory for a specific equipment type is the leading cause of premature lining failure in this industry. Highland’s equipment-matched approach eliminates this risk.
Operating Temperature: 700–1000°C | Key Threat: Molten aluminum penetration + fluoride vapor erosion
Molten aluminum is exceptionally aggressive toward conventional refractories — its low viscosity and high surface tension allow it to penetrate micro-pores and react with SiO₂-containing materials, causing structural heaving and rapid lining failure. Highland specifies low-iron corundum castable (Al₂O₃ ≥95%, Fe₂O₃ ≤0.3%) for the working lining in aluminum melting furnaces. The near-zero iron content prevents Fe-Al intermetallic contamination of the melt, while the dense corundum matrix (AP ≤15%) blocks aluminum penetration to a depth of less than 2mm after 12 months of service. For the furnace roof and sidewall backup lining, lightweight mullite insulating brick provides thermal efficiency without structural compromise.
Recommended: Low-Iron Corundum Castable (Al₂O₃ ≥95%, Fe₂O₃ ≤0.3%) | Mullite Insulating Backup
Operating Temperature: 950–980°C | Key Threat: Cryolite (Na₃AlF₆) fluoride electrolyte penetration
The electrolysis cell sidewall and bottom lining face continuous immersion in molten cryolite — one of the most chemically aggressive environments in industrial processing. Standard alumina refractories are rapidly dissolved by fluoride melt, collapsing cell life to under 3 years. Highland specifies silicon nitride-bonded silicon carbide brick (Si₃N₄-SiC) for the cell sidewall: its nitride bonding phase is chemically inert to cryolite at operating temperature, while the SiC aggregate provides the thermal conductivity required to maintain the frozen ledge — the self-renewing protective crust that shields the lining from direct fluoride contact. Paired with anti-fluoride castable for the cell bottom, this system extends electrolysis cell campaign life to 5+ years, reducing relining frequency and associated production loss.
Recommended: Si₃N₄-Bonded SiC Brick (Sidewall) | Anti-Fluoride Castable (Cell Bottom)
Operating Temperature: 1200–1350°C | Key Threat: Alkaline copper matte slag + mechanical impact
Copper converters and flash smelting furnaces expose the lining to highly alkaline copper matte slag (FeO-SiO₂-Cu₂S system) at temperatures up to 1350°C. The slag’s low viscosity combined with the converter’s tilting and charging impact creates an environment that destroys acid and neutral refractories within weeks. Highland specifies direct-bonded magnesia-chrome brick (MgO ≥70%, Cr₂O₃ 8–12%) for the converter slag line and tuyere zones — the only material class proven to resist this specific slag chemistry over multi-month campaigns. For facilities requiring chrome-free alternatives due to environmental regulation, magnesia-alumina spinel brick (MgO ≥80%) provides comparable slag resistance while eliminating hexavalent chromium environmental liability. The hot spot zones receive an additional magnesia-carbon brick (MgO ≥80%, C 10–14%) layer for maximum erosion resistance at peak temperature points.
Recommended: Direct-Bonded MgO-Cr₂O₃ Brick / MgO-Spinel (chrome-free) | MgO-C Brick at hot spots
Operating Temperature: 900–1100°C | Key Threat: Thermal shock from batch cycling + sulfur-bearing gas erosion
Zinc roasting and distillation furnaces operate in batch mode — repeated heat-up and cool-down cycles generate thermal shock stresses that crack conventional dense bricks within months. Simultaneously, SO₂ and SO₃ gases attack silica-containing refractories, forming low-melting-point sulfate phases that accelerate surface erosion. Highland specifies high-alumina castable with SiC addition (Al₂O₃ ≥70%, SiC 5–10%) for the working lining: the SiC phase forms a protective SiO₂ glaze under oxidizing conditions that blocks gas penetration, while the castable’s monolithic construction eliminates brick joints — the primary crack initiation sites under thermal cycling. For the distillation retort, silicon carbide-mullite composite brick provides both sulfur corrosion resistance and the dimensional stability required to maintain precise retort geometry over extended campaigns.
Recommended: High-Alumina + SiC Castable (Working Lining) | SiC-Mullite Brick (Distillation Retort)
Operating Temperature: 1300–1600°C | Key Threat: High-pressure gas scouring + sulfur-rich slag at extreme temperature
Nickel flash smelting operates at higher temperatures than copper smelting (up to 1600°C) with a more complex slag system (FeO-SiO₂-NiO) and high-pressure oxygen-enriched gas injection that physically scours the lining surface. This combination of chemical erosion, thermal load, and mechanical abrasion requires the highest-performance refractory system in the non-ferrous sector. Highland specifies fused cast corundum brick (Al₂O₃ ≥99%) for the reaction shaft and settler roof, where temperatures are highest and gas turbulence is most severe. For the settler sidewall and slag tap area, high-purity magnesia brick (MgO ≥95%) provides maximum resistance to the NiO-bearing slag that attacks aluminum-based refractories through a dissolution mechanism unique to nickel smelting chemistry.
Recommended: Fused Cast Corundum (Reaction Shaft) | High-Purity Magnesia Brick (Settler Sidewall)
Four commitments that directly address the procurement concerns of smelter and refinery operations teams.
There is no universal refractory for non-ferrous metals. Highland formulates material composition — Al₂O₃ grade, MgO content, SiC addition, bonding system — specifically for your equipment type, slag chemistry, and operating temperature profile. Generic materials applied without this analysis fail prematurely and generate warranty disputes. We eliminate that risk before material leaves the factory.
Every day of unplanned furnace downtime in a smelter or refinery represents significant production loss and contractual risk. Highland’s installation team works within your planned maintenance schedule — with written timeline commitment before mobilization. If the timeline cannot be met due to material or installation factors within our scope, we cover the cost of schedule overrun.
When Highland supplies both material and installation, material defects and workmanship failures are covered under a single 12-month warranty — eliminating the accountability gap between separate material suppliers and installation contractors. One contact, one warranty, one resolution path for any post-commissioning issue.
Highland maintains standing inventory of high-frequency non-ferrous grades — corundum castable, magnesia brick, SiC-mullite brick — in Zhengzhou. For unplanned lining failures, standard-grade materials can be dispatched within 48 hours domestically and reach major Middle East and Southeast Asia ports within 7 working days, minimizing production loss from emergency shutdowns.
Representative completed projects across copper, aluminum, and zinc production.
MIDDLE EAST
Challenge: Converter slag line lining failing within 4 months due to aggressive copper matte alkaline slag attack. Frequent relining cycles disrupting smelter production schedule.
Solution: Supplied direct-bonded magnesia-chrome brick (MgO ≥70%, Cr₂O₃ 10%) with controlled open porosity ≤14%. Installation completed within 8-day planned shutdown window.
Outcome: Slag line campaign life extended from 4 to 14 months. No unplanned shutdown in subsequent operating cycle.
SOUTHEAST ASIA
Challenge: Working lining contaminating aluminum melt with iron inclusions, causing quality rejection rates above acceptable thresholds for downstream casting operations.
Solution: Replaced existing high-silica lining with low-iron corundum castable (Al₂O₃ ≥95%, Fe₂O₃ ≤0.3%). Full lining installation and thermal cure completed in 10 working days.
Outcome: Iron inclusion rejection rate reduced to below specification threshold. Furnace campaign life extended beyond 18 months.
NORTH AFRICA
Challenge: Unplanned lining failure during peak production season. Facility required material on-site within 12 days to avoid extended production loss and contractual penalties.
Solution: Activated emergency stock of high-alumina SiC castable from Zhengzhou warehouse. Combined sea and air freight arranged; materials cleared customs and reached site within 11 days.
Outcome: Furnace restarted within plant’s target window. Production loss contained to planned shutdown duration only.
Yes. Highland’s product range covers the full spectrum of non-ferrous refractory requirements — from corundum castable for aluminum furnaces to magnesia-chrome brick for copper converters and SiC-mullite brick for zinc roasters. Multi-equipment projects are managed under a single supply contract with consolidated batch certification, simplifying your procurement process and quality audit trail. Contact us with your full equipment list for a consolidated quotation.
Standard-grade materials (high-alumina brick, corundum castable, magnesia brick) require 30–40 working days from order confirmation. Custom-formulated or custom-profiled materials — including equipment-specific castable compositions or non-standard brick geometries — require 40–60 working days from drawing and specification confirmation. We recommend initiating the order during the preceding campaign to align material arrival with your planned maintenance shutdown.
Yes. For facilities operating under chrome-free environmental mandates — increasingly common in European and North American supply chains — Highland supplies magnesia-alumina spinel brick (MgO ≥80%) as a proven chrome-free alternative for copper converter slag lines. While direct-bonded magnesia-chrome brick delivers maximum campaign life in conventional operations, our spinel-based alternative has demonstrated comparable slag resistance in independent trials while fully eliminating Cr⁶⁺ environmental liability. We can provide comparative technical data on request.
Yes. Highland dispatches experienced refractory installation engineers to project sites across Asia, the Middle East, and Africa. For other regions, we provide detailed installation technical drawings, curing curve specifications, and remote video support to work alongside your local installation team. Site mobilization logistics are confirmed at the project planning stage before material order placement.
Yes. Highland accepts partial relining and emergency patch supply projects with no minimum equipment scope requirement. Whether you need converter slag line brick only, aluminum furnace working lining castable, or zinc roaster emergency repair material, we provide the same equipment-matched material specification and batch certification as a full-facility project. MOQ for partial projects is 5 tons for standard grades. Contact us with your equipment type and damaged zone dimensions for a same-day material availability confirmation.
Tell us your equipment type (furnace/converter/cell), metal produced, operating temperature, and current lining campaign life. Highland’s technical team will respond within 2 business hours with:
Request Equipment-Specific Quote Now
Or email directly: info@highlandrefractory.com
Magnesite Brick, also known as Magnesia Brick or MgO Brick, is one of the most widely used basic refractory products in high-temperature industrial furnaces. With excellent refractoriness, strong resistance to alkaline slag, good thermal stability, and outstanding mechanical strength, magnesite bricks are essential materials in steelmaking, non-ferrous metals, cement, glass, and various thermal processing industries.
Fused AZS bricks are produced through a high-temperature fusion casting process, where precisely controlled proportions of Al₂O₃ (alumina), ZrO₂ (zirconia), and SiO₂ (silica) are melted and cast into dense refractory blocks. Unlike sintered refractory bricks, fused AZS bricks feature: Extremely low porosity Dense microstructure Superior resistance to glass penetration Stable performance at temperatures up to 1550–1600°C
White corundum castable is a high-quality high-temperature refractory material with high-purity alumina powder as the main raw material.
Highland Refractory supplies JM23, JM26, JM28 and JM30 mullite insulation bricks. Max service temp 1260–1650°C. ISO certified, factory direct. Get technical specs & quote within 2 hours.
Highland Refractory provides ultra-high-performance Silicon Carbide solutions engineered for extreme thermal conductivity and superior erosion resistance. We specialize in Nitride-bonded (NBSC), Oxide-bonded (OSiC), and Reaction-sintered (SiSiC) grades with SiC content ranging from 85% to 98%. Designed for waste incinerators, ceramic kilns, and non-ferrous metallurgy, our SiC bricks and custom plates ensure exceptional thermal shock stability up to 1550°C. Direct factory supply with high-precision sizing (±0.5mm). Request your 2026 technical catalog and bulk quote in 2 hours.
Magnesia Alumina Spinel Brick is a high-performance basic refractory brick developed to meet the increasingly demanding operating conditions of modern high-temperature industrial furnaces. By introducing alumina-based spinel (MgAl₂O₄) into a magnesia matrix, this type of refractory brick achieves an excellent balance between mechanical strength, thermal shock resistance, chemical corrosion resistance, and volume stability. Magnesia alumina spinel bricks are widely used in critical zones such as kiln burning zones, transition zones, safety linings, and furnace working linings, where resistance to thermal cycling, alkali attack, and slag penetration is essential.
