Monolithic Refractories for Iron and Steel Industry - Lightweight Castable Refractory Castable by Casting
- Ref Price:
-
- Loading Port:
- Shanghai
- Payment Terms:
- TT or LC
- Min Order Qty:
- 20000 kg
- Supply Capability:
- 10000000000 kg/month
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General Information of Lightweight castable
Lightweight castable is made from lightweight aggregate of lightweight ceramic grains and sand grog and floating beads, mixed with binding agent of aluminate cement and superfine powder, having different aggregates of different materials to meet the design requirements.
Features of Lightweight Castable
◆High strength
◆Good wear resistance
◆Excellent heat-insulation
◆Small reheating liner change
Application of Lightweight Castable
Chimney linings and heat-insulating
Wear proof layers of the
Technical Data of Lightweight Castable
| Technical Data of Lightweight Castable | ||||||
| Physical Properties | LC-1.4 | LC-1.2 | LC-1.0 | LC-0.9 | LC-0.8 | |
| Classification Temperature | ℃ | 1200 | 1100 | 1100 | 1000 | 1000 |
| ℉ | 2190 | 2010 | 2010 | 1830 | 1830 | |
| Buk Densiy(g/cm) | 110℃×24h | 1.4 | 1.2 | 1.0 | 0.9 | 0.8 |
| 815cx3h | 1.3 | 1.1 | 0.9 | 0.8 | 0.7 | |
| Compressive Strength (Mpa) | 110℃×24h | 12 | 10 | 7 | 4.5 | 4 |
| 815cx3h | 10 | 8 | 6 | 4 | 3 | |
| Modulus of Rupture(Mpa) | 110℃×24h | 3 | 2 | 1.5 | 1.0 | 0.8 |
| 815cx3h | 2.5 | 1.5 | 1.0 | 0.8 | 0.5 | |
| Permanent Liner Change (%) | 815℃×3h | 0.2 | 0.2 | 0.2 | 0.2 | 0.2 |
| Thermal Conductivity(W/m.k) | 350℃ | 0.35 | 0.30 | 0.25 | 0.23 | 0.21 |
Photo of Lightweight Castable
- Q:What are the considerations for selecting monolithic refractories for reheating furnaces?
- When selecting monolithic refractories for reheating furnaces, there are several important considerations to take into account. 1. Temperature requirements: Reheating furnaces operate at high temperatures, so it is crucial to choose monolithic refractories that can withstand the desired temperature range without experiencing significant thermal degradation or failure. The refractories must have a high refractoriness to maintain their structural integrity under these conditions. 2. Thermal shock resistance: Reheating furnaces often undergo rapid temperature changes due to the heating and cooling cycles. Monolithic refractories with good thermal shock resistance are essential to prevent cracking and spalling, which can lead to premature failure of the lining. 3. Mechanical strength: The monolithic refractories should have sufficient mechanical strength to withstand the stresses induced by the weight of the materials being heated and any mechanical movements within the furnace. This helps to prevent deformation or structural failure of the refractory lining. 4. Chemical compatibility: The refractories must be chemically compatible with the atmosphere and process gases present in the reheating furnace. They should resist chemical attacks from the gases or any corrosive substances generated during the reheating process. This ensures a longer service life for the refractory lining. 5. Abrasion resistance: Reheating furnaces often handle abrasive materials, such as hot billets or slabs. Selecting monolithic refractories with good abrasion resistance will help to minimize wear and extend the lifespan of the lining. 6. Ease of installation: Monolithic refractories offer advantages in terms of ease of installation compared to traditional brick refractories. However, it is important to consider the installation method and time required for the chosen monolithic refractory. Some monolithic refractories may require specialized equipment or techniques for installation. 7. Cost-effectiveness: While the initial cost of monolithic refractories may be higher than traditional brick refractories, their longer service life and ease of installation can result in overall cost savings. Assessing the cost-effectiveness of different monolithic refractory options is crucial for selecting the most suitable one for the reheating furnace. By considering these factors, one can make an informed decision when selecting monolithic refractories for reheating furnaces, ensuring optimal performance, durability, and cost-effectiveness.
- Q:What are the key properties of gunning mixes used for monolithic refractory repairs?
- The key properties of gunning mixes used for monolithic refractory repairs are high strength, good adhesion, excellent workability, and high resistance to thermal shock and abrasion. These properties ensure that the gunning mix can withstand the intense heat and harsh conditions of refractory applications, providing a durable and long-lasting repair solution.
- Q:How do monolithic refractories provide thermal insulation in the iron and steel industry?
- Monolithic refractories play a crucial role in providing thermal insulation in the iron and steel industry. These refractories are commonly used to line the furnaces and other high-temperature equipment used in the production processes. One way monolithic refractories provide thermal insulation is by their ability to withstand high temperatures without degrading or melting. They are designed to have high heat resistance, which allows them to be used in environments where temperatures can reach several thousand degrees Celsius. By withstanding these extreme temperatures, the refractories prevent the transfer of heat to the surrounding structure, thus providing insulation. Another way monolithic refractories provide thermal insulation is through their low thermal conductivity. These materials have a low thermal conductivity, meaning they are not efficient in conducting heat. Instead, they trap the heat within their structure and minimize its transfer to the surrounding equipment or environment. This characteristic helps to maintain the temperature inside the furnaces and other high-temperature equipment, allowing for efficient and controlled metal production. Furthermore, monolithic refractories can be applied as a thick lining layer, which creates an additional barrier between the high-temperature environment and the surrounding equipment. The thickness of the refractory lining helps to minimize heat transfer and acts as a buffer, reducing the impact of high temperatures on the structural integrity of the equipment. In addition to providing thermal insulation, monolithic refractories also offer excellent resistance to chemical attack and mechanical wear, which are common challenges in the iron and steel industry. This resistance ensures the longevity of the refractory lining, allowing for consistent and reliable insulation over time. Overall, monolithic refractories provide thermal insulation in the iron and steel industry through their high-temperature resistance, low thermal conductivity, thick lining layer, and resistance to chemical attack and mechanical wear. These properties contribute to maintaining the desired temperature inside the equipment and protecting the surrounding structure from the intense heat generated during metal production processes.
- Q:What are the key differences between acidic and basic monolithic refractories?
- The chemical compositions and behaviors in varying environments distinguish acidic and basic monolithic refractories. Acidic refractories mainly consist of acidic oxides like silica or alumina. These materials exhibit high resistance to acidic environments and find common usage in industries where contact with acidic gases or liquids occurs. They can endure high temperatures and resist chemical erosion, but are unsuitable for basic or alkaline conditions as they can lose effectiveness by reacting with basic compounds. Conversely, basic monolithic refractories comprise basic oxides such as magnesia or dolomite. These materials possess high resistance to basic or alkaline environments and are commonly used in industries where contact with basic compounds like lime or cement is prevalent. Basic refractories can endure high temperatures and resist chemical erosion from basic compounds, but are not suitable for acidic conditions as they may react and lose effectiveness. Regarding physical properties, acidic monolithic refractories tend to have higher melting points and better thermal shock resistance compared to basic monolithic refractories. This is due to the higher melting points of acidic oxides and their ability to form stable silicate or aluminate structures at high temperatures. On the other hand, basic monolithic refractories generally exhibit higher density and better resistance to penetration by molten materials. In conclusion, acidic and basic monolithic refractories differ in their chemical compositions and behaviors in various environments. Acidic refractories are suitable for acidic conditions, possess higher melting points, and exhibit better thermal shock resistance. Basic refractories, on the other hand, are suitable for basic conditions, have higher density, and offer superior resistance to penetration by molten materials.
- Q:How do monolithic refractories improve the efficiency of reheating furnaces in steel plants?
- Monolithic refractories play a crucial role in improving the efficiency of reheating furnaces in steel plants. These refractories are specially designed to withstand high temperatures and harsh operating conditions, making them ideal for use in steel plants. One of the key ways in which monolithic refractories enhance furnace efficiency is by reducing heat loss. These refractories have excellent insulation properties, which help to minimize heat transfer from the furnace to its surroundings. As a result, less energy is wasted, and the furnace can maintain its desired temperature more efficiently. Additionally, monolithic refractories contribute to a more uniform and controlled heat distribution within the furnace. They can be easily shaped and installed to create a seamless lining, ensuring that heat is evenly distributed throughout the furnace chamber. This uniform heat distribution prevents hotspots and cold spots, leading to a more efficient heating process. Monolithic refractories also play a crucial role in minimizing downtime and maintenance requirements. Unlike traditional brick linings, which are prone to cracking and erosion, monolithic refractories offer superior resistance to wear and tear. This enhanced durability reduces the need for frequent repairs and replacements, allowing for uninterrupted furnace operation and increased overall efficiency. Furthermore, monolithic refractories contribute to improved energy efficiency by reducing fuel consumption. The superior insulation properties of these refractories help to retain heat within the furnace, reducing the amount of energy required to maintain the desired temperature. This leads to significant energy savings for steel plants, as less fuel is needed to achieve the same heating results. In conclusion, monolithic refractories significantly improve the efficiency of reheating furnaces in steel plants by reducing heat loss, ensuring uniform heat distribution, minimizing downtime and maintenance, and reducing fuel consumption. By incorporating these refractories into their furnace linings, steel plants can enhance their productivity, reduce energy costs, and improve the overall efficiency of their operations.
- Q:What are the advantages of using low-cement castables in the iron and steel industry?
- There are several advantages of using low-cement castables in the iron and steel industry. Firstly, low-cement castables have a lower water content, which leads to better refractoriness and higher strength, enabling them to withstand high temperatures and thermal shocks experienced in iron and steel manufacturing processes. Secondly, low-cement castables exhibit excellent flowability and workability, allowing for easier installation and shaping. This results in reduced labor and time required for installation, leading to cost savings. Moreover, low-cement castables have a reduced porosity, which enhances their resistance to slag and metal penetration during the iron and steel production processes. This property improves the lining's durability and extends its service life, reducing maintenance and downtime. Additionally, low-cement castables offer superior mechanical properties, such as higher abrasion resistance and better thermal conductivity, making them ideal for various applications in the iron and steel industry, including ladles, tundishes, and blast furnaces. Overall, the advantages of using low-cement castables in the iron and steel industry include enhanced refractoriness, increased strength, improved workability, reduced porosity, and superior mechanical properties, ultimately resulting in improved efficiency, cost-effectiveness, and longer-lasting linings.
- Q:What are the key factors to consider when designing the lining system with monolithic refractories?
- To ensure optimal performance and longevity of the lining, several key factors must be taken into account when designing a system with monolithic refractories. These factors include: 1. Material selection: It is crucial to choose the appropriate monolithic refractory material, considering factors such as operating temperature, chemical environment, and mechanical stress. Different materials have varying properties and performance characteristics, so selecting the most suitable one for the specific application is essential. 2. Thermal expansion: Like any other material, monolithic refractories expand and contract with temperature changes. Therefore, it is important to consider the thermal expansion properties and how they will interact with the surrounding structure. To prevent cracking or spalling, proper expansion joints or design features should be incorporated. 3. Installation technique: The method of installation plays a critical role in the lining system's performance. Following the manufacturer's guidelines for mixing, placing, and curing the refractory material is essential. Improper installation can compromise lining integrity, thermal conductivity, and structural stability. 4. Bonding and anchoring: To ensure effective lining performance, a strong bond between the monolithic refractory and the substrate is necessary. Proper surface preparation, suitable bonding agents, and appropriate anchoring techniques should be considered to enhance adhesion and stability. 5. Structural design: The structural design of the lining system should be carefully planned to withstand mechanical stresses and operational conditions. Load-bearing capacity, thermal shock resistance, and thermal cycling must be taken into consideration during the design phase. Reinforcement materials, such as steel fibers or mesh, may be required to enhance structural integrity and prevent cracking or spalling. 6. Maintenance and repair: Anticipating the need for maintenance and repair is crucial for the lining system's longevity. Access points, inspection ports, and repair techniques should be considered. Regular inspections and proactive maintenance can help identify and address issues before they escalate and cause major failures. By considering these key factors, a well-designed and effective lining system with monolithic refractories can be ensured, capable of withstanding harsh conditions and providing long-term performance.
- Q:How do monolithic refractories improve the efficiency of ladle and tundish drying systems?
- Monolithic refractories play a crucial role in improving the efficiency of ladle and tundish drying systems. These systems are used in the steel industry for the drying process of ladles and tundishes before they are used for casting molten steel. One of the main advantages of monolithic refractories is their ability to provide a seamless lining, without any joints or gaps. This ensures that there are no weak points in the lining, reducing the risk of heat loss during the drying process. By maintaining a uniform and continuous lining, monolithic refractories help to achieve faster and more efficient drying of ladles and tundishes. Furthermore, monolithic refractories have excellent thermal insulation properties. They have low thermal conductivity, which means that they can effectively retain heat and prevent its transfer to the surroundings. This insulation capability allows for better heat retention within the ladles and tundishes during the drying process, resulting in faster and more energy-efficient drying. Monolithic refractories also offer superior thermal shock resistance. During the drying process, ladles and tundishes are subjected to rapid temperature changes, which can cause thermal stress and lead to cracks or spalling of the lining. However, monolithic refractories have high resistance to thermal shock, ensuring the durability and longevity of the lining. This resistance to thermal shock minimizes the need for frequent repairs or replacements, thereby increasing the overall efficiency of the ladle and tundish drying systems. In addition, monolithic refractories have good corrosion resistance. They are designed to withstand the harsh conditions and corrosive environments that ladles and tundishes are exposed to during the drying process. This corrosion resistance helps to maintain the integrity of the lining, preventing any degradation or damage that could affect the efficiency of the drying systems. Overall, the use of monolithic refractories in ladle and tundish drying systems improves their efficiency by providing a seamless lining, excellent thermal insulation, thermal shock resistance, and corrosion resistance. These properties contribute to faster drying times, energy savings, reduced maintenance requirements, and increased longevity of the equipment.
- Q:How do monolithic refractories help in reducing energy consumption in iron and steel production?
- Monolithic refractories play a vital role in the reduction of energy consumption in iron and steel production. These refractories are heat-resistant materials utilized to line the walls and floors of furnaces and other high-temperature equipment. One of the main ways monolithic refractories aid in energy reduction is through their exceptional thermal insulation properties. These materials possess low thermal conductivity, which effectively minimizes heat loss from the furnace or equipment. By keeping heat loss to a minimum, monolithic refractories help maintain a consistent and high temperature inside the furnace, resulting in enhanced energy efficiency. This allows for better utilization of generated heat, reducing the need for additional energy input and ultimately leading to energy savings. Additionally, monolithic refractories exhibit high thermal stability and resistance to thermal shock. This enables them to withstand the extreme temperatures and rapid temperature changes frequently encountered in iron and steel production processes. By having a robust and dependable lining, these refractories prevent heat leakage and ensure efficient heat transfer to desired areas, reducing energy wastage. Furthermore, monolithic refractories contribute to energy reduction by resisting chemical attack and erosion. In iron and steel production, furnaces and equipment linings are exposed to aggressive substances like molten metal, slag, and gases. Monolithic refractories exhibit excellent resistance to these corrosive elements, prolonging their lifespan and reducing the need for frequent repairs or replacements. This not only saves energy required for maintenance but also avoids production interruptions and associated energy losses. In conclusion, monolithic refractories aid in the reduction of energy consumption in iron and steel production by providing effective thermal insulation, withstanding extreme temperatures, and resisting chemical attack. By optimizing heat management and extending equipment durability, these refractories significantly contribute to energy efficiency and cost savings in the industry.
- Q:How can the lifespan of monolithic refractories be extended?
- There are several measures that can be taken to extend the lifespan of monolithic refractories. To begin with, it is essential to ensure their proper installation. This involves following the guidelines provided by the manufacturer, using appropriate equipment and techniques, and ensuring correct curing and drying processes. By installing them correctly, the monolithic refractories become better equipped to withstand thermal stresses and chemical attacks, thus prolonging their lifespan. Regular maintenance is also crucial in extending the lifespan of monolithic refractories. This includes conducting routine inspections to identify any signs of wear, erosion, or cracking. Timely repairs or replacements should be carried out to prevent further damage. Moreover, applying protective coatings or sealants can help reduce erosion and chemical attacks, thereby enhancing the refractories' longevity. Another important aspect is implementing effective operating practices. This involves maintaining optimal operating conditions, such as controlling temperature fluctuations, to minimize thermal shocks and reduce the risk of spalling or cracking. Proper material selection is also key, as using refractories specifically designed for the intended application can increase their resistance to chemical attacks and extend their lifespan. Furthermore, ensuring proper handling and storage of monolithic refractories is essential. They should be stored in a dry, clean environment, away from moisture and extreme temperatures, to prevent premature degradation. Careful handling should be exercised, avoiding excessive impact or rough treatment that could cause damage. Lastly, it is beneficial to seek guidance from experienced professionals or consult refractory suppliers. Their expertise can provide valuable insights and guidance on best practices for extending the lifespan of monolithic refractories. By making informed decisions regarding installation, maintenance, and operating practices, the refractories' lifespan can be maximized and their performance optimized.
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Monolithic Refractories for Iron and Steel Industry - Lightweight Castable Refractory Castable by Casting
- Ref Price:
-
- Loading Port:
- Shanghai
- Payment Terms:
- TT or LC
- Min Order Qty:
- 20000 kg
- Supply Capability:
- 10000000000 kg/month
OKorder Service Pledge
Quality Product, Order Online Tracking, Timely Delivery
OKorder Financial Service
Credit Rating, Credit Services, Credit Purchasing
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