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Porous clinker refractory castable is a lightweight refractory castable with excellent properties and is widely used in large coke ovens, blast furnaces, steel rolling heating furnaces, ammonia synthesis plants, and other fields. This article analyzes the raw materials, mix ratio, and molding process of porous clinker refractory castables, summarizes the key technical measures to improve its performance, and compares the performance of ordinary porous clinker refractory castables and high-strength porous clinker refractory castables. 1. Raw materials and characteristics of porous clinker refractory castables Porous clinker is a synthetic material with the characteristics of small bulk density, high cylinder pressure or particle strength, high refractoriness, and low thermal conductivity. There are many varieties, usually porous pyrophyllite or siliceous clinker, porous clay or high alumina clinker, porous mullite or corundum clinker, porous zirconium-containing and alumina clinker, etc. In China, porous clinker refractory castables have been formulated from porous clay, high alumina, and mullite clinker, with a volume density of 1.0~1.8g/cm³ and a service temperature of 1300~1600°C. 2. Preparation process and performance optimization of porous clinker refractory castables The mix ratio and molding process of porous clinker refractory castables have a significant impact on their performance. First, the amount of cement should be...
In recent years, self-flowing refractory castables have been widely used in thermal equipment. The refractory castables of this new construction method are innovatively developed based on low-cement series refractory castables and are based on the solid closest packing principle and rheology theory. Self-flowing refractory castables not only have significant economic benefits but have also achieved initial success in thermal equipment such as spoons, tundishes, blast furnace tap trenches, slag trenches, boiler tube protective layers, incinerator grates, heating furnaces, and cement kilns. Results. Self-flowing refractory castable (S.F.C) is a highly thixotropic mixture that can flow and degas by its gravity. Compared with vibration-type low-cement series refractory castables, self-flowing refractory castables have better performance and do not require vibration equipment, steel drills, or beating of external molds, thereby reducing construction costs, noise pollution, and labor intensity. However, raw material costs increase slightly due to the high quality and large quantities of matrix materials. To improve the performance of self-flowing refractory castables, research and development work mainly focuses on the optimization of critical particle size and particle gradation (including ultrafine powder), binders, and admixtures of refractory aggregates. The application of ultrafine powder technology has created a new era for low-cement series refractory castables....
The construction process of refractory plastics needs to be carried out in strict accordance with the design requirements. The following are the specific construction steps: 1. Construction preparation Before starting construction, it is necessary to conduct a comprehensive inspection of the furnace steel structure, baselines, holes, and other parts. Construction can only be carried out after passing the inspection. The construction department should clean up debris in and around the furnace and transport air compressors, construction tools, scaffolding, etc. to the site. The air compressor must be connected to the power supply and tested to run normally. Fire-resistant plastic blanks should be stored in a cool warehouse. Their plasticity should be checked before construction, and construction can only proceed if they meet the requirements. If the ambient temperature is lower than 10℃, cold protection measures need to be taken. Close cooperation between various types of work is required during the construction process. Once construction begins, it must be carried out continuously without interruption. Cover the knotted surface with plastic sheeting to prevent dehydration if interruption is necessary. 2. Ramming construction When pounding the refractory plastic furnace wall, the blanks must be laid out tightly and flat, and only one layer...
There are many types of refractory castables produced by castable manufacturers, mainly including the following: 1. High-aluminum castable: High-aluminum castable uses alumina as its main component and has high refractoriness, slag resistance, and thermal shock resistance. It is widely used in high-temperature furnaces and hearths in steel, non-ferrous metals, chemicals, and other industries. 2. Steel fiber reinforced castable: Steel fiber reinforced castable is based on ordinary castable, adding steel fiber to enhance its thermal shock resistance, wear resistance, and slag resistance. They are mainly used in furnaces, furnace bottoms, and other parts of steel, metallurgy, petrochemical, and other industries. 3. Mullite castable: Mullite castable is mainly composed of mullite and has good wear resistance, refractory resistance, and slag resistance. It is often used in key parts such as steel-making furnaces and converters in steel, metallurgy, and other industries. 4. Silicon carbide castable: Silicon carbide castable uses silicon carbide as the main component and has excellent wear, slag, and thermal shock resistance. It is widely used in high-temperature furnaces, hearths, and other parts of non-ferrous metals, chemicals, ceramics, and other industries. 5. Low-cement castables: refer to castables with a low cement content. The cement content is generally about 5%, and some...
Refractory cement for wood stove furnaces is a type of cement specially used for refractory materials such as high-temperature furnaces and ovens. It is usually mixed with a variety of high-quality raw materials, such as bauxite, alumina, and other materials, and processed through special processes. The durable temperature of refractory cement can reach over 1300℃, which can effectively limit high-temperature interference and oxygen oxidation. Different from traditional cement, the main component of refractory cement is the alumina triplet, which has excellent high-temperature resistance and corrosion resistance. Therefore, the refractory cement used in wood-burning stoves can withstand high temperatures, chemical attacks, and wear and maintain stable performance. Refractory cement used in wood stoves is typically used in places where high temperatures can be generated, such as wood fireplaces, stoves, and furnaces. In addition to being durable at high temperatures, refractory cement used in wood stove furnaces also has good adhesion, shock resistance, and chemical stability, which can ensure the high efficiency, safety, and long life of wood stoves.
High alumina brick is a high-temperature refractory material, which is mainly made of high-purity bauxite through smelting, shaping, drying, and sintering processes. It has good high-temperature, acid, alkali corrosion, and wear resistance. High alumina bricks are widely used in high-temperature equipment such as furnaces, kilns, converters, electric furnaces, and heat treatment furnaces to meet the requirements for use under high-temperature conditions. This article will detail the manufacturing process, performance characteristics, application fields, and other related content of high alumina bricks. Manufacturing process High alumina bricks are mainly made from high-purity bauxite through crushing, mixing, shaping, drying, and sintering processes. Its alumina content is above 48%. During the manufacturing process, the sintering temperature of high-alumina bricks can be as high as over 1750°C, allowing them to remain stable in high-temperature environments. Performance characteristics 1. High-temperature resistance: The high aluminum content and dense structure of high alumina bricks give them excellent high-temperature resistance and can be used for a long time in high-temperature environments without melting, softening, or expansion. 2. Acid and alkali corrosion resistance: High alumina bricks contain a large amount of aluminum oxide, which gives them good acid and alkali corrosion resistance. 3. Anti-wear performance: High-aluminum bricks have high surface...
Clay refractory bricks can work stably in high-temperature environments for a long time, and are therefore widely used in various industrial equipment, furnaces, and buildings. Specific application areas include: 1. Metallurgical industry: Clay refractory bricks can be used in the lining, furnace bottom, hot air duct, and other parts of metallurgical equipment such as iron furnaces, steel furnaces, blast furnaces, ladles, converters, and electric furnaces. 2. Chemical industry: Clay refractory bricks can be used for lining, reactors, pipelines, heating furnaces, and other parts of chemical equipment such as refining, fertilizers, and ethylene. 3. Electric power industry: Clay refractory bricks can be used in high-temperature areas such as power plant boilers, flues, desulfurization equipment, dust removal equipment, and burners. 4. Construction industry: Clay refractory bricks can be used in firewalls, fire doors, smoke ducts, and other parts of buildings. 5. Other industries: Clay refractory bricks can also be used in fields such as glass, ceramics, petrochemicals, mining, and machinery manufacturing. Manufacturing process and inspection standards for clay refractory bricks The manufacturing process of clay refractory bricks includes steps such as mixing raw materials, forming, drying, and high-temperature firing. Among them, precise mixing of raw materials is required, and the molding process...
Heat-resistant concrete is a special concrete that can withstand high temperatures for a long time. It is mud made of refractory aggregates, cementitious materials (sometimes with mineral admixtures or organic admixtures), and water in a certain proportion. Refractory products with a certain strength are obtained by pounding or vibrating into shape, hardening, curing, and drying. Bauxite, waste refractory bricks, blast furnace slag, etc. are usually used as aggregates, and alumina cement, Portland cement, phosphoric acid, and water glass are used as cementing materials. Heat-resistant concrete is divided into many types according to the different aggregate materials and cementitious materials. Their compositions are different, their properties are different, and therefore their scope of use is also different. This kind of refractory product has the following advantages compared with refractory bricks: 1. Strength develops rapidly at room temperature and does not decrease at operating temperature. 2. It does not need to be fired before use, which reduces the complex process of making refractory bricks. The preparation process is simple and can be cast into various shapes on-site. 3. It can reduce the joints of masonry bricks, simplify the structure, and simplify the brick type, thus innovating the masonry work and speeding up...
Chrome corundum castable is a high-performance amorphous refractory material, mainly composed of refractory aggregates such as chromium corundum, corundum, aluminum chromium spinel, and special binders and additives. Due to its excellent high-temperature resistance, wear resistance, erosion resistance, slag resistance, and other properties, chromium corundum castable has been widely used in high-temperature equipment in metallurgy, petrochemicals, building materials, and other industries. The main components of chrome corundum castable: 1. Chromium corundum: Chromium corundum is a synthetic refractory aggregate composed of corundum (Al2O3) and chromium (Cr2O3). Chrome corundum has a high melting point, hardness, stability, and excellent slag and wear resistance. 2. Corundum: Corundum (Al2O3) is a common refractory material with a high melting point, high strength, high hardness, and good wear resistance. Corundum provides additional fire resistance and strength in chrome corundum castables. 3. Aluminum chromium spinel: Aluminum chromium spinel (Al2O3-Cr2O3-MgO) is a refractory material with excellent high-temperature and corrosion resistance. In chromium corundum castables, aluminum-chromium spinel can improve corrosion and slag resistance. 4. Binders and additives: According to specific needs, appropriate binders (such as cement, phosphates, silicates, etc.) and additives (such as defoaming agents, water-reducing agents, expansion agents, etc.) can be selected to improve chromium corundum pouring Material process performance.
Ladle coating is a refractory material specially used to protect the lining of ladles (also known as ladles and ladles). The ladle is a container transporting molten metal in the metallurgical industry. The main function of the coating is to protect the ladle’s lining, increase the ladle’s service life, prevent metal corrosion, reduce heat loss, maintain the stability of the molten steel, and improve the quality of the molten steel. The quality of. The main ingredients and characteristics of ladle coating materials: Refractory aggregate: Refractory aggregate is the main component of the ladle coating material. Refractory materials such as bauxite clinker, mullite, corundum, and magnesia-aluminum spinel are usually used. The selection of aggregates has a great influence on the performance of the coating material. Refractory powder: Powder can improve the coating material’s wear resistance, slag resistance, and other properties. Common refractory powders include silica powder, alumina powder, magnesium aluminum spinel powder, etc. Binder: The binder is a key component of the coating material, which gives the coating material a certain degree of adhesion and strength. Common binders include aluminate cement, phosphate, organic binders, etc. Additives: Additives are mainly used to improve the process performance of coating materials, such as improving...
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