Monolithic Refractories for Iron and Steel Industry - Mould Powders / Continuous Casting Powders and Granules
- Ref Price:
-
- Loading Port:
- Tianjin
- Payment Terms:
- TT or LC
- Min Order Qty:
- 10 m.t.
- Supply Capability:
- 100000 m.t./month
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Product Description:
The Mould Powders are composed essentially of CaO-Al2O3-SiO2 with addition of fluxing agents and carbon.
Mold Powders have different functions:
Lubrication between the solidifying strand and mould wall
Control of heat transfer between the strand and mould
Thermal insulation of the liquid steel surface
Prevention of re-oxidation
Inclusion absorption
The above functions are controlled by the following properties:
Basicity
Viscosity
Melting speed
Melting behaviour
Crystallization
The choice of a mould powder depends on:
Mould size
Oscillation conditions
Casting speed
Steel grade
Technical Data:
FAQ
Q:Are you a trading company or manufacturer?
A:CNBM is a large-scale central governmental industrial group with its own manufacturing sector, research and development sector, trading sector and logistics sector.
Q:I have some special requirement about specifications.
A:We have a well-rounded product range, which endows us with the capability of applying many special specifications. Please feel free to contact us with yours.
Q:Do you accept OEM service?
A:Yes, we do.
Q:What is your delivery time?
A:It depends on the size/complexity of your order and our own production schedule. Usually we provide a faster delivery than the industry's average.
Q:What is the payment term?
A:Our payment terms are negotiable.
Q:Can I have my own logo on the product?
A:Sure, we can apply your own logo on the products according to your drawings.
- Q: What are the challenges faced in the application of monolithic refractories?
- The application of monolithic refractories presents several challenges. Firstly, a major hurdle is the correct installation of these refractories. Unlike traditional brick refractories that can be easily stacked, specialized skills and techniques are required for the proper application of monolithic refractories. The consistency and workability of the refractory material must be carefully controlled, and specialized equipment such as gunning machines or vibrating tools are often necessary for the installation process. Another challenge lies in selecting the appropriate monolithic refractory material for a specific application. There are various types of monolithic refractories available, each with its own unique properties and suitability for different environments. Choosing the wrong type of refractory material can lead to premature failure and expensive repairs. Therefore, it is crucial to understand the operating conditions, including temperature, chemical exposure, and mechanical stress, in order to select the most suitable monolithic refractory material. Additionally, monolithic refractories are prone to thermal shock and erosion due to their composition and method of application. They are typically made from fine powders that are mixed with water or other binding agents to form a paste. This paste is then applied and dried to create a solid refractory lining. However, during the heating and cooling cycles, monolithic refractories can experience thermal expansion and contraction, resulting in cracks and spalling. Furthermore, chemical reactions occurring in certain industrial processes can cause chemical attack and erosion of the refractory lining, reducing its lifespan. Furthermore, the maintenance and repair of monolithic refractories can also pose a challenge. Unlike brick refractories that can be easily replaced, repairing monolithic refractories often requires skilled personnel and specialized techniques. The damaged area must be removed, and a new layer of refractory material must be applied, ensuring proper bonding and compatibility with the existing lining. This process can be time-consuming and costly, especially in high-temperature applications where extended downtime can result in significant production losses. In conclusion, the application of monolithic refractories presents challenges in terms of proper installation techniques, material selection, susceptibility to thermal shock and erosion, and complex maintenance and repair procedures. Overcoming these challenges requires expertise, careful planning, and a comprehensive understanding of the specific operating conditions and requirements for each application.
- Q: What are the advantages of using low-cement castables in the iron and steel industry?
- There are numerous benefits associated with the utilization of low-cement castables in the iron and steel sector. To begin with, low-cement castables necessitate less water compared to traditional castables. Consequently, the installation process becomes faster and more efficient due to the reduced water requirement. Moreover, the lower water content results in enhanced strength development and shorter drying time, facilitating faster turnaround times during production. In addition, low-cement castables exhibit exceptional resistance to extreme temperatures and thermal shocks. Given the high temperatures prevalent in the iron and steel industry, these castables possess excellent refractory properties that enable them to withstand such harsh conditions. Consequently, the refractory lining enjoys an extended service life, reducing the need for frequent repairs or replacements. Furthermore, low-cement castables demonstrate remarkable mechanical strength and abrasion resistance. Given the nature of the iron and steel sector, where heavy materials and abrasive substances are handled, the refractory lining is susceptible to wear and tear. However, low-cement castables are capable of enduring these mechanical stresses, thereby enhancing the durability and longevity of the lining. Moreover, low-cement castables possess low porosity and high density, resulting in reduced permeability. Consequently, they exhibit high resistance to alkali attacks, chemical corrosion, and slag penetration, all of which are common challenges faced in the iron and steel industry. By employing low-cement castables, the risk of refractory failure caused by these corrosive elements is minimized. Lastly, low-cement castables contribute to improved energy efficiency. Their lower thermal conductivity ensures that less heat is conducted through the refractory lining, leading to reduced heat losses. This, in turn, translates into energy savings, as less heat is wasted and more heat is retained within the system. The significance of this advantage is particularly evident in the iron and steel industry, where energy costs can be substantial. In conclusion, the use of low-cement castables in the iron and steel sector offers a multitude of advantages, including reduced water requirement, superior thermal resistance, enhanced mechanical strength, improved resistance to chemical corrosion, and increased energy efficiency. These benefits contribute to overall cost savings, heightened productivity, and improved operational performance in the iron and steel manufacturing process.
- Q: How long is the lifespan of monolithic refractories in iron and steel applications?
- The lifespan of monolithic refractories in iron and steel applications can vary depending on several factors. These factors include the type of refractory material used, the specific application, the operational conditions, and the maintenance practices implemented. In general, monolithic refractories used in iron and steel applications are designed to withstand high temperatures, thermal shock, chemical attack, and mechanical stress. They are expected to have a relatively long lifespan compared to other refractory materials. Under normal operating conditions and proper maintenance, monolithic refractories can typically last anywhere from several months to several years in iron and steel applications. However, it is important to note that certain areas of the application may experience more severe conditions and may require more frequent repairs or replacements. Regular inspections and monitoring of the refractories' condition are crucial to identify any signs of deterioration or damage. Any necessary repairs or replacements should be carried out promptly to prevent further damage and minimize downtime. It is also worth mentioning that advancements in refractory technology and materials have led to the development of more durable and long-lasting monolithic refractories. These advancements have increased the lifespan of refractories in iron and steel applications, ultimately improving the overall efficiency and productivity of the operations.
- Q: What are the key properties of ramming mixes used for monolithic refractory installations?
- Ramming mixes for monolithic refractory installations must possess several key properties. Firstly, they need to have high thermal stability to withstand extreme temperatures and thermal cycling. This ensures that the mix remains intact under varying thermal conditions. Secondly, a high density is necessary to resist thermal conductivity and minimize heat loss. This helps maintain the desired temperature in the refractory lining. Thirdly, low porosity is crucial to reduce the penetration of molten metals or slag, enhancing the durability of the installation. Additionally, good mechanical strength is required to withstand stresses and loads, preventing physical damage. The mixes should also exhibit chemical resistance to protect against corrosive substances. Furthermore, they should be easy to install and work with, allowing for efficient installation. Lastly, a controlled setting time is important to allow for proper placement and consolidation. Overall, these properties contribute to the performance and longevity of the refractory lining in high-temperature applications.
- Q: What are the factors influencing the choice of monolithic refractories for different furnace types?
- The choice of monolithic refractories for different furnace types is influenced by various factors that need to be considered in order to ensure optimal performance and efficiency. These factors include the operating temperature, type of heat transfer mechanism, chemical composition of the furnace atmosphere, thermal cycling, mechanical stresses, and specific application requirements. One of the primary factors to consider is the operating temperature of the furnace. Different monolithic refractories have different temperature limits, and it is crucial to select a refractory material that can withstand the specific temperature range of the furnace without significant degradation or failure. For high-temperature applications, materials like alumina, magnesia, and silica are commonly used due to their excellent thermal stability. The type of heat transfer mechanism is another important consideration. Furnaces can use various methods to transfer heat, such as radiation, conduction, or convection. Each of these mechanisms may require different refractory properties. For example, radiation-dominated furnaces may require a refractory material with high thermal conductivity to efficiently transfer heat, while convection-dominated furnaces may require a material with good resistance to gas flow erosion. The chemical composition of the furnace atmosphere is also a crucial factor. Depending on the process being carried out in the furnace, the atmosphere may contain highly corrosive gases or chemicals. In such cases, it is essential to select a monolithic refractory that is resistant to chemical attack and can maintain its structural integrity in the presence of aggressive substances. Thermal cycling, which involves repeated heating and cooling cycles, is another factor influencing the choice of monolithic refractories. Some refractory materials may be prone to thermal shock or spalling when subjected to rapid temperature changes. In contrast, others may have better resistance to thermal cycling, making them more suitable for applications that involve frequent temperature variations. Mechanical stresses, such as load or vibration, can also impact the choice of refractories. Furnaces that experience mechanical stresses require materials with good mechanical strength and resistance to abrasion. Refractory materials like silicon carbide or zirconia may be preferred in such cases due to their high strength and toughness. Lastly, specific application requirements should be considered when selecting monolithic refractories. Factors such as installation method, ease of maintenance, availability, and cost-effectiveness may influence the choice of refractory material. In summary, the choice of monolithic refractories for different furnace types is influenced by the operating temperature, heat transfer mechanism, chemical composition of the furnace atmosphere, thermal cycling, mechanical stresses, and specific application requirements. Considering these factors is essential to ensure the longevity, performance, and efficiency of the refractory lining in various furnace applications.
- Q: How do monolithic refractories withstand mechanical stress in the iron and steel industry?
- Monolithic refractories are designed to endure mechanical stress in the iron and steel industry due to their distinctive composition and properties. Unlike traditional brick-like refractories, which consist of multiple pieces, these refractories have a single, uniform structure. This monolithic structure offers several advantages in terms of mechanical stress resistance. To begin with, monolithic refractories possess greater strength and density compared to traditional refractories. This enables them to withstand the mechanical forces exerted during various processes in the iron and steel industry, such as the movement of molten metal, the impact of scrap materials, or the pressure from gases and liquids. Their superior strength and density help prevent cracking, deformation, or failure under these stressful conditions. Moreover, monolithic refractories provide excellent resistance to thermal shock, which is crucial in the iron and steel industry. The rapid heating and cooling cycles experienced in processes like steelmaking or iron casting can subject refractories to thermal stress. However, the monolithic structure of these refractories allows for better thermal conductivity and expansion, reducing the risk of thermal shock damage. This ability to withstand thermal stress contributes to their overall resistance to mechanical stress. Furthermore, monolithic refractories can be customized and applied on-site, resulting in a seamless lining that eliminates joints or weak spots. This seamless application ensures a more uniform distribution of stress and prevents the formation of cracks or gaps that could weaken the refractory lining. By eliminating these vulnerabilities, monolithic refractories enhance their ability to resist mechanical stress in the demanding conditions of the iron and steel industry. In conclusion, monolithic refractories endure mechanical stress in the iron and steel industry due to their high strength and density, superior resistance to thermal shock, and seamless application. These properties enable them to withstand the intense mechanical forces encountered during various processes, ensuring the durability and efficiency of refractory linings in this demanding industry.
- 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 include: 1. High durability: Gunning mixes should have excellent resistance to thermal shock, abrasion, and chemical attack. This ensures that the repaired refractory material can withstand the harsh conditions in industrial furnaces and kilns. 2. High strength: Gunning mixes should have a high compressive strength to provide structural integrity to the repaired refractory lining. This is especially important in areas that are subjected to high mechanical stress or load. 3. Easy application: Gunning mixes should have good gunning properties, allowing for easy and efficient application. They should have the ability to be sprayed or gunned onto the surface to be repaired, providing a smooth and even coating. 4. Quick setting and drying: Gunning mixes should have a fast setting and drying time to minimize downtime during repairs. This ensures that the repaired refractory lining can be quickly put back into service, reducing production losses. 5. Good adhesion: Gunning mixes should have excellent adhesion to the existing refractory material. This ensures a strong bond between the new repair material and the old lining, preventing any potential delamination or separation. 6. Thermal stability: Gunning mixes should have a high resistance to thermal cycling and temperature fluctuations. They should be able to maintain their structural integrity and mechanical properties even under extreme heat conditions. 7. Chemical compatibility: Gunning mixes should be chemically compatible with the materials they come into contact with, such as molten metals or corrosive gases. This ensures that the repaired refractory lining can withstand the corrosive effects of these substances. Overall, the key properties of gunning mixes for monolithic refractory repairs are focused on providing durability, strength, easy application, quick setting, good adhesion, thermal stability, and chemical compatibility. These properties ensure that the repaired refractory lining can effectively withstand the harsh operating conditions in industrial furnaces and kilns, prolonging their lifespan and reducing maintenance costs.
- Q: How do monolithic refractories withstand high temperatures and thermal shocks?
- Monolithic refractories are able to withstand high temperatures and thermal shocks due to their unique composition and design. These refractories are made from a single piece or structure, hence the term "monolithic". This structural integrity allows them to resist the extreme heat and sudden temperature changes experienced in high-temperature applications. One key factor that enables monolithic refractories to withstand high temperatures is the use of high-quality raw materials. These materials are carefully selected for their ability to withstand heat and thermal stress. Common components include silica, alumina, magnesia, and other refractory minerals with high melting points. Additionally, the manufacturing process plays a crucial role in enhancing the thermal resistance of monolithic refractories. The raw materials are mixed with binders, such as clay or cement, to form a homogenous mixture. This mixture is then shaped and installed in its final position, either by pouring or gunning, depending on the application. The binder ensures that the refractory maintains its shape and integrity during thermal cycling. Furthermore, monolithic refractories possess excellent thermal conductivity and low thermal expansion properties. This means that they can efficiently transfer and dissipate heat, minimizing the risk of thermal stress and cracking. The low thermal expansion also reduces the likelihood of spalling or delamination, which is crucial for withstanding thermal shocks. Another factor contributing to the high-temperature resistance of monolithic refractories is their ability to form a protective layer or slag at the surface. This layer acts as a barrier, preventing the refractory from direct contact with corrosive materials or aggressive atmospheres. It helps to improve the refractory's longevity and resistance to thermal shocks. Overall, the combination of high-quality raw materials, careful manufacturing techniques, and beneficial thermal properties enables monolithic refractories to withstand high temperatures and thermal shocks. These refractories are widely used in various industries, including steel, cement, glass, and petrochemical, where they serve as reliable linings in furnaces, kilns, and other high-temperature equipment.
- Q: How do monolithic refractories contribute to the quality of iron and steel products?
- Enhancing the quality of iron and steel products is a crucial role played by monolithic refractories. These refractories consist of a single, solid structure that grants them high resistance against thermal and mechanical stresses. Their unique properties make them suitable for a range of high-temperature applications in the iron and steel industry. To start with, monolithic refractories excel in thermal insulation, maintaining a consistent temperature within furnaces and kilns. This temperature stability is vital for the proper heat treatment of iron and steel, ensuring ideal metallurgical properties and reducing the risk of defects. By preventing heat loss, monolithic refractories promote efficient energy utilization, resulting in cost savings and environmental benefits. In addition, monolithic refractories demonstrate remarkable endurance in the face of harsh operating conditions. The iron and steel manufacturing process involves extreme temperatures, aggressive chemical environments, and mechanical stresses. Monolithic refractories exhibit exceptional resistance to these conditions, ensuring durability and longevity. Their ability to resist thermal shock prevents cracking or spalling, which can lead to contamination and compromised product quality. Furthermore, monolithic refractories provide excellent corrosion resistance, shielding iron and steel products from chemical reactions with molten metal, slag, and other aggressive substances. This resistance not only preserves the integrity of the refractory lining but also prevents contamination of the metal, resulting in improved product quality. Monolithic refractories also offer flexibility in design and installation. They can be shaped, cast, or gunned into various complex geometries, allowing for customization based on the specific requirements of the iron and steel production process. This versatility ensures optimal lining performance, maximizing efficiency and product quality. In conclusion, monolithic refractories significantly contribute to the quality of iron and steel products. Their thermal insulation properties, resistance to harsh operating conditions, corrosion resistance, and design flexibility all play a vital role. By providing a reliable and durable lining in high-temperature applications, monolithic refractories help guarantee consistent and high-quality output in the iron and steel industry.
- Q: How do monolithic refractories contribute to reducing downtime in iron and steel plants?
- Monolithic refractories play a crucial role in reducing downtime in iron and steel plants by offering several key advantages over traditional brick refractories. Firstly, monolithic refractories are highly versatile and can be easily molded and installed, allowing for quicker repairs and replacements. Unlike brick refractories that require time-consuming and labor-intensive processes, such as bricklaying and mortar application, monolithic materials can be directly applied in a castable or gunning form, significantly reducing the downtime required for repairs. Additionally, monolithic refractories provide better thermal insulation and improved resistance to thermal shocks, which are common occurrences in iron and steel plants. This enhanced thermal performance helps to maintain stable operating temperatures and prevents sudden temperature fluctuations that can lead to refractory failure and subsequent downtime. By minimizing these thermal shocks, monolithic refractories increase the overall lifespan of the refractory lining, reducing the need for frequent repairs and replacements. Furthermore, monolithic refractories offer superior chemical resistance compared to traditional brick refractories. Iron and steel plants often encounter aggressive chemical environments due to the presence of molten metal, slag, and other corrosive substances. Monolithic refractories are specifically designed to withstand these harsh conditions, preventing chemical attacks and erosion of the refractory lining. As a result, the need for unscheduled shutdowns due to refractory degradation is significantly reduced. Lastly, monolithic refractories provide better dimensional stability, minimizing the risk of cracks and spalling that can occur due to thermal cycling and mechanical stress. This increased resistance to wear and tear ensures that the refractory lining remains intact for a longer period, reducing the frequency of maintenance and enhancing the overall operational efficiency of the iron and steel plant. In summary, monolithic refractories contribute to reducing downtime in iron and steel plants by offering faster installation, improved thermal insulation, superior chemical resistance, and enhanced dimensional stability. Their versatility and performance advantages make them a reliable choice for maintaining a reliable and efficient refractory lining, ultimately reducing the frequency and duration of plant shutdowns.
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Monolithic Refractories for Iron and Steel Industry - Mould Powders / Continuous Casting Powders and Granules
- Ref Price:
-
- Loading Port:
- Tianjin
- Payment Terms:
- TT or LC
- Min Order Qty:
- 10 m.t.
- Supply Capability:
- 100000 m.t./month
OKorder Service Pledge
Quality Product, Order Online Tracking, Timely Delivery
OKorder Financial Service
Credit Rating, Credit Services, Credit Purchasing
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