Monolithic Refractories for Iron and Steel Industry:Mullite Heat Insulating Castable
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characteristic:
construction convenient
using for furnace lining
wear-resistant,flame-proof
| Item | | insulating castable | ||||||
| JNL-45 | JBN-40 | JGL-85 | JGL-70 | JDL-80 | JLL-75 | JLL-60 | ||
| Al2O3 % | 45 | 40 | 80 | 70 | 80 | 75 | 60 | |
| CaO % | — | — | — | — | 2.5 | — | — | |
| Refractoriness °C | 1700 | 1670 | 1790 | 1750 | 1790 | 1790 | 1750 | |
| Linear change affter sintered ≤±1% | 1350°C ×3h | 1000°C ×3h | 1500°C ×3h | 1450°C ×3h | 1500 °C ×3h | 1500°C ×3h | 1450°C× 3h | |
| 110°C±5 After drying | Crushing strength Mpa | 8 | 20 | 35 | 30 | 40 | 30 | 25 |
| Modulus rupture Mpa | 1 | — | 5 | 5 | 6 | 5 | 4 | |
| Bonder | clay | water glass | cement | cement | lower cement | phosphate | phosphate | |
High-strength lightweight Insulating refractory castable
1. low bulk density, low thermal conductivity, high intension.
2. good integrity and excellent air impermeability.
3. be used as cover of warm or low- temperature heat engineering equipments
4. It can also be thensulating material in hot temperature furnace.
5. way of usagre: daubing or casting.
The index is as follows:
- Q:How do monolithic refractories contribute to the overall efficiency of ladle transfer processes?
- Monolithic refractories play a crucial role in enhancing the overall efficiency of ladle transfer processes. These refractories are made of a single, homogeneous material, which allows for easy installation and maintenance. This feature significantly reduces downtime during the ladle transfer process, resulting in increased productivity. One way monolithic refractories contribute to efficiency is through their high thermal conductivity. Ladle transfer processes involve the transfer of molten metal, which generates immense heat. Monolithic refractories have excellent heat resistance, ensuring that they can withstand the extreme temperatures of the molten metal. This property prevents refractory failure and prolongs the lifespan of the ladle, leading to more efficient and uninterrupted ladle transfer operations. Additionally, monolithic refractories offer superior corrosion resistance. The corrosive nature of molten metal can cause significant damage to ladles over time. However, monolithic refractories are designed to withstand chemical attacks from molten metal, preventing the degradation of the ladle's integrity. As a result, ladles lined with monolithic refractories have a longer lifespan and require less frequent replacement, leading to cost savings and improved efficiency. Furthermore, the ability of monolithic refractories to conform to complex shapes and designs is another contributing factor to the efficiency of ladle transfer processes. Ladles come in various sizes and shapes, and the use of monolithic refractories allows for customized linings that perfectly fit the ladle's dimensions. This precise fit minimizes heat loss and maximizes energy efficiency during ladle transfer processes. Moreover, monolithic refractories offer excellent mechanical strength and resistance to thermal shock. Ladle transfer processes involve the handling and movement of ladles, which can subject refractories to mechanical stresses. The outstanding mechanical properties of monolithic refractories ensure their durability and prevent cracking or spalling, reducing the risk of refractory failure and improving the efficiency of ladle transfer operations. In summary, monolithic refractories contribute to the overall efficiency of ladle transfer processes by providing high thermal conductivity, corrosion resistance, precise lining fit, and excellent mechanical properties. These refractories enhance the ladle's durability, reduce downtime, and improve energy efficiency, resulting in cost savings and increased productivity in the steelmaking industry.
- 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:What are the challenges faced in the application of monolithic refractories?
- There are several challenges faced in the application of monolithic refractories. Firstly, one of the major challenges is the proper installation of monolithic refractories. Unlike traditional brick refractories that can be easily laid and stacked, monolithic refractories require specialized skills and techniques for proper application. The consistency and workability of the refractory material must be carefully controlled, and the installation process often requires the use of specialized equipment such as gunning machines or vibrating tools. Another challenge is the selection of 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 result in premature failure and costly repairs. Therefore, it is essential to understand the operating conditions, such as temperature, chemical exposure, and mechanical stress, to select the most suitable monolithic refractory material. Additionally, monolithic refractories are susceptible to thermal shock and erosion due to their composition and application method. 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 form a solid refractory lining. However, during the heating and cooling cycles, monolithic refractories can experience thermal expansion and contraction, leading to cracking and spalling. Moreover, the chemical reactions occurring in some industrial processes can cause chemical attack and erosion of the refractory lining, reducing its lifespan. Furthermore, maintenance and repair of monolithic refractories can also be challenging. Unlike brick refractories that can be easily replaced, repairing monolithic refractories often requires skilled personnel and specialized techniques. The damaged area needs to 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, particularly in high-temperature applications where extended downtime can result in significant production losses. In summary, the challenges faced in the application of monolithic refractories include proper installation techniques, selection of the appropriate material, susceptibility to thermal shock and erosion, and complex maintenance and repair procedures. Overcoming these challenges requires expertise, careful planning, and a thorough understanding of the specific operating conditions and requirements for each application.
- Q:How do monolithic refractories resist chemical attack from molten metals and slags?
- A combination of factors enables monolithic refractories to withstand chemical attack from molten metals and slags. Firstly, these refractories are composed of high-quality materials with excellent chemical resistance properties, such as alumina, magnesia, or silica. These materials possess a stable chemical structure that can endure the corrosive nature of molten metals and slags. Secondly, additives or binders are often incorporated into monolithic refractories to enhance their resistance to chemical attack. By improving the refractory's capability to form a protective layer on its surface, these additives act as a barrier between the refractory material and the corrosive molten metal or slag. Furthermore, monolithic refractories are designed with a dense microstructure that restricts the infiltration of molten metals and slags. This dense structure minimizes the pathways through which corrosive agents can reach the refractory material, effectively reducing the risk of chemical attack. In addition, proper joint design and anchoring systems can be employed during the installation of monolithic refractories to prevent the infiltration of corrosive substances. This ensures that the refractory lining remains intact and capable of effectively resisting chemical attack. In summary, the combination of high-quality materials, additives, dense microstructure, and proper installation techniques contribute to the ability of monolithic refractories to resist chemical attack from molten metals and slags. This, in turn, extends their lifespan and maintains the integrity of the refractory lining in high-temperature applications.
- Q:What are the recommended drying procedures for monolithic refractories?
- Drying methods for monolithic refractories differ based on the specific type and composition of the material. Nevertheless, there exist general guidelines that can be adhered to. Initially, it is crucial to eliminate any excess moisture from the refractory material prior to drying. This can be achieved by storing the refractory in a dry environment or utilizing a dehumidifier if necessary. Once the refractory material has been adequately dried, the drying process can commence. It is advisable to initiate the process with a low drying temperature in order to prevent cracking or spalling. Gradually raising the temperature over time will allow for the gradual release of moisture. This can be accomplished by employing a controlled drying oven or furnace. The duration of the drying process will differ depending on the thickness and composition of the refractory. It is imperative to adhere to the manufacturer's guidelines for the specific refractory material being utilized, as they will provide the recommended drying duration and temperature range. Throughout the drying process, it is important to closely monitor the refractory for any indications of cracking or spalling. Should any cracks or damage occur, the drying process should be immediately halted to prevent further harm. It may be necessary to repair or replace the damaged areas before proceeding with the drying process. Once the refractory material has been fully dried, it is crucial to gradually cool it down to avoid thermal shock. This can be achieved by gradually reducing the temperature over time or allowing the refractory to naturally cool in a controlled environment. In conclusion, the recommended drying procedures for monolithic refractories involve gradually increasing the temperature over time, closely monitoring for any signs of damage, and slowly cooling down the refractory to prevent thermal shock. It is essential to adhere to the manufacturer's guidelines and recommendations for the specific refractory material being utilized to ensure proper drying and optimal performance.
- 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.
- Q:How do monolithic refractories contribute to the quality of iron and steel products?
- Monolithic refractories play a crucial role in enhancing the quality of iron and steel products. These refractories are comprised of a single, solid structure, making them highly resistant to thermal and mechanical stresses. Their unique properties make them well-suited for various high-temperature applications in the iron and steel industry. Firstly, monolithic refractories provide excellent thermal insulation, which helps to maintain a consistent temperature within the furnace or kiln. This stability in temperature is essential for the proper heat treatment of iron and steel, ensuring optimal metallurgical properties and reducing the risk of defects. By preventing heat loss, monolithic refractories enable efficient energy utilization, leading to cost savings and environmental benefits. Another significant contribution of monolithic refractories lies in their ability to withstand 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 high resistance to thermal shock prevents cracking or spalling, which can lead to contamination and compromised product quality. Furthermore, monolithic refractories offer excellent corrosion resistance, protecting the 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 enable flexibility in design and installation. They can be shaped, cast, or gunned into various complex geometries, allowing for customization according to the specific requirements of the iron and steel production process. This versatility ensures optimal lining performance, maximizing efficiency and product quality. Overall, monolithic refractories contribute significantly to the quality of iron and steel products through their thermal insulation properties, resistance to harsh operating conditions, corrosion resistance, and design flexibility. By providing a reliable and durable lining in high-temperature applications, monolithic refractories help to ensure consistent and high-quality output in the iron and steel industry.
- Q:What are the main factors affecting the abrasion resistance of monolithic refractories?
- The main factors affecting the abrasion resistance of monolithic refractories can be categorized into three key aspects: material composition, microstructure, and service conditions. Firstly, material composition plays a crucial role in determining the abrasion resistance of monolithic refractories. The choice of raw materials, such as aggregates and binders, directly influences the overall hardness, strength, and wear resistance of the refractory. For instance, high-alumina refractories, which contain a high percentage of alumina as the main component, tend to exhibit excellent abrasion resistance due to the hardness and toughness of alumina. Conversely, refractories with a high proportion of softer materials like clay or magnesia may have lower abrasion resistance. Secondly, the microstructure of monolithic refractories greatly affects their ability to withstand abrasion. The distribution and orientation of aggregates, as well as the bond strength between the particles and the matrix, play significant roles in determining the resistance to wear. A well-distributed and interconnected network of aggregates can enhance the refractory's strength and resistance to abrasion. Additionally, a dense and well-sintered matrix can inhibit the penetration of abrasive particles, thereby reducing wear. Lastly, the service conditions in which the monolithic refractories are exposed to are crucial factors in determining their abrasion resistance. Factors such as temperature, atmosphere, and mechanical stress can significantly impact the wear behavior of refractories. High temperatures can cause thermal expansion and contraction, leading to cracks and spalling, which can accelerate abrasion. The presence of corrosive gases or chemicals can also deteriorate the refractory's microstructure, reducing its resistance to wear. Furthermore, mechanical stress from impact or friction can cause localized wear and damage the refractory. In conclusion, the main factors affecting the abrasion resistance of monolithic refractories include material composition, microstructure, and service conditions. By carefully selecting the appropriate raw materials, optimizing the microstructure, and considering the specific service conditions, it is possible to enhance the abrasion resistance of monolithic refractories and improve their overall performance in high-wear applications.
- Q:How do monolithic refractories contribute to the control of spalling in iron and steel processes?
- Monolithic refractories play a crucial role in controlling spalling in iron and steel processes. Spalling refers to the phenomenon of the refractory material breaking or flaking off due to thermal stress, mechanical stress, or chemical reactions. This can lead to severe damage to the lining of the furnace or kiln, reducing its efficiency and productivity. To address this issue, monolithic refractories are specifically designed to be more resistant to spalling compared to traditional brick or tile refractories. They are composed of a single, homogenous material that is able to withstand high temperatures and thermal shock, making them less prone to cracking or breaking under extreme conditions. The ability of monolithic refractories to control spalling in iron and steel processes is primarily attributed to their high thermal conductivity and low thermal expansion properties. These characteristics allow them to effectively distribute and absorb the intense heat generated during melting or heat treatment processes, minimizing the thermal stress on the refractory lining. Additionally, monolithic refractories offer better resistance to chemical reactions and erosion caused by molten metal, slag, or gases that are present in iron and steel processes. They are formulated with additives and binders that enhance their chemical stability and protect against corrosion, reducing the risk of spalling due to chemical attack. Furthermore, the monolithic nature of these refractories eliminates the need for joints or seams, which are common weak points in traditional brick or tile refractories. This seamless design ensures a more uniform and durable lining, reducing the chances of spalling occurring at these vulnerable areas. Overall, monolithic refractories contribute significantly to the control of spalling in iron and steel processes by providing superior thermal conductivity, low thermal expansion, chemical resistance, and a seamless lining. This helps to maintain the integrity of the refractory lining, prolonging its lifespan and ensuring efficient and safe operation of the furnace or kiln.
- Q:How do monolithic refractories withstand high temperatures and thermal cycling?
- Monolithic refractories withstand high temperatures and thermal cycling due to their unique composition and structure. They are made from a single piece or material, which eliminates joints or seams that could be vulnerable to thermal stress. Additionally, they are designed with a high thermal conductivity and low thermal expansion, allowing them to expand and contract without cracking or spalling. This enables them to maintain their integrity and mechanical strength even under extreme temperature fluctuations, making them highly durable and suitable for applications in industries such as steel, cement, and petrochemical.
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Monolithic Refractories for Iron and Steel Industry:Mullite Heat Insulating Castable
- 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
Credit Rating, Credit Services, Credit Purchasing
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