$Monolithic Refractories for Iron and Steel Industry:High Alumina Raw Bauxite Products System 1$

$Monolithic Refractories for Iron and Steel Industry:High Alumina Raw Bauxite Products$

$Monolithic Refractories for Iron and Steel Industry:High Alumina Raw Bauxite Products System 1$

Monolithic Refractories for Iron and Steel Industry:High Alumina Raw Bauxite Products

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Loading Port:: Qingdao

Payment Terms:: TT OR LC

Min Order Qty:: 400 m.t.

Supply Capability:: 5000 m.t./month

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Specifications

raw bauxite
1. Producing for 20 years.
2. refractory and abrasive
3. Competitive price
4. Al2O3 95%min

It is made by electric arc furnace melting under high temperature of 1100 degrees to 1400 degrees with the raw material of bauxite, anthracite and scrap iron. The main ingredient is AL2O3. With its high micro hardness of 1800-2200kg/mm2, it has many uses like abrasives and refractory. This kind of product has two types P sand and F sand with different uses。

Application:

1. Be used in polishing, grinding.

2. Suitablefor making grinding wheel, cutting, wheel, grinding disc.

3. Its high hardness and abrasion adapt to abrasive tools.

4. For advanced refractory materials

Application	Model	Al2O3	Na2O	Fe2O3	SiO2	TiO2	LOI	True density	a-Al2O3	D50	Particle size	specific surface
Application	Unit	≥ %	≤%	≤%	≤%	≤%	≤%	g/m3	≥ %	um	um	m2/g
Dry pressing/CIP series	TCH-101	99.7	0.08	0.02	0.018	0.006	0.15	3.96	96	75	2--3	0.6-0.8
	TCH-102	99.6	0.1	0.02	0.018	0.006	0.15	3.95	95	75	2--3	0.6-0.8
	TCH-103	99.5	0.2	0.02	0.018	0.006	0.2	3.95	95	75	2--3	0.8-1.0
	TCH-105	99.4	0.3	0.02	0.018	0.006	0.2	3.93	93	75	2--3	0.8-1.0
Injection moulding	TCH-213	99.5	0.15	0.02	0.018	0.006	0.15	3.95	95	75	3-4	0.5-0.6
Injection moulding	TCH-211	99.7	0.1	0.02	0.018	0.006	0.1	3.96	96	75	3-5

Q: How do monolithic refractories perform in rotary hearth furnace applications?: Monolithic refractories are known for their excellent performance in rotary hearth furnace applications. These refractories are designed to withstand the extreme temperatures and harsh conditions found in rotary hearth furnaces, making them an ideal choice for this specific application. One of the main advantages of monolithic refractories is their ability to resist thermal shock. In a rotary hearth furnace, the material being processed is subjected to rapid heating and cooling cycles, which can cause significant thermal stress on the refractory lining. Monolithic refractories have high thermal conductivity and low thermal expansion, allowing them to withstand these temperature fluctuations without cracking or spalling. Another key characteristic of monolithic refractories is their excellent abrasion resistance. In a rotary hearth furnace, the material being processed can contain abrasive particles that can erode the refractory lining over time. Monolithic refractories are formulated with high-quality aggregates and binders that offer superior resistance to abrasion, ensuring a longer service life for the lining. Furthermore, monolithic refractories have good chemical resistance, making them suitable for a wide range of applications in rotary hearth furnaces. They can withstand exposure to various chemical substances, such as molten metals, slags, and gases, without undergoing significant chemical reactions or degradation. This chemical stability ensures that the refractory lining remains intact and maintains its performance in the demanding environment of a rotary hearth furnace. Additionally, monolithic refractories offer excellent installation flexibility. Unlike traditional brick or tile refractories, which require complex installation procedures, monolithic refractories can be easily shaped and applied in-situ using various methods, such as gunning, casting, or ramming. This flexibility allows for quicker and more efficient lining repairs or replacements, reducing downtime and maintenance costs. In conclusion, monolithic refractories are highly reliable and efficient in rotary hearth furnace applications. Their ability to resist thermal shock, abrasion, and chemical attack, coupled with their easy installation, make them the preferred choice for lining materials in these demanding environments.

Q: How do monolithic refractories handle thermal expansion and contraction?: Thermal expansion and contraction pose challenges that monolithic refractories are specifically designed to tackle. Unlike traditional brick or tile refractories, these materials are composed of a single solid structure. This unique composition allows them to better accommodate the thermal stresses associated with temperature changes. One method employed by monolithic refractories to manage thermal expansion and contraction is their ability to endure high temperatures. These materials are engineered to have a high melting point, enabling them to preserve their structural integrity even in extreme heat conditions. This characteristic prevents them from cracking or disintegrating due to thermal expansion. Additionally, monolithic refractories often contain a binder or bonding agent that holds the refractory particles together. This binder can be formulated to possess a certain level of flexibility, enabling the material to expand and contract without incurring cracks or breaks. This flexibility aids in absorbing the stresses caused by thermal expansion and contraction, ensuring the long-lasting performance of the refractory. Furthermore, monolithic refractories can be applied in a manner that allows for expansion and contraction. Installers can leave joints or gaps between sections, which accommodate the movement caused by temperature changes. This technique, referred to as joint design or expansion joint systems, permits the refractory to expand and contract without causing any harm to the overall structure. Overall, monolithic refractories are designed to handle thermal expansion and contraction by withstanding high temperatures, incorporating flexible binders, and employing joint design techniques. These properties enable them to maintain their structural integrity and performance in extreme heat conditions, making them a reliable choice for applications that necessitate resistance to thermal stress.

Q: How can the lifespan of monolithic refractories be extended?: The lifespan of monolithic refractories can be extended through various measures, including proper installation, regular maintenance, and implementing effective operating practices. Firstly, it is crucial to ensure proper installation of monolithic refractories. This involves following the manufacturer's guidelines, using appropriate equipment and techniques, and ensuring correct curing and drying processes. When installed correctly, monolithic refractories are better equipped to withstand thermal stresses and chemical attacks, thereby prolonging their lifespan. Regular maintenance plays a key role in extending the lifespan of monolithic refractories. This includes routine inspections to identify any signs of wear, erosion, or cracking. Timely repairs or replacements should be carried out to prevent further damage. Additionally, applying protective coatings or sealants can help reduce erosion and chemical attacks, further enhancing the refractories' longevity. Implementing effective operating practices is another crucial aspect. Maintaining optimal operating conditions, such as controlling temperature fluctuations, can minimize thermal shocks and reduce the risk of spalling or cracking of the refractories. Proper material selection is also important, as using refractories that are 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. Handling should be done with care, avoiding excessive impact or rough treatment that could cause damage. Finally, it is beneficial to engage with experienced professionals or consult with refractory suppliers to gain valuable insights and guidance on best practices for extending the lifespan of monolithic refractories. Their expertise can help in making informed decisions regarding installation, maintenance, and operating practices, ultimately maximizing the refractories' lifespan and optimizing their performance.

Q: What are the key properties of gunning mixes used for monolithic refractory repairs?: Gunning mixes used for monolithic refractory repairs must possess several key properties. These include: 1. Exceptional durability: Gunning mixes should display outstanding resistance to thermal shock, abrasion, and chemical attack. This quality is crucial in ensuring that the repaired refractory material remains intact in the face of the harsh conditions prevalent in industrial furnaces and kilns. 2. High strength: Gunning mixes need to possess a significant compressive strength to provide structural integrity to the repaired refractory lining. This is particularly important in areas subjected to high mechanical stress or load. 3. User-friendly application: Gunning mixes should have favorable gunning properties, simplifying and streamlining the application process. They should be easily sprayed or gunned onto the surface requiring repair, resulting in a smooth and even coating. 4. Rapid setting and drying: Gunning mixes should boast a swift setting and drying time to minimize downtime during repairs. This ensures that the repaired refractory lining can be promptly reintroduced into service, reducing any potential production losses. 5. Excellent adhesion: Gunning mixes should demonstrate exceptional adhesion to the existing refractory material. This guarantees a strong bond between the new repair material and the old lining, preventing any potential delamination or separation. 6. Thermal stability: Gunning mixes should possess a high resistance to thermal cycling and temperature fluctuations. They should retain 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. In summary, the essential properties of gunning mixes for monolithic refractory repairs revolve around providing durability, strength, easy application, rapid setting, good adhesion, thermal stability, and chemical compatibility. These properties guarantee that the repaired refractory lining can effectively endure the challenging operating conditions in industrial furnaces and kilns, thereby extending their lifespan and reducing maintenance costs.

Q: How do monolithic refractories resist chemical attacks from molten metals and slag?: Monolithic refractories resist chemical attacks from molten metals and slag due to their high chemical stability, which is achieved through the use of carefully selected raw materials and advanced manufacturing processes. These refractories are designed to have low porosity, which prevents the penetration of molten metals and slag into the material. Additionally, they possess high resistance to corrosion and erosion, even at high temperatures, allowing them to withstand the harsh chemical environments created by molten metals and slag.

Q: What are the common failure mechanisms of monolithic refractories?: Common failure mechanisms of monolithic refractories include thermal spalling, chemical attack, erosion, and mechanical stress. Thermal spalling occurs when the refractory material is exposed to rapid temperature changes, leading to the cracking and breaking of the refractory lining. This can happen due to thermal shock, such as when a cold material is suddenly exposed to high temperatures, or when the refractory is subjected to cyclic heating and cooling. Chemical attack occurs when the refractory material comes into contact with aggressive chemicals or gases that can react with and degrade the refractory lining. This can lead to the formation of new compounds or the dissolution of the refractory material, weakening its structure and reducing its resistance to further chemical attack. Erosion is another common failure mechanism, especially in applications where the refractory lining is exposed to high-velocity gas or liquid flows. The abrasive action of the flowing medium can gradually wear away the refractory material, leading to thinning and eventual failure of the lining. Mechanical stress, such as thermal expansion or contraction mismatch, can also cause failure in monolithic refractories. When the refractory material is subjected to rapid temperature changes, differential expansion or contraction can occur, leading to the development of cracks and fractures in the lining. To mitigate these failure mechanisms, various techniques can be employed, such as proper material selection based on the specific operating conditions, careful design to minimize thermal gradients, use of protective coatings, and regular inspection and maintenance to identify and address any signs of failure or degradation.

Q: What are the typical compositions of monolithic refractories?: Monolithic refractories are typically composed of a combination of aggregates, binders, and additives. Aggregates are materials such as alumina, magnesia, or silicon carbide that provide the main refractory properties. The choice of aggregate depends on the desired characteristics of the refractory, such as resistance to high temperatures, thermal shock, or chemical attack. Binders are used to bind the aggregates together and give the refractory its shape and strength. Common binders include clay, calcium aluminate cement, or colloidal silica. The binder also contributes to the overall performance of the refractory, influencing properties such as thermal conductivity and chemical resistance. Additives are often incorporated into the composition to improve specific properties or enhance the processing of the monolithic refractory. These additives can include plasticizers, which improve workability and allow for easier installation, or antioxidants, which can increase the refractory's resistance to oxidation. Overall, the specific composition of a monolithic refractory can vary depending on the intended application and the desired performance characteristics. Different combinations of aggregates, binders, and additives can be tailored to suit specific temperature ranges, chemical environments, or mechanical stresses.

Q: How do monolithic refractories resist corrosion and erosion in iron and steel applications?: Monolithic refractories, unlike traditional refractory bricks, consist of a single, homogeneous material and are highly resilient and effective in combating corrosion and erosion in iron and steel applications. Their monolithic nature provides several advantages when it comes to corrosion and erosion resistance. One key advantage is their low porosity, which prevents corrosive agents like molten metal or slag from infiltrating the refractory structure. By minimizing interconnected pores, monolithic refractories significantly reduce the likelihood of chemical reactions that cause corrosion. Moreover, monolithic refractories exhibit excellent resistance to thermal shock, a common issue in iron and steel applications due to rapid temperature changes. Their high thermal conductivity and low thermal expansion enable them to withstand thermal shock without compromising their integrity. This characteristic allows them to resist erosion caused by the flow of molten metal or slag. Additionally, monolithic refractories are highly durable and possess good mechanical strength, enabling them to withstand the abrasive forces often encountered in iron and steel applications. The intense mechanical impact, vibrations, and abrasive wear experienced in these environments can be effectively resisted by monolithic refractories, ensuring their longevity and reliability. In conclusion, monolithic refractories are the preferred choice for lining furnaces, ladles, and other equipment used in the production of iron and steel due to their resistance to corrosion and erosion. Their low porosity, excellent resistance to thermal shock, and high mechanical strength make them an ideal option for these demanding applications.

Q: Can monolithic refractories be used for the lining of reheating furnaces and walking beam furnaces?: Monolithic refractories, which are refractory materials that can be cast or gunned into place rather than being made up of individual bricks or precast shapes, can be utilized for the lining of both reheating furnaces and walking beam furnaces. This characteristic makes them highly adaptable and versatile for a variety of furnace applications. Reheating furnaces are employed to heat metal products to a specific temperature before undergoing further processing, such as rolling or forging. The lining of these furnaces is exposed to high temperatures, thermal cycling, and mechanical stress. Given their exceptional thermal shock resistance and ability to withstand rapid temperature changes without cracking or spalling, monolithic refractories are well-suited for these conditions. In the steel industry, walking beam furnaces are utilized for the continuous heating and transportation of steel slabs or billets. These furnaces necessitate a lining material that can endure the abrasion and mechanical stress caused by the movement of the material. Monolithic refractories with high abrasion resistance and good mechanical strength are ideal for lining walking beam furnaces. Moreover, monolithic refractories provide additional advantages such as straightforward installation, decreased downtime for repairs, and enhanced energy efficiency. They can be customized to fit specific furnace designs and can be easily repaired or replaced as needed. In conclusion, monolithic refractories are a suitable option for lining reheating furnaces and walking beam furnaces due to their ability to withstand high temperatures, thermal cycling, mechanical stress, and abrasion. Their versatility, ease of installation, and repair make them the preferred choice for these furnace applications.

Q: How are monolithic refractories installed in iron and steel production processes?: Monolithic refractories are installed in iron and steel production processes using various methods depending on the specific application and requirements. The installation process typically involves the following steps: 1. Surface Preparation: Before installing monolithic refractories, the surface where they will be applied must be properly prepared. This involves cleaning and removing any loose materials, dust, or contaminants from the substrate. 2. Mixing: Monolithic refractories consist of different materials such as aggregates, binders, and additives. These components are mixed in specific proportions to achieve the desired properties and consistency. The mixing process can be done manually or using mechanical mixers. 3. Application: There are different techniques for applying monolithic refractories, including gunning, casting, ramming, and troweling. The chosen method depends on factors such as the shape of the structure, accessibility, and required thickness. - Gunning: This method involves using a gunning machine to spray the refractory material onto the surface. It is commonly used to repair or patch existing linings or for rapid installation in areas that are difficult to access. - Casting: In casting, the refractory material is poured into molds or forms and left to set and harden. This method is suitable for creating complex shapes and large-sized components. - Ramming: Ramming involves manually or mechanically compacting the refractory material into a mold or form using a ramming tool. This technique is commonly used for lining induction furnaces, ladles, and other equipment. - Troweling: Troweling is a manual method where the refractory material is applied and smoothed using a trowel. It is often used for smaller repairs or touch-ups. 4. Curing: After the refractory material is applied, it needs to be cured to achieve its optimum strength and performance. Curing involves allowing the material to dry and harden at a controlled temperature and humidity for a specified period. This step is crucial to ensure the long-term durability and resistance of the monolithic refractory lining. Overall, the installation of monolithic refractories in iron and steel production processes requires careful preparation, proper mixing, and the appropriate application technique. It is essential to follow manufacturer guidelines and industry best practices to ensure a successful installation that meets the specific needs of the production process.

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