Iran Leads in Production of Nano Refractory Bricks for Energy Sector
WANA (Oct 07) – Iranian engineers have successfully developed a high-tech refractory brick used in gas turbines — a component once imported from abroad — to safeguard the country’s electricity network from potential shutdowns.
The project began in 2009 after sanctions halted the supply of critical turbine components, including a small but vital heat-resistant brick used in combustion chambers. Without it, power plants faced the risk of turbine failure and costly damage to blades worth billions of rials.
A team of local specialists in advanced ceramics and refractory materials, led by Mohammad Hosseinzadeh, took on the challenge. With 27 years of experience in refractory production and an international research background, Hosseinzadeh’s company developed a unique cryogenic manufacturing process to replace conventional heat-based methods.
Mohammad Hosseinzadeh, CEO of a knowledge-based company with 27 years of experience in refractory materials, international research credentials, and membership in several specialized NGOs. Social media/ WANA News Agency
A Unique Cryogenic Manufacturing Process
Unlike traditional refractory bricks that are fired in thermal furnaces, the Iranian team adopted a freezing-based process at –70°C using liquid nitrogen. This innovative technique — similar to gelation in the food industry but on an industrial scale — produces ultra-strong yet self-sacrificing bricks that shatter under impact to protect turbine blades from damage.
Explaining the process, Hosseinzadeh said:
“We start with a mix of raw materials of varying grain sizes, including nano-alumina and nano-silica particles. These are combined into a paste, poured into molds, homogenized on a vibrating table, and then pressed. After pressing, the molds are sealed and moved into a freezing tunnel, where liquid nitrogen is injected to intensify cooling.”
Inside the tunnel, a phenomenon known as co-pressing occurs.
“As the water within the material freezes, it tries to expand — but the mold prevents this. The resulting counter-pressure compresses the material even further, giving it exceptional density and strength,” Hosseinzadeh explained.
Refractory brick. Social media/ WANA News Agency
After the molds are removed from the freezer, the gelation phase takes place — a process similar to how gelatin solidifies in a refrigerator.
“When the piece comes out of the mold, it’s so strong that even a hammer can’t damage it,” he added. “Afterward, it undergoes final firing to complete the production.”
From Years of Testing to Nationwide Use
Despite passing all international lab tests, power plants required nearly nine years of field trials due to the part’s critical nature. Starting with a single turbine and one test brick, the product is now used in 23 power plants across Iran, covering about 60% of Class E gas turbines, with no failures or complaints reported.
Each brick carries a unique laser code for up to 10 years of traceability, and installation is handled solely by trained technicians to ensure precision and safety.
Refractory brick. Social media/ WANA News Agency
Next Generation and Export Prospects
The product is currently optimized for Class E turbines, but research for Class F high-efficiency turbines has been completed. Large-scale production, however, awaits new investment from power plants or the Ministry of Energy.
The company has also exported test samples to Russia, where demand has grown following the war in Ukraine and sanctions on Western suppliers. Negotiations with South Africa and several Arab countries are also underway. With an annual production capacity of 500 tons — five times the country’s domestic need — the company aims to become a regional supplier.
Today, this Iranian knowledge-based firm stands as the only domestic producer of nano-engineered self-sacrificing refractory bricks, and one of only three manufacturers worldwide, alongside companies in Germany and the United States.
What began as a crisis-driven project has evolved into a strategic industrial success, reinforcing Iran’s energy resilience and opening the door to global markets for advanced turbine materials.
