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: How do monolithic refractories contribute to the overall efficiency of iron and steel production?
- Monolithic refractories play a crucial role in enhancing the overall efficiency of iron and steel production. These refractories, which are made from a single material, provide exceptional thermal insulation, resistance to high temperatures, and excellent mechanical strength. By lining the furnaces, ladles, and other equipment used in the production process, monolithic refractories help in maintaining and regulating the required high temperatures for melting, refining, and shaping iron and steel. This insulation reduces heat loss, minimizes energy consumption, and ensures a more efficient and cost-effective production process. Additionally, the mechanical strength of monolithic refractories allows for better protection against wear and tear, resulting in increased equipment lifespan and reduced downtime for repairs and maintenance. Overall, the use of monolithic refractories significantly contributes to the efficiency, productivity, and sustainability of the iron and steel production industry.
- Q: What are the key trends in the use of monolithic refractories in the iron and steel industry?
- One key trend in the use of monolithic refractories in the iron and steel industry is the increasing demand for tailored solutions. As the industry continues to evolve and become more specialized, there is a growing need for refractory materials that can be customized to meet specific requirements and challenges. Another important trend is the development of advanced monolithic refractories with enhanced performance characteristics. Manufacturers are constantly working on improving the properties of these materials, such as higher resistance to thermal shock, better thermal conductivity, and increased durability. This allows for improved efficiency and productivity in the iron and steel production processes. Additionally, there is a shift towards environmentally friendly refractory solutions. With growing concerns over sustainability and emissions, the industry is looking for refractory materials that have a lower carbon footprint and are made from renewable or recycled materials. This trend aligns with the broader push towards greener practices in the iron and steel sector. Overall, the key trends in the use of monolithic refractories in the iron and steel industry revolve around customization, performance enhancement, and sustainability. These trends are driven by the evolving needs of the industry and the desire to optimize production processes while minimizing environmental impact.
- Q: How do monolithic refractories contribute to the reduction of heat loss in iron and steel furnaces?
- Reducing heat loss in iron and steel furnaces is a crucial role played by monolithic refractories. These refractories are specifically designed to create a seamless lining throughout the furnace, eliminating any joints or seams that could result in thermal leaks. Monolithic refractories effectively contribute to heat loss reduction in two ways. Firstly, they possess excellent thermal insulation properties that restrict the transfer of heat from the furnace to its surroundings. With their low thermal conductivity, they effectively maintain the high temperatures required for efficient iron and steel production within the furnace, while minimizing heat loss to the surrounding environment. Secondly, monolithic refractories act as a protective barrier, preventing the escape of hot gases and molten metal. This barrier ensures the integrity of the furnace lining, preventing any gaps or cracks that could allow heat to escape. By creating a tight and continuous lining, monolithic refractories significantly reduce heat loss by keeping the heat contained within the furnace. Furthermore, monolithic refractories exhibit a high resistance to thermal shock and erosion, which are common challenges faced in iron and steel furnaces. These refractories can withstand rapid temperature changes, preventing sudden cracks or failures that could result in heat loss. Additionally, they are resistant to the corrosive effects of molten metal and hot gases, guaranteeing the longevity of the lining and preserving its insulating properties over time. To summarize, monolithic refractories contribute to the reduction of heat loss in iron and steel furnaces through their exceptional thermal insulation properties, ability to provide a continuous lining, resistance to thermal shock and erosion, and protection against corrosive substances. By minimizing heat loss, these refractories optimize energy efficiency and productivity in the furnace, leading to cost savings and improved overall performance in the iron and steel industry.
- Q: What are the different techniques for installing monolithic refractories?
- There are several techniques for installing monolithic refractories, each with its own advantages and suitability for different applications. Some of the common techniques include: 1. Casting: In this technique, the refractory material is mixed with water or a binder to form a slurry. The slurry is then poured into molds or directly onto the prepared surface. The material is allowed to set and harden, forming a solid monolithic structure. 2. Gunning: Gunning involves spraying the refractory material onto the surface using a gunning machine. The material is mixed with water or a binder to form a wet mix, which is then propelled onto the surface at high velocity. This technique is commonly used for repairing or lining larger areas and can be done onsite. 3. Ramming: Ramming involves compacting the refractory material into place using a pneumatic or manual ramming tool. The material is typically preheated to reduce moisture content and increase workability. This technique is often used for lining smaller areas or for filling gaps between bricks or precast shapes. 4. Shotcreting: Shotcreting is a technique similar to gunning, but it involves using a dry mix of refractory material. The dry mix is combined with water or a binder just before it is sprayed onto the surface using a high-pressure nozzle. Shotcreting is commonly used for lining larger areas or for creating complex shapes. 5. Troweling: Troweling involves applying the refractory material onto the surface using a trowel or a similar tool. The material is typically a wet mix and is spread and smoothed manually. This technique is often used for patching or repairing small areas or for finishing touches. 6. Vibrating: Vibrating involves using a vibrating tool or a vibrator to compact the refractory material and remove air pockets. This technique is commonly used for improving the density and strength of the monolithic refractory after it has been installed using other techniques. It is important to note that the selection of the technique depends on various factors such as the type of refractory material, the size and shape of the area to be lined, and the specific requirements of the application. Additionally, proper preparation of the surface and adherence to installation guidelines are crucial for ensuring the effectiveness and longevity of the monolithic refractory.
- Q: How do monolithic refractories improve the efficiency of ladle and tundish preheating furnaces?
- Monolithic refractories greatly contribute to the efficiency of ladle and tundish preheating furnaces. These refractories, made from a single material, are easily installed, repaired, and replaced, making them versatile and cost-effective. The efficiency of these furnaces is improved thanks to the outstanding thermal insulation properties of monolithic refractories. With low thermal conductivity, they effectively retain heat and prevent its escape. This insulation capability ensures an efficient preheating process, reducing energy consumption and costs by minimizing heat loss. Additionally, monolithic refractories possess high thermal shock resistance, which is crucial in ladle and tundish preheating furnaces. These furnaces experience rapid temperature changes during the pouring of molten metal, which can lead to cracking or failure of traditional refractories. However, monolithic refractories are specifically designed to withstand thermal shock, remaining intact and maintaining their insulating properties even in extreme conditions. This durability reduces downtime and maintenance requirements, thus enhancing overall efficiency. Furthermore, monolithic refractories provide a seamless and uniform lining surface, improving heat transfer within the furnace. The absence of joints or seams reduces the risk of heat leakage and ensures even distribution of heat throughout the lining. This promotes uniform heating of the ladle or tundish, allowing for more efficient preheating and better temperature control. In conclusion, the use of monolithic refractories in ladle and tundish preheating furnaces results in improved efficiency due to their exceptional thermal insulation properties, high thermal shock resistance, and ability to provide a seamless and uniform lining. These refractories minimize heat loss, reduce energy consumption, and enhance the overall performance of the preheating process.
- Q: How do monolithic refractories prevent thermal radiation in the iron and steel industry?
- Monolithic refractories play a crucial role in preventing thermal radiation in the iron and steel industry. Thermal radiation refers to the transfer of heat energy through electromagnetic waves, and it can be a significant challenge in this industry due to the high temperatures involved. Monolithic refractories, which are single-piece refractory materials, are designed to have excellent thermal insulation properties. They have low thermal conductivity, which means they are not good conductors of heat. This property allows them to act as a barrier against thermal radiation. When used in the iron and steel industry, monolithic refractories are typically applied as linings in furnaces, ladles, and other equipment that are exposed to extremely high temperatures. These linings serve as a protective layer, preventing the heat from escaping and reducing the amount of thermal radiation emitted. Additionally, monolithic refractories have high emissivity, which refers to their ability to absorb and re-emit thermal radiation. This property allows them to effectively capture and contain the heat within the equipment, minimizing the amount of radiation that escapes into the surroundings. By preventing thermal radiation, monolithic refractories help to maintain the desired temperatures within the iron and steel production process. This is crucial for achieving efficient and controlled operations, as well as ensuring the quality of the final products. Furthermore, the use of monolithic refractories in the iron and steel industry also contributes to energy savings. By reducing the heat loss through thermal radiation, less energy is required to maintain the desired temperatures, resulting in lower energy consumption and cost savings. In conclusion, monolithic refractories are essential in preventing thermal radiation in the iron and steel industry. Their excellent thermal insulation properties, low thermal conductivity, and high emissivity make them effective barriers against heat transfer through radiation. By minimizing heat loss and ensuring controlled temperatures, monolithic refractories contribute to efficient operations, high-quality products, and energy savings.
- Q: How do monolithic refractories improve the efficiency of ladle and tundish purging furnaces?
- Monolithic refractories improve the efficiency of ladle and tundish purging furnaces by providing better insulation, reducing heat loss, and enhancing the overall thermal efficiency of the furnaces. These refractories have high thermal conductivity and low thermal expansion, allowing for better heat transfer and uniform temperature distribution. Additionally, their superior resistance to thermal shocks and chemical attacks prolongs the lifespan of the furnaces, reducing maintenance and downtime.
- Q: How are monolithic refractories installed and repaired in iron and steel applications?
- To ensure optimal performance and longevity in iron and steel applications, specific procedures are employed for the installation and repair of monolithic refractories. The installation process typically involves the following steps: 1. Proper surface preparation is crucial. This entails removing loose material, dirt, and dust to create a smooth and clean substrate that facilitates good adherence of the refractory material. 2. The refractory material, supplied as dry powders or granules, is mixed with water or a specific bonding agent according to the manufacturer's instructions to achieve the desired properties. 3. The mixed refractory material is then applied to the prepared surface using techniques such as troweling, spraying, or casting, depending on the installation requirements and the type of monolithic refractory. 4. Curing is necessary to maximize the strength and durability of the refractory material. The curing process can involve air drying, heat treatment, or a combination of both, in accordance with the specific refractory material's recommendations. When it comes to repairing monolithic refractories in iron and steel applications, the following steps are generally followed: 1. Thorough assessment of the damaged area or component is conducted to determine the extent of the damage and the appropriate repair method. 2. The damaged monolithic refractory material is carefully removed using suitable tools and techniques while ensuring the underlying substrate remains intact. 3. Similar to the installation process, the surface where the repair will take place is cleaned and prepared by removing any loose material, dirt, and dust. 4. The repair material, typically the same or similar to the original monolithic refractory, is mixed and applied to the damaged area. The application method may vary depending on the nature of the repair and the specific requirements of the refractory material. 5. The repaired area is properly cured and inspected to ensure the quality and effectiveness of the repair, following the manufacturer's guidelines for curing and post-repair inspection procedures. In conclusion, the meticulous execution of surface preparation, proper mixing and application of refractory material, and appropriate curing procedures are essential for the installation and repair of monolithic refractories in iron and steel applications. These steps guarantee reliable and durable refractory linings, which are vital for the efficient operation of iron and steel processes.
- Q: How do monolithic refractories contribute to the reduction of downtime in iron and steel plants?
- The unique properties and applications of monolithic refractories play a vital role in minimizing downtime in iron and steel plants. These refractories consist of a single, uniform material, which makes them highly versatile and easier to install compared to traditional brick refractories. To begin with, monolithic refractories provide exceptional thermal insulation, preventing heat loss and maintaining high temperatures in different areas of the plant. This insulation capability reduces the need for frequent repairs and replacements by minimizing thermal stress and extending the lifespan of equipment and furnaces. As a result, less downtime is required for maintenance and repair work. Furthermore, monolithic refractories demonstrate superior resistance to thermal shock. The extreme temperatures encountered in iron and steel plants can cause rapid and significant temperature changes, leading to the cracking and failure of refractory linings. However, monolithic refractories offer better thermal shock resistance, enabling them to withstand sudden temperature fluctuations without sustaining damage. This property enhances their durability and contributes to the reduction of downtime. Additionally, monolithic refractories possess enhanced mechanical strength and chemical resistance, making them suitable for the harsh operating conditions in iron and steel plants. These refractories can withstand the erosive effects of molten metal, slag, and other corrosive materials, ensuring the longevity of equipment and reducing the frequency of maintenance interventions. Moreover, the installation process of monolithic refractories is faster and more efficient compared to brick refractories. They can be easily applied using various techniques, such as shotcreting or gunning, allowing for quick repairs or renovations during planned shutdowns or emergency situations. The reduced installation time results in shorter downtime periods, enabling the plant to resume operations promptly. In conclusion, monolithic refractories play a crucial role in reducing downtime in iron and steel plants through their excellent thermal insulation, resistance to thermal shock, mechanical strength, and chemical resistance. Their ease of installation and quick repair capabilities further enhance their role in minimizing downtime and ensuring uninterrupted production in these critical industries.
- Q: What are the specific requirements of monolithic refractories for continuous casting applications?
- The specific requirements of monolithic refractories for continuous casting applications are designed to withstand the extreme temperatures and thermal shock conditions experienced during the continuous casting process. Firstly, these refractories must have high thermal conductivity to effectively transfer heat away from the molten metal and maintain a stable casting temperature. This helps to prevent the formation of defects such as cracks, hot spots, and uneven solidification in the cast product. Secondly, monolithic refractories for continuous casting applications must have high refractoriness, meaning they can withstand the high temperatures of the molten metal without melting or deforming. This ensures the refractories can provide a protective lining and maintain their structural integrity throughout the casting process. Additionally, these refractories must have excellent resistance to thermal shock. The continuous casting process involves rapid cooling and heating cycles, which can create significant temperature differentials and induce thermal stresses. Monolithic refractories with low thermal expansion and high thermal shock resistance can withstand these conditions without cracking or spalling. Furthermore, good erosion and corrosion resistance are crucial requirements for monolithic refractories in continuous casting applications. The molten metal and slag can be highly corrosive and abrasive, leading to wear and chemical attack on the refractory lining. Hence, 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 have good workability and ease of installation. This allows for efficient and precise lining installation, reducing downtime during maintenance or repairs. Overall, the specific requirements of monolithic refractories for continuous casting applications include high thermal conductivity, refractoriness, thermal shock resistance, erosion and corrosion resistance, as well as good workability. Meeting these requirements ensures the refractories can effectively protect the casting equipment and maintain the quality of the cast products.
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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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