Monolithic Refractories for Iron and Steel Industry - Castable Refractory for Cement Kiln and Boiler
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Benefits:
1) Good performance to thermal stability, slag and abrasion resistance.
2) Good fluidity and convenient to install and maintain
3) Less installation and drying/sintering time
4) Efficiently reduced the production stoppages & downtimes
5) Labor and cost saving by prolonging campaign length.
| Refractory Castable for cement kiln | | | | |
| Items | HGJ-1 | HAJ-3 | HAM-2 | HAL-2 |
| Main Contents | Al2O3 | Al2O3 | MgO-Al2O3 | Al2O3-SiO2 |
| Characteristics | High strength anti-abrasion steel fiber castables | Chemical-bonding refractory castables | Low cement magnesium-aluminum castables | high purity bauxite low cement |
| Refractoriness | 1950℃ | 2150℃ | 2150℃ | 1700℃ |
| Density | 2.95g/cm3 | 2.89g/cm3 | 2.92g/cm3 | 2.55g/cm3 |
| Compressive Strength | 110℃×2h68.5MPa; | 110℃×2h59.2MPa; | 110℃×2h40.8MPa; | 110℃×2h52MPa |
| | 1500℃×3h 96.8 MPa | 1500℃×3h106.1MPa | 1500℃×3h102.5MPa | 1500 ℃×3h 75 MPa |
| Permanent Linear Changing Rate | 1500℃×3h+0.21% | 1500℃×3h+0.29% | 1500℃×3h+0.32% | 1500℃×3h±0.5% |
| Installation mode | casting | casting | casting | casting |
| Additive required | 5-10%water | 5-10%water | 5-10%water | 5-10%water |
| Application | Rotary kiln or industry furnace | Industry kiln | Ladle | differentpartsforcementkiln |
characteristics:
1. The dosage of cement is low, the content of calcium only accounts for 1/4-1/3 of common Refractory Castable
2. Wter consumption rate during the construction is almost 1/2 or 1/3 of the common Refractory Castable, so the Low Cement Refractory Castable has high density and low porosity.
3. High normal temperature cure property, intensity will be increased after medium temperature and high temperature. Three or five times more than common Refractory Castable.
4. Good volume stability under high temperature.
Application:
Material for metallurgy, petroleum, chemical and other industries kilns
Part of refining installation, like ladle cover
Insert for roof of the kiln
- Q: What are the common failure modes of monolithic refractories in iron and steel applications?
- The common failure modes of monolithic refractories in iron and steel applications include thermal spalling, erosion, chemical attack, and mechanical damage. Thermal spalling occurs when the refractories cannot withstand the extreme temperature changes, leading to cracking and flaking. Erosion occurs due to the abrasive nature of molten metal or slag, causing the refractory material to wear away. Chemical attack happens when the refractory reacts with the corrosive components of the molten metal or slag, leading to degradation. Mechanical damage can occur from mechanical stress, such as thermal expansion or contraction, causing cracks or fractures in the refractory material.
- Q: How do monolithic refractories contribute to energy efficiency in iron and steel production?
- Monolithic refractories contribute to energy efficiency in iron and steel production by providing superior insulation and heat containment properties. These refractories have low thermal conductivity, which minimizes heat loss and ensures that the intense temperatures required for the production process are maintained within the furnace or kiln. This reduces the need for excessive fuel consumption and enables more efficient use of energy resources. Additionally, monolithic refractories can withstand high temperatures without significant structural damage, prolonging their lifespan and reducing the frequency of replacement, further contributing to energy efficiency in the industry.
- Q: What are the common manufacturing processes used for monolithic refractories?
- The common manufacturing processes used for monolithic refractories include mixing the raw materials, shaping the mixture into the desired form, and then curing or firing it at high temperatures to achieve the desired strength and properties. Some specific processes used are casting, gunning, ramming, and spraying.
- Q: What are the common testing methods used to evaluate the performance of monolithic refractories?
- To evaluate the performance of monolithic refractories, various commonly used testing methods are employed. These methods aid in determining the durability and suitability of refractory materials for different applications. Some of the frequently utilized testing methods include: 1. Thermal Conductivity Testing: This method gauges the heat conductivity of a refractory material. It assists in assessing the insulation properties and resistance to thermal shocks. 2. Compression Testing: This test measures the compressive strength of the refractory material. It provides insights into its ability to withstand external forces and pressure without fracturing or deforming. 3. Abrasion Testing: This method assesses the refractory material's resistance against wear and tear caused by abrasive forces. It helps evaluate its ability to endure erosive conditions and prolonged exposure to harsh environments. 4. Creep Testing: By measuring the deformation or sagging of the refractory material under high temperatures and constant loading, this testing method assesses its resistance to deformation and ability to maintain shape over time. 5. Thermal Expansion Testing: This test determines the expansion and contraction characteristics of the refractory material when exposed to different temperatures. It aids in evaluating its ability to withstand thermal cycling without cracking or fracturing. 6. Chemical Resistance Testing: This method evaluates the refractory material's resistance to chemical attacks, such as corrosion or erosion resulting from chemical reactions. It assists in determining its suitability for applications involving contact with corrosive substances. 7. Refractoriness Under Load (RUL) Testing: This test measures the refractory material's ability to withstand high temperatures while maintaining structural integrity. It aids in assessing its resistance to thermal stresses and suitability for high-temperature applications. These testing methods provide valuable data for evaluating the performance of monolithic refractories and ensuring their appropriateness for specific industrial applications. By considering these properties, manufacturers and users can make well-informed decisions regarding the selection and usage of refractory materials.
- Q: What are monolithic refractories and how are they used in the iron and steel industry?
- Monolithic refractories possess a unified and uninterrupted structure, distinguishing them as a distinct type of refractory material. Unlike traditional refractory bricks, which involve the firing of individual pieces in a kiln, monolithic refractories consist of a single, seamless mass. This characteristic grants them superior versatility in terms of shape and size, rendering them ideal for a plethora of iron and steel industry applications. The iron and steel industry widely employs monolithic refractories due to their exceptional thermal and mechanical properties. They find application in various areas, including the lining of furnaces, kilns, ladles, and tundishes. These refractories are engineered to endure extreme temperatures, chemical erosion, and mechanical strain, ensuring the continuous and efficient operation of the steelmaking process. One prominent utilization of monolithic refractories within the iron and steel industry pertains to the lining of blast furnaces. These furnaces are substantial, cylindrical structures utilized for the production of pig iron from iron ore. The lining of these furnaces encounters intense heat, chemical reactions, as well as the abrasive nature of iron ore and hot gases. Monolithic refractories, such as castables and gunning mixes, are employed to establish a robust lining that can withstand these harsh conditions. Another application involves the lining of ladles, which transport molten metal from the blast furnace to the steelmaking process. Monolithic refractories are used to line these ladles, protecting them from the corrosive impact of hot metal and slag. In this scenario, the ability to shape monolithic forms facilitates precise fitting and effortless installation. Monolithic refractories also play a crucial role in tundishes, vessels employed to evenly distribute molten metal into molds during continuous casting. The refractories utilized in tundishes must exhibit exceptional resistance to thermal shock and erosion to endure the high temperatures and abrasive nature of the molten metal. Monolithic refractories, such as ramming and patching mixes, are employed to mend and maintain the tundish lining. In summary, the iron and steel industry relies on monolithic refractories for their capacity to endure harsh conditions and provide enduring linings in various applications. By harnessing these advanced refractory materials, the industry can achieve heightened efficiency, reduced downtime, and enhanced productivity in the steelmaking process.
- Q: How are monolithic refractories different from conventional refractories?
- Monolithic refractories are different from conventional refractories in that they are composed of a single, continuous structure, whereas conventional refractories are made up of multiple individual bricks or shapes. Monolithic refractories offer greater flexibility in terms of installation, as they can be easily shaped and molded to fit various applications. Additionally, monolithic refractories usually have better thermal shock resistance and are more resistant to cracking, making them more durable and long-lasting compared to conventional refractories.
- Q: What are some common maintenance practices for monolithic refractories in iron and steel furnaces?
- There are several common maintenance practices for monolithic refractories in iron and steel furnaces: 1. It is essential to conduct regular inspections. Trained professionals should inspect the refractories to identify any potential issues, such as wear, erosion, or damage. 2. Promptly repairing and patching damaged or eroded areas is crucial to maintain the integrity of the refractories. Refractory mortars or castable refractories can be used for this purpose. 3. Regularly cleaning the refractory lining is important to remove any build-up of impurities that can affect performance. Mechanical cleaning with brushes or scrapers, as well as chemical cleaning with acids, can be employed. 4. Controlled thermal cycling is often performed to condition and strengthen the refractories. Gradually increasing and decreasing the furnace temperature improves their resistance to thermal shock. 5. Applying protective coatings or sealants to the refractory lining enhances its resistance to chemical attack, erosion, and thermal cycling. These act as barriers against molten metals or slags. 6. Monitoring and controlling operating conditions inside the furnace, such as temperature, pressure, and atmosphere, is crucial. This helps prevent sudden changes that may negatively affect the refractories. 7. Regular training and education for furnace operators and maintenance personnel are crucial. This ensures they understand the importance of proper refractory maintenance, reducing the risk of premature failure. Implementing these maintenance practices significantly prolongs the lifespan of monolithic refractories in iron and steel furnaces. It maximizes their performance, leading to improved efficiency and cost-effectiveness in the production process.
- Q: How do monolithic refractories prevent thermal shock in the iron and steel industry?
- Monolithic refractories prevent thermal shock in the iron and steel industry by providing a continuous and seamless lining that can withstand extreme temperatures and sudden temperature changes. Their high thermal conductivity and low thermal expansion properties allow them to effectively distribute and absorb heat, reducing the likelihood of thermal stress and cracking. Additionally, their ability to form strong bonds with the furnace walls prevents the entry of hot gases and molten metal, further protecting against thermal shock.
- Q: How do monolithic refractories resist corrosion and erosion in iron and steel applications?
- Monolithic refractories resist corrosion and erosion in iron and steel applications through several mechanisms. Firstly, their high-density composition and low porosity make them less susceptible to chemical attack and penetration by corrosive agents. Secondly, their high thermal conductivity ensures efficient heat transfer, minimizing the formation of localized hotspots that can accelerate corrosion. Additionally, monolithic refractories are often designed with specific additives and bonding agents that enhance their resistance to chemical reactions and erosion caused by molten metals and slag. Overall, their robust structure and tailored formulation make monolithic refractories highly effective in withstanding the harsh conditions of iron and steel applications.
- Q: How do monolithic refractories improve energy efficiency in the iron and steel industry?
- Monolithic refractories improve energy efficiency in the iron and steel industry by providing better insulation and reducing heat loss. They have lower thermal conductivity compared to traditional refractory bricks, which means less heat is conducted through the lining of the furnaces or kilns. This leads to reduced energy consumption and improved thermal efficiency. Additionally, monolithic refractories offer better resistance to thermal shock, minimizing the need for frequent repairs or replacements, thereby saving energy and reducing downtime.
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Monolithic Refractories for Iron and Steel Industry - Castable Refractory for Cement Kiln and Boiler
- Ref Price:
-
- Loading Port:
- China Main Port
- Payment Terms:
- TT OR LC
- Min Order Qty:
- -
- Supply Capability:
- -
OKorder Service Pledge
Quality Product, Order Online Tracking, Timely Delivery
OKorder Financial Service
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