Monolithic Refractories for Iron and Steel Industry - Steel Fiber Castable for Fireplace and Industrial Furnace
- Ref Price:
-
- Loading Port:
- China main port
- Payment Terms:
- TT OR LC
- Min Order Qty:
- 1000 kg
- Supply Capability:
- 3000000 kg/month
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Steel Fiber Castable For Fireplace and Industrial Furnace
Product Description:
Steel fiber castable is manufactured according to international standards. The product is famous for its excellent abrasion resistance and low thermal conductivity. Further, these can be provided in different specifications as required by the clients. The Steel fiber castables are used high purity raw materials and additives as the main material, and made of under superfine powder adding technology.
Product Advantages:
The material has excellent structural stability and air tightness, and has high physical and chemical properties, also has a fine working ability.They should be used with the same material products.They are widely used in various kinds of kiln lining.Such as boiler, blast furnace hot blast stove, heating furnace, ceramic kiln, etc.Furnaces of metallurgy industry, heat treatment furnace. Furnace of incineration of garbage, recirculating fluidized bed furnace. Furnaces of chemical industry and construction industry.
Product Applications:
For feature of Steel fiber castable, they have excellent abrasion resistance, thermal shock resistance, high-temperature resistance, anti-corrode and have high intensity.
Designed for refractory lining of blast furnace iron and slag runners, skimmers and soon
They can be used in troughs of small and mid size BFs and in all positions of the troughs where fast tapping is required.
Main Product Features:
1. High refractoriness, High refractoriness under load.
2. High density, low porosity.
3. Good slag resistance and corrosion resistance.
4. High strength and wear resistance.
5. Good resistance to flake performance.
6. Good thermal shock stability.
7. Scouring resistance
8. Good hot strength.
Product Specifications:
FAQ:
1. How you can control your quality?
For each production processing, we have complete QC system for the chemical composition
and Physical properties. After production, all the goods will be tested, and the quality certificate
will be shipped along with goods.
2. What's your delivery time?
It usually needs about 20days- 45 days after receiving the deposit.
3. Do you provide free samples?
Yes, we can provide a free sample for testing, If we have sample in stock,
The quantity based on the material type, The buyer should bear all the shipping costs.
4. What's your payment terms?
We can accept 30% deposit, 70% balance before shipment for ordrs over $ 2000.
5. Can we visit your Company?
Yes, certainly. You are very welcome to China and we will be honored to have a customer and friend.
Product Picture:
- Q:What are the common applications of monolithic refractories in blast furnaces?
- Monolithic refractories are commonly used in blast furnaces for various applications such as lining and repairing the hearth, taphole, and slag line, as well as for hot repairs and maintenance. These refractories provide high-temperature resistance, erosion and corrosion resistance, and thermal shock resistance, thereby ensuring the efficient and reliable operation of blast furnaces in the iron and steel industry.
- Q:How are monolithic refractories installed and repaired in iron and steel production facilities?
- Monolithic refractories are vital components in iron and steel production facilities, as they provide insulation and protection against high temperatures, chemical corrosion, and mechanical wear. The installation and repair processes for monolithic refractories in these facilities require careful planning, expertise, and adherence to safety protocols. When installing monolithic refractories, the first step is to prepare the surface by removing any loose material and cleaning the area thoroughly. This ensures proper adhesion of the refractory material. The surface may also need to be roughened or textured to improve bonding. Next, the monolithic refractory material is mixed with water or a binder to create a workable consistency. It is then applied to the prepared surface using various methods such as casting, gunning, ramming, or troweling. The choice of application method depends on factors such as the type of refractory material, the area being repaired, and the desired outcome. During installation, it is essential to carefully follow the manufacturer's instructions regarding mixing ratios, curing times, and drying temperatures. Improper installation can lead to reduced refractory performance, premature failure, and safety hazards. Repairing monolithic refractories in iron and steel production facilities is an ongoing process due to the harsh operating conditions and mechanical stresses they endure. When a refractory lining shows signs of damage or wear, it is crucial to address the issue promptly to prevent further deterioration. The first step in repairing monolithic refractories is to assess the extent of the damage. This can be done through visual inspection, thermal imaging, or non-destructive testing techniques. Once the damage is identified, the repair method can be determined. Minor repairs can often be carried out using patching materials. These materials are typically the same or similar to the original refractory composition and are mixed with water or a binder to form a paste. The paste is then applied to the damaged area and allowed to cure. For more extensive repairs, the damaged refractory material may need to be removed entirely. This can be done through mechanical methods such as chipping, grinding, or cutting. After the damaged material is removed, the surface is prepared as mentioned earlier, and new refractory material is installed using the appropriate application method. It is important to note that the repair process should be conducted by trained personnel with expertise in refractory installation and repair. Safety precautions such as wearing protective clothing, using proper tools, and following established procedures should always be observed. In conclusion, the installation and repair of monolithic refractories in iron and steel production facilities require careful planning, adherence to manufacturer's instructions, and expertise in refractory materials. By following proper procedures and promptly addressing any damage, these facilities can ensure the longevity and efficiency of their refractory linings, ultimately contributing to the smooth operation of their production processes.
- Q:How do monolithic refractories withstand chemical attack from molten metals and slag?
- Monolithic refractories are highly resistant to chemical attack from molten metals and slag due to their unique composition and structure. These refractories are typically made from a single, solid piece with no joints or seams, which minimizes the opportunity for chemical penetration. One of the key factors that enables monolithic refractories to withstand chemical attack is their high melting point. These materials are designed to have a melting point significantly higher than the temperature of the molten metal or slag they are exposed to. This prevents the refractory from melting or deforming when in contact with the hot molten substances. In addition to their high melting point, monolithic refractories are formulated with materials that have excellent chemical resistance. They are often composed of a combination of oxides, such as alumina, magnesia, and zirconia, which have a strong affinity for oxygen and form stable compounds. This allows the refractory to form a protective oxide layer on its surface when exposed to molten metals and slag, effectively shielding it from chemical attack. Furthermore, the dense and compact structure of monolithic refractories plays a crucial role in their resistance to chemical attack. The absence of joints and seams minimizes the chances of molten metals and slag infiltrating the refractory and causing chemical reactions. This dense structure also reduces the porosity of the material, making it less permeable to aggressive substances. Moreover, manufacturers often add specialized additives to monolithic refractories to enhance their chemical resistance. These additives can include fibers, binders, and corrosion inhibitors, which further improve the refractory's ability to withstand chemical attack. In conclusion, monolithic refractories are designed to withstand chemical attack from molten metals and slag through their high melting point, chemical-resistant composition, dense structure, and specialized additives. These properties allow them to maintain their integrity and performance even in the harshest environments, making them an ideal choice for applications involving high-temperature and corrosive substances.
- Q:What are the limitations of monolithic refractories in high-temperature applications?
- Monolithic refractories are renowned for their versatility and ease of installation, which has made them a popular choice in various high-temperature settings. However, it is important to take into account their specific limitations. To begin with, monolithic refractories have a restricted ability to withstand thermal shock. Significant temperature changes, such as those encountered during start-up or shutdown procedures, can subject them to thermal stress, resulting in cracking or spalling. This can be a significant issue in scenarios where the refractory is exposed to frequent temperature fluctuations. Moreover, monolithic refractories possess comparatively lower mechanical strength in comparison to traditional brick or block refractories. This can lead to a diminished ability to withstand mechanical stress, including abrasion or impact, particularly in high-temperature environments. Consequently, they may not be suitable for applications that involve high mechanical loading or abrasive conditions. Another drawback of monolithic refractories is their vulnerability to chemical attack. Certain aggressive chemical environments can trigger chemical reactions with the refractory material, leading to deterioration or corrosion. This becomes a concern in applications that involve acidic or alkaline substances, where specialized refractory materials may be necessary. Additionally, monolithic refractories are more susceptible to spalling or erosion caused by thermal cycling. The repetitive expansion and contraction of the refractory material due to temperature changes can result in the formation of cracks or gaps, making them more prone to erosion from gases or liquids. This limitation must be carefully considered in applications where long-term durability is crucial. Lastly, repairing or replacing monolithic refractories can be challenging compared to brick or block refractories. Once installed, removing and replacing a monolithic lining can prove difficult, especially in complex shapes or confined spaces. This limitation can lead to prolonged downtime or increased maintenance and repair costs. In conclusion, while monolithic refractories offer numerous advantages in high-temperature applications, they also come with limitations in terms of thermal shock resistance, mechanical strength, chemical resistance, erosion, and repairability. It is crucial to thoroughly assess these limitations to ensure the suitability of monolithic refractories for specific application requirements.
- Q:How do monolithic refractories contribute to the overall reliability of iron and steel processes?
- Monolithic refractories play a crucial role in enhancing the overall reliability of iron and steel processes in several ways. Firstly, they provide excellent thermal insulation, which helps in maintaining consistent and controlled temperatures within the furnaces and other equipment involved in the production process. This ensures the stability of the process and avoids any sudden temperature fluctuations that could lead to equipment failure or product quality issues. Secondly, monolithic refractories offer high resistance to thermal shocks and mechanical stresses, which are common in iron and steelmaking operations. These refractories can withstand extreme temperatures, rapid heating and cooling cycles, and the corrosive nature of molten metals, thereby prolonging the lifespan of the equipment and reducing the frequency of repairs or replacements. Moreover, monolithic refractories have a superior ability to resist chemical attacks from molten metals, slag, and other harsh substances encountered in iron and steel processes. This resistance prevents the refractories from deteriorating or corroding over time, ensuring their integrity and preventing any contamination of the metal being produced. Lastly, the use of monolithic refractories allows for greater design flexibility and ease of installation compared to traditional brick refractories. This flexibility enables the construction of complex shapes and structures, optimizing the efficiency and productivity of iron and steelmaking processes. Overall, monolithic refractories contribute significantly to the reliability of iron and steel processes by providing excellent thermal insulation, resistance to thermal shocks and chemical attacks, and facilitating flexible design and installation options.
- Q:How are monolithic refractories installed and repaired in iron and steel applications?
- Monolithic refractories are installed and repaired in iron and steel applications using specific procedures to ensure optimal performance and longevity. The installation process typically involves the following steps: 1. Surface preparation: The surface where the monolithic refractory will be installed needs to be properly cleaned and prepared. This includes removing any loose material, dirt, and dust. It is crucial to have a smooth and clean substrate to ensure good adherence of the refractory material. 2. Mixing the refractory material: Monolithic refractories are typically supplied as dry powders or granules that need to be mixed with water or a specific bonding agent to form a workable consistency. The mixing process should be done according to the manufacturer's instructions to achieve the desired properties of the refractory. 3. Application: The mixed refractory material is then applied to the prepared surface using various techniques such as troweling, spraying, or casting. The choice of application method depends on the specific requirements of the installation and the type of monolithic refractory being used. 4. Curing: After the refractory material is applied, it needs to be properly cured to achieve its maximum strength and durability. Curing can be done by air drying, using heat, or a combination of both, depending on the specific refractory material being used. The curing process should be carried out gradually and according to the manufacturer's recommendations. When it comes to repairs of monolithic refractories in iron and steel applications, the following steps are generally followed: 1. Assessment: The damaged area or component needs to be thoroughly assessed to determine the extent of the damage and the appropriate repair method. 2. Removal of damaged material: The damaged monolithic refractory material is carefully removed using appropriate tools and techniques. It is important to remove all the damaged material while ensuring that the underlying substrate is not further compromised. 3. Surface preparation: Similar to the installation process, the surface where the repair will be carried out needs to be properly cleaned and prepared. Any loose material, dirt, and dust should be removed to create a clean and smooth substrate. 4. Application of repair material: The repair material, which is 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. Curing and post-repair inspection: The repaired area should be properly cured and inspected to ensure the quality and effectiveness of the repair. Curing and inspection procedures should adhere to the manufacturer's guidelines. In summary, the installation and repair of monolithic refractories in iron and steel applications require careful surface preparation, proper mixing and application of the refractory material, and appropriate curing procedures. Following these steps in a meticulous manner ensures reliable and durable refractory linings, which are essential for the efficient operation of iron and steel processes.
- Q:How are monolithic refractories installed in iron and steel production processes?
- The installation of monolithic refractories in iron and steel production processes necessitates various methods depending on the specific application and requirements. The installation process typically encompasses the subsequent steps: 1. Surface Preparation: Prior to installing monolithic refractories, it is imperative to adequately prepare the surface where they will be applied. This involves cleansing and eliminating any loose materials, dust, or contaminants from the substrate. 2. Mixing: Monolithic refractories comprise diverse materials, including aggregates, binders, and additives. These constituents are blended in specific proportions to attain the desired properties and consistency. The mixing process can be executed manually or using mechanical mixers. 3. Application: Various techniques exist for applying monolithic refractories, such as gunning, casting, ramming, and troweling. The chosen method is contingent upon factors such as the structure's shape, accessibility, and required thickness. - Gunning: This technique entails utilizing a gunning machine to spray the refractory material onto the surface. It is frequently employed for repairing or patching existing linings or for swift installation in hard-to-reach areas. - Casting: In casting, the refractory material is poured into molds or forms and allowed to solidify and harden. This method is suitable for fabricating intricate 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 approach is commonly employed for lining induction furnaces, ladles, and other equipment. - Troweling: Troweling is a manual method wherein the refractory material is applied and smoothed using a trowel. It is frequently utilized for minor repairs or touch-ups. 4. Curing: Subsequent to the application of the refractory material, curing is necessary to attain its optimal strength and performance. Curing involves allowing the material to dry and harden at a controlled temperature and humidity for a specified duration. This step is crucial to ensure the monolithic refractory lining's long-term durability and resistance. In conclusion, the installation of monolithic refractories in iron and steel production processes necessitates meticulous preparation, proper mixing, and the appropriate application technique. It is imperative to adhere to manufacturer guidelines and industry best practices to ensure a successful installation that fulfills the specific requirements of the production process.
- Q:What are the factors influencing the choice of monolithic refractories for different furnace types?
- There are several factors that influence the choice of monolithic refractories for different furnace types. Firstly, the operating temperature of the furnace is a crucial factor as different monolithic refractories have different temperature resistance levels. Secondly, the type of material being processed in the furnace is important as certain materials may require specific refractories to withstand their corrosive or abrasive nature. Thirdly, the furnace design and its heating method also play a role in determining the suitable refractory material. Additionally, the thermal conductivity, thermal shock resistance, and mechanical strength of the refractory are considered to ensure optimal performance and durability. Finally, cost, availability, and installation requirements are factors that can influence the choice of monolithic refractories for different furnace types.
- Q:How do monolithic refractories resist thermal shock in the iron and steel industry?
- Monolithic refractories are designed specifically to withstand thermal shock in the iron and steel industry, achieved primarily through their unique composition and structure. To begin, high-quality raw materials, such as alumina, magnesia, and silica, are used to create monolithic refractories. These materials are chosen carefully for their excellent thermal properties, including a high melting point, low thermal conductivity, and favorable thermal expansion characteristics. The manufacturing process of monolithic refractories involves precise control over the distribution of grain sizes and the addition of bonding agents. This results in a dense and uniform structure, enhancing their resilience against thermal shock. The bonding agents also play a crucial role in strengthening and maintaining the integrity of the refractories. Furthermore, additives are often incorporated into monolithic refractories to increase their resistance to thermal shock. These additives, such as zirconia, silicon carbide, or graphite, enhance the refractories' ability to endure rapid temperature changes. Moreover, monolithic refractories are designed with low porosity to minimize the penetration of molten metal or slag into the material. This helps prevent the formation of cracks and spalling, which can occur due to thermal shock. In addition, monolithic refractories are commonly applied as a lining or coating on furnace surfaces or other equipment. This creates a protective barrier, reducing direct exposure to extreme temperatures and thermal cycling. Overall, the combination of high-quality raw materials, meticulous manufacturing processes, additives, low porosity, and appropriate application techniques make monolithic refractories highly resistant to thermal shock in the iron and steel industry. They can endure rapid temperature changes, prevent cracks, and maintain their structural integrity, ensuring the reliable and efficient operation of furnaces and other equipment in this demanding industry.
- Q:What are some common maintenance practices for monolithic refractories in iron and steel furnaces?
- Some common maintenance practices for monolithic refractories in iron and steel furnaces include: 1. Regular inspections: Conducting routine inspections is essential to identify any potential issues with the monolithic refractories. Inspections should be carried out by trained professionals who can assess the condition of the refractories and detect any signs of wear, erosion, or damage. 2. Repair and patching: Promptly repairing any damaged or eroded areas is crucial to prevent further deterioration and maintain the integrity of the refractories. Patching materials, such as refractory mortars or castable refractories, can be used to fill in gaps or repair small cracks. 3. Cleaning: Regularly cleaning the refractory lining helps to remove any build-up of slag, scale, or other impurities that can negatively impact the performance of the refractories. Cleaning can be done mechanically, using brushes or scrapers, or through chemical methods such as acid cleaning. 4. Thermal cycling: Controlled thermal cycling is often performed to condition and strengthen the monolithic refractories. This involves gradually increasing and decreasing the temperature of the furnace to improve the refractory's resistance to thermal shock. 5. Coating and sealing: Applying protective coatings or sealants to the refractory lining can help enhance its resistance to chemical attack, erosion, and thermal cycling. These coatings act as a barrier, preventing the penetration of molten metals or slags into the refractory material. 6. Monitoring and control: Continuous monitoring of operating conditions such as temperature, pressure, and atmosphere inside the furnace is important to prevent any sudden changes that may negatively affect the refractories. Maintaining proper control over these parameters helps to extend the life of the monolithic refractories. 7. Training and education: Providing regular training and education to furnace operators and maintenance personnel is crucial for them to understand the importance of proper refractory maintenance practices. This ensures that the refractories are handled and operated correctly, reducing the risk of premature failure. Overall, implementing these maintenance practices can significantly prolong the lifespan of monolithic refractories in iron and steel furnaces and maximize their performance, ultimately leading to improved efficiency and cost-effectiveness in the production process.
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Monolithic Refractories for Iron and Steel Industry - Steel Fiber Castable for Fireplace and Industrial Furnace
- Ref Price:
-
- Loading Port:
- China main port
- Payment Terms:
- TT OR LC
- Min Order Qty:
- 1000 kg
- Supply Capability:
- 3000000 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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