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: How do monolithic refractories withstand the chemical attacks in copper smelting applications?
- Due to their unique properties and composition, monolithic refractories are capable of enduring chemical attacks in copper smelting applications. These refractories are specifically engineered to resist the harsh and corrosive environment found in copper smelting processes. To begin with, monolithic refractories are crafted from high-quality materials such as alumina, silica, and magnesia. These materials possess high melting points and chemical stability. Carefully selected, they are able to withstand the corrosive effects of copper smelting, including the presence of sulfur compounds and acidic gases. The refractory's composition also includes various additives and bonding agents that enhance its resistance to chemical attacks. In addition, monolithic refractories exhibit exceptional thermal shock resistance. This means they can withstand rapid temperature changes without cracking or spalling. In copper smelting applications, where extreme temperatures are involved, this refractory quality is crucial in preventing the formation of cracks and ensuring long-term performance. Furthermore, monolithic refractories possess a dense and compact structure. This structure serves as an effective barrier against the infiltration of molten copper and other corrosive substances. By preventing the penetration of chemical attacks, the refractory lining's durability and longevity are ensured. Moreover, monolithic refractories offer superior erosion resistance. This is particularly important in copper smelting applications, where high-velocity gases and flows of molten metal can cause erosion of the refractory lining. The refractory's erosion resistance prevents the degradation of the lining and maintains its structural integrity. In conclusion, monolithic refractories are specially designed to withstand the chemical attacks encountered in copper smelting applications. Through the use of high-quality materials, the incorporation of additives, and the possession of excellent thermal shock resistance, density, and erosion resistance, these refractories provide a reliable and durable lining that can endure the harsh conditions of copper smelting processes.
- Q: How are monolithic refractories different from traditional brick refractories?
- There are several differences between monolithic refractories and traditional brick refractories. Firstly, monolithic refractories are composed of a single, homogeneous material, whereas traditional brick refractories are made up of individual bricks that are pieced together. This variance in construction allows monolithic refractories to possess a more uniform and consistent structure, which can enhance their performance and durability. Secondly, installing monolithic refractories is typically easier compared to traditional brick refractories. Due to their composition, they can be poured or sprayed into place, eliminating the need for precise bricklaying and mortar application. This simplified installation process saves time and labor during construction or repair projects. Furthermore, monolithic refractories often exhibit superior resistance to thermal shock when compared to traditional brick refractories. The homogeneous structure of monolithic refractories enables them to expand and contract more uniformly under thermal stress, reducing the risk of cracking and failure. This characteristic makes monolithic refractories more suitable for applications with rapid temperature changes, such as in furnaces or kilns. Additionally, monolithic refractories offer better resistance to chemical attacks and erosion. Traditional brick refractories may have joints and gaps between bricks, which can become vulnerable to chemical reactions or erosion over time. Conversely, monolithic refractories possess a seamless structure that minimizes the risk of chemical penetration and erosion, enhancing their longevity and performance. In conclusion, monolithic refractories provide advantages in terms of uniformity, ease of installation, thermal shock resistance, and chemical resistance compared to traditional brick refractories. These disparities make monolithic refractories the preferred choice for numerous industrial applications that involve high temperatures and harsh environments.
- Q: How do monolithic refractories improve the lining of converters and refining vessels?
- Monolithic refractories enhance the lining of converters and refining vessels by providing superior thermal insulation, chemical resistance, and structural integrity. They eliminate the need for bricklaying, offering a seamless lining with reduced joints, thereby minimizing heat loss and ensuring efficient heat transfer. Additionally, monolithic refractories are highly resistant to the corrosive effects of molten metals and slag, prolonging the lifespan of the lining. Their flexibility enables easy installation and repair, resulting in reduced downtime and improved overall performance of converters and refining vessels.
- Q: What are the key properties of shotcrete mixes used for monolithic refractory applications?
- The key properties of shotcrete mixes used for monolithic refractory applications include high strength, low porosity, high abrasion resistance, good thermal shock resistance, and excellent adhesion to the substrate. These properties ensure the durability and effectiveness of the shotcrete in withstanding high temperatures and harsh conditions in refractory applications.
- Q: How do monolithic refractories enhance the performance of ladle and tundish preheating systems?
- Monolithic refractories play a crucial role in enhancing the performance of ladle and tundish preheating systems in several ways. Firstly, monolithic refractories offer excellent thermal insulation properties, which help in retaining heat within the ladle and tundish preheating systems. This insulation capability minimizes heat loss, ensuring that the preheating systems operate at optimal temperatures. By maintaining a consistent and high heat level, monolithic refractories enable efficient preheating of ladles and tundishes, reducing the time required for the preheating process. Secondly, monolithic refractories have high refractoriness, meaning they can withstand extreme temperatures without undergoing any significant degradation. This feature is essential in ladle and tundish preheating systems, as they are subjected to intense heat during operation. The ability of monolithic refractories to withstand high temperatures ensures their longevity and prevents premature failure, leading to improved performance and reliability of the preheating systems. Furthermore, monolithic refractories have excellent resistance to thermal shock. Ladles and tundishes are often subjected to rapid temperature changes during the preheating process, which can cause thermal stress and result in cracking and spalling of the refractory lining. However, monolithic refractories, with their superior thermal shock resistance, can withstand these rapid temperature fluctuations without sustaining any significant damage. This resistance to thermal shock ensures the integrity of the refractory lining, prolonging the lifespan of the ladle and tundish preheating systems and enhancing their overall performance. Additionally, monolithic refractories offer good mechanical strength and abrasion resistance. Ladles and tundishes are frequently subjected to mechanical forces, such as stirring and pouring of molten metal. The presence of monolithic refractories with high mechanical strength and abrasion resistance ensures that the refractory lining remains intact even under such harsh conditions. This durability allows for prolonged and efficient operation of the preheating systems, contributing to their enhanced performance. In summary, monolithic refractories enhance the performance of ladle and tundish preheating systems by providing excellent thermal insulation, high refractoriness, resistance to thermal shock, and good mechanical strength and abrasion resistance. These properties enable efficient and reliable preheating, minimize heat loss, prevent premature failure, and prolong the lifespan of the preheating systems, ultimately improving their overall performance.
- Q: What are some common applications of monolithic refractories in the iron and steel industry?
- Monolithic refractories are widely used in the iron and steel industry due to their superior performance and versatility. Some common applications of monolithic refractories in this industry include: 1. Blast Furnace: Monolithic refractories are used in the lining of blast furnaces to withstand high temperatures and chemical reactions. They help in maintaining the structural integrity of the furnace and provide insulation against heat loss. 2. Ladle Lining: Monolithic refractories are used to line ladles, which are used for transferring molten iron or steel from the blast furnace to the steelmaking process. These refractories provide excellent resistance to thermal shock and erosion caused by the aggressive molten metal. 3. Tundish Lining: Tundish is an intermediate vessel used to distribute molten steel to multiple casting molds. Monolithic refractories are employed in the tundish lining to ensure proper thermal insulation and prevent contamination of the steel during casting. 4. Electric Arc Furnace (EAF): Monolithic refractories are used in the lining of EAFs to withstand the extreme temperatures and chemical reactions involved in the steelmaking process. They provide excellent resistance to high heat and erosion caused by the molten metal and slag. 5. Induction Furnace: Induction furnaces are used for melting and refining metals. Monolithic refractories are used in the lining of induction furnaces to provide insulation and protect the furnace structure from the high temperatures and chemical reactions occurring during the melting process. 6. Continuous Casting: Monolithic refractories are used in the lining of continuous casting machines to ensure smooth and consistent casting of molten steel. They provide excellent resistance to high temperatures, thermal shock, and erosion caused by the molten metal and slag. Overall, monolithic refractories play a crucial role in the iron and steel industry by providing durability, thermal insulation, and resistance to chemical reactions, thereby enhancing the overall efficiency and productivity of the manufacturing process.
- Q: How do monolithic refractories prevent heat loss through radiation?
- Monolithic refractories prevent heat loss through radiation by forming a continuous and seamless layer that acts as a barrier to thermal radiation. This layer reflects and absorbs the radiant heat, preventing it from escaping and thus minimizing heat loss. Additionally, the high thermal conductivity of monolithic refractories allows them to efficiently conduct and distribute heat, further reducing the potential for radiation heat loss.
- Q: How do monolithic refractories perform in torpedo ladle applications?
- Due to their excellent performance and durability, monolithic refractories are commonly used in torpedo ladle applications. Torpedo ladles are utilized in the steelmaking process to transport and pour molten metal from the blast furnace to the steelmaking furnace. Also known as unshaped refractories, monolithic refractories are made from a single material and can be applied as a cohesive mass, making them highly versatile and easy to install in the torpedo ladle. In torpedo ladle applications, monolithic refractories offer numerous advantages. Firstly, they possess high heat resistance, enabling them to endure the extreme temperatures and thermal shocks experienced during the transfer and pouring of molten metal. This ensures that the refractories do not crack or fail under these harsh conditions. Additionally, monolithic refractories exhibit excellent corrosion resistance properties, which is imperative in torpedo ladles where the molten metal can be highly corrosive. They can withstand the aggressive chemical environment and prevent chemical reactions that could result in refractory deterioration. Moreover, monolithic refractories possess good thermal insulation properties, reducing heat loss from the molten metal and promoting energy efficiency. This helps to maintain the desired temperature of the metal, ensuring optimal steelmaking conditions. Furthermore, monolithic refractories offer strong mechanical strength and resistance to abrasion, making them highly suitable for torpedo ladle applications where the refractory lining is subjected to mechanical stress and wear. Overall, monolithic refractories perform exceptionally well in torpedo ladle applications due to their high heat resistance, corrosion resistance, thermal insulation properties, and mechanical strength. They can endure the extreme conditions and provide a reliable and long-lasting lining for torpedo ladles in the steelmaking industry.
- Q: What are the specific requirements of monolithic refractories for continuous casting applications?
- To withstand the extreme temperatures and thermal shock conditions experienced during continuous casting, monolithic refractories have specific requirements. First and foremost, these refractories must possess high thermal conductivity, enabling them to efficiently transfer heat away from the molten metal and maintain a stable casting temperature. This is crucial in preventing the formation of defects such as cracks, hot spots, and uneven solidification in the cast product. Secondly, monolithic refractories for continuous casting applications need to exhibit high refractoriness. This means they can endure the high temperatures of the molten metal without melting or deforming, ensuring the refractories can provide a protective lining and maintain their structural integrity throughout the casting process. In addition, these refractories must demonstrate excellent resistance to thermal shock. The continuous casting process involves rapid cooling and heating cycles, resulting in significant temperature differentials and inducing thermal stresses. Monolithic refractories with low thermal expansion and high thermal shock resistance can endure these conditions without cracking or spalling. Moreover, good erosion and corrosion resistance are vital requirements for monolithic refractories in continuous casting applications. The molten metal and slag can be highly corrosive and abrasive, causing wear and chemical attack on the refractory lining. Therefore, refractories with high resistance to erosion and corrosion are essential to ensure the longevity and stability of the lining. Lastly, monolithic refractories for continuous casting applications should possess good workability and ease of installation. This allows for efficient and precise lining installation, minimizing downtime during maintenance or repairs. Overall, the specific requirements for monolithic refractories in continuous casting encompass high thermal conductivity, refractoriness, thermal shock resistance, erosion and corrosion resistance, as well as good workability. Fulfilling these requirements guarantees that the refractories effectively safeguard the casting equipment and maintain the quality of the cast products.
- Q: How does the choice of monolithic refractory impact the overall cost of iron and steel production?
- The choice of monolithic refractory can significantly impact the overall cost of iron and steel production. Monolithic refractories are used to line the furnaces and other high-temperature areas in the production process, providing insulation and protection against extreme heat and chemical erosion. The cost of monolithic refractories varies depending on their composition, quality, and performance properties. Opting for high-quality monolithic refractories can increase their initial cost but can result in longer refractory lifespan, reduced downtime for repairs, and improved productivity. On the other hand, choosing lower-quality or inadequate refractories may save costs initially but can lead to frequent replacements, increased downtime, and decreased production efficiency. Additionally, monolithic refractories play a crucial role in energy efficiency. Using refractories with better insulation properties can help to reduce heat loss, leading to lower energy consumption and cost savings in the long run. Therefore, the selection of the right monolithic refractory is crucial in iron and steel production, as it directly impacts the overall cost by influencing refractory lifespan, productivity, maintenance, energy consumption, and overall operational efficiency.
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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:
- -
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Quality Product, Order Online Tracking, Timely Delivery
OKorder Financial Service
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