2024 - RS Kiln Refractory Bricks

In industries that rely heavily on high-temperature operations, such as steel manufacturing, foundries, and cement plants, maintaining the integrity and efficiency of furnaces is crucial. Over time, the intense heat, thermal cycling, and exposure to corrosive materials can cause wear and tear on the furnace linings. To ensure that these furnaces continue to operate efficiently and safely, regular maintenance and patching are essential. One of the most effective solutions for this is the use of Castable Gunmix. In this blog post, we’ll explore how Castable Gunmix is utilized for furnace patching and maintenance, and why it is an indispensable tool for industries dealing with high-temperature processes.

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What is Castable Gunmix?

Castable Gunmix is a type of refractory material specifically designed for repairing and maintaining high-temperature industrial furnaces. Refractories are materials that can withstand extremely high temperatures without degrading. Castable Gunmix is a mix of refractory aggregates, binders, and additives that can be applied using a gunning machine, making it easier to repair worn-out or damaged areas in a furnace lining.

Unlike traditional refractory bricks, which require precise cutting and placement, Castable Gunmix can be applied directly to the affected areas, ensuring a quick and efficient repair process. This method of application not only saves time but also reduces labor costs and minimizes downtime, which is crucial in industries where furnace availability is key to production.

The Role of Castable Gunmix in Furnace Patching

Furnace patching is a vital part of furnace maintenance, as it addresses localized damage that, if left untreated, could lead to more extensive repairs or even complete furnace failure. Castable Gunmix plays a critical role in this process due to its unique properties and application method.

Flexibility in Application: Castable Gunmix can be applied to various furnace linings, including those with complex shapes and hard-to-reach areas. The gunning process allows for precise application, ensuring that the material adheres well to the existing lining and forms a strong bond. This flexibility is particularly important for patching cracks, spalls, and other localized damage that may not warrant a full lining replacement.

High-Temperature Resistance: One of the most important characteristics of Castable Gunmix is its ability to withstand high temperatures. Depending on the specific formulation, Castable Gunmix can resist temperatures well above 1000°C (1832°F). This makes it suitable for use in furnaces operating under extreme conditions, where other materials might fail.

Thermal Shock Resistance: Furnace linings are often subjected to rapid temperature changes, which can cause thermal shock and lead to cracking or spalling. Castable Gunmix is designed to have excellent thermal shock resistance, meaning it can absorb and dissipate the stresses caused by sudden temperature fluctuations. This property helps extend the life of the furnace lining and reduces the frequency of repairs.

Abrasion and Corrosion Resistance: In many industrial processes, furnace linings are exposed to abrasive materials, molten metals, and corrosive gases. Castable Gunmix is formulated to resist these harsh conditions, ensuring that the patched areas remain intact and functional for longer periods. This resistance to abrasion and corrosion is particularly valuable in industries like steelmaking, where furnace linings are constantly under attack from molten slag and other aggressive substances.

Ease of Installation: The gunning process for applying Castable Gunmix is relatively straightforward and can be performed by trained personnel with minimal disruption to the furnace operation. This ease of installation is a significant advantage, as it allows for quick repairs that minimize downtime and keep the furnace running at optimal capacity.

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The Maintenance Benefits of Using Castable Gunmix

Regular maintenance of industrial furnaces is essential to ensure their longevity and efficiency. By incorporating Castable Gunmix into the maintenance routine, industries can reap several benefits:

Extended Furnace Life: By addressing minor damages promptly with Castable Gunmix, industries can prevent small issues from escalating into major problems that require costly repairs or even furnace replacement. Regular patching with Castable Gunmix helps extend the overall life of the furnace lining, reducing the need for frequent and expensive overhauls.

Reduced Downtime: Downtime in industrial operations can be incredibly costly. The quick and efficient application of Castable Gunmix allows for repairs to be completed in a fraction of the time compared to traditional methods. This means that furnaces can be back in operation sooner, minimizing production losses and maximizing efficiency.

Cost-Effective Solution: Castable Gunmix offers a cost-effective solution for furnace maintenance. The material itself is relatively inexpensive, and the gunning process reduces labor costs and the need for extensive preparation. Additionally, the longer lifespan of the repaired linings translates to lower maintenance costs over time.

Improved Safety: A well-maintained furnace is a safer furnace. By using Castable Gunmix to patch and maintain furnace linings, industries can reduce the risk of catastrophic failures that could lead to accidents, equipment damage, or even loss of life. Regular maintenance with Castable Gunmix ensures that the furnace operates safely and reliably.

Importance of Furnace Maintenance

In high-temperature industries, the importance of furnace maintenance cannot be overstated. Castable Gunmix provides an efficient, cost-effective, and reliable solution for patching and maintaining furnace linings. Its unique properties, including high-temperature resistance, thermal shock resistance, and ease of application, make it an indispensable tool for industries that rely on continuous furnace operation.

By incorporating Castable Gunmix into their maintenance routines, industries can extend the life of their furnaces, reduce downtime, lower maintenance costs, and improve overall safety. As the demands on industrial furnaces continue to increase, the role of Castable Gunmix in furnace patching and maintenance will only become more critical. Whether you are in steel manufacturing, cement production, or any other high-temperature industry, investing in regular maintenance with Castable Gunmix is a smart choice that will pay off in the long run.

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Aug 29 2024

Ceramic Fiber Boards for Energy Efficiency in High-Temperature Applications

In the world of industrial processes, where temperatures often soar to extreme levels, maintaining energy efficiency while ensuring safety is a top priority. High-temperature applications, such as furnaces, kilns, and reactors, demand materials that can withstand intense heat while minimizing energy loss. This is where Insulation Ceramic Fiber Boards come into play, offering an advanced solution for thermal insulation in such demanding environments. These boards not only enhance energy efficiency but also contribute to the longevity and safety of high-temperature systems.

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Understanding Ceramic Fiber Boards

Insulation Ceramic Fiber Boards are a type of refractory material designed to provide superior thermal insulation in high-temperature environments. Composed of ceramic fibers, these boards are lightweight yet highly resistant to thermal shock and high temperatures, often withstanding temperatures up to 1600°C (2912°F). Their exceptional insulating properties make them an ideal choice for a wide range of applications, from industrial furnaces to power generation plants.

Ceramic fiber boards are manufactured by forming alumina-silicate fibers into a rigid structure. These fibers are derived from high-purity raw materials, ensuring that the boards maintain their integrity even under extreme conditions. The result is a durable, lightweight, and easy-to-handle insulation material that offers excellent thermal stability and low thermal conductivity.

The Role of Ceramic Fiber Boards in High-Temperature Applications

In industries where high-temperature processes are routine, the need for reliable insulation cannot be overstated. Effective insulation not only helps maintain the desired temperature within a system but also reduces energy consumption, lowers operational costs, and minimizes the environmental impact.

Insulation Ceramic Fiber Boards play a crucial role in achieving these objectives. Here’s how:

Energy Efficiency

One of the primary benefits of using Ceramic Fiber Boards in high-temperature applications is their ability to significantly reduce heat loss. These boards have low thermal conductivity, meaning they are highly effective at blocking the transfer of heat. This property ensures that the heat generated within a system remains where it is needed, reducing the amount of energy required to maintain high temperatures. In turn, this leads to lower fuel consumption and operational costs, making the entire process more energy-efficient.

Thermal Stability

Ceramic Fiber Boards are engineered to withstand extreme temperatures without degrading or losing their insulating properties. This thermal stability is essential for maintaining consistent operating conditions in high-temperature applications. Whether used in a furnace lining, a kiln door, or as a protective barrier in a reactor, these boards ensure that the system operates efficiently and safely, even under prolonged exposure to intense heat.

Resistance to Thermal Shock

In many industrial processes, rapid temperature changes are common, posing a significant challenge for insulation materials. Insulation Ceramic Fiber Boards are designed to resist thermal shock, meaning they can endure sudden temperature fluctuations without cracking or deteriorating. This resistance not only extends the lifespan of the insulation but also helps prevent costly downtime and maintenance.

Lightweight and Easy Installation

Despite their impressive insulating capabilities, Ceramic Fiber Boards are remarkably lightweight. This characteristic makes them easy to handle and install, reducing labor costs and installation time. Their rigidity also allows them to be cut and shaped to fit specific applications, providing a custom insulation solution that meets the unique needs of each system.

Versatility in Application

The versatility of Insulation Ceramic Fiber Boards is another key advantage. These boards can be used in a variety of high-temperature applications across different industries. Common uses include furnace linings, kiln linings, back-up insulation, and as heat shields. They are also employed in power generation, petrochemical, and metallurgical industries, where reliable thermal insulation is essential for operational efficiency and safety.

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Enhancing Energy Efficiency with Insulation Ceramic Fiber Boards

Energy efficiency is a critical concern in industries that rely on high-temperature processes. The energy required to heat a system to the necessary temperature represents a significant portion of operational costs. By minimizing heat loss, Insulation Ceramic Fiber Boards help reduce the amount of energy required to maintain optimal operating conditions.

Here’s how these boards contribute to energy efficiency:

Reduced Heat Loss

The low thermal conductivity of Ceramic Fiber Boards means that less heat escapes from the system. This reduction in heat loss translates directly into energy savings, as less fuel or electricity is needed to sustain high temperatures. Over time, these savings can be substantial, particularly in energy-intensive industries.

Improved Process Control

Consistent temperature maintenance is crucial for many industrial processes. By providing reliable insulation, Ceramic Fiber Boards help maintain a stable temperature within the system. This consistency improves process control, leading to higher-quality products and more efficient operations.

Extended Equipment Lifespan

High temperatures can take a toll on industrial equipment, leading to wear and tear that shortens the lifespan of critical components. By insulating the system effectively, Ceramic Fiber Boards reduce the thermal stress on equipment, helping to extend its lifespan and reduce the frequency of maintenance and replacements.

Environmental Impact

Energy efficiency is not just about cost savings; it also has a significant environmental impact. By reducing the amount of energy required for high-temperature processes, Ceramic Fiber Boards help lower the carbon footprint of industrial operations. This reduction in energy consumption is particularly important in industries that are striving to meet stringent environmental regulations and reduce their impact on climate change.

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Selecting the Right Insulation Ceramic Fiber Boards

When choosing Insulation Ceramic Fiber Boards for high-temperature applications, it’s essential to consider several factors to ensure optimal performance:

Temperature Rating

Different Ceramic Fiber Boards are rated for different maximum temperatures. It’s crucial to select a board with a temperature rating that matches or exceeds the operating temperature of your application.

Density

The density of the board can affect its insulating properties and mechanical strength. Higher-density boards offer better insulation but may be more rigid and less flexible. The right balance between density and flexibility depends on the specific requirements of your application.

Chemical Compatibility

In some applications, the insulation may be exposed to corrosive chemicals or gases. It’s important to choose a Ceramic Fiber Board that is chemically compatible with the environment in which it will be used.

Installation Requirements

Consider the ease of installation and the ability to customize the boards to fit your application. Some boards are easier to cut and shape than others, which can be an important factor in complex installations.

Exceptional Thermal Insulation of Ceramic Fiber Boards

Insulation Ceramic Fiber Boards are a critical component in optimizing energy efficiency in high-temperature applications. Their exceptional thermal insulation properties, combined with their resistance to thermal shock, ease of installation, and versatility, make them an ideal choice for industries that rely on high-temperature processes. By selecting the right Ceramic Fiber Board for your application, you can enhance the efficiency, safety, and longevity of your operations, while also contributing to a more sustainable and environmentally friendly industrial process. As the demand for energy-efficient solutions continues to grow, Insulation Ceramic Fiber Boards will remain a vital tool in the pursuit of cost-effective and reliable thermal insulation.

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Aug 15 2024

Optimizing Cupola Furnace Lining with Castable Gunmix Refractory

Cupola furnaces are a vital part of the metalworking industry, particularly in the production of cast iron. These furnaces operate under extreme temperatures, often reaching up to 1500°C (2732°F), which makes their maintenance and lining a critical factor for operational efficiency. The lining of a cupola furnace is subjected to intense heat, abrasion, and chemical wear, making it essential to use materials that can withstand these harsh conditions. This is where Castable Gunmix comes into play.

Understanding Cupola Furnace Lining

The lining of a cupola furnace is a protective layer that shields the furnace’s structure from the intense heat and wear caused by molten metal and slag. Traditionally, these linings have been made from refractory bricks or monolithic refractories. However, advancements in material science have introduced new solutions, such as Castable Gunmix, which offer superior performance and easier application. The choice of material for furnace lining directly affects the furnace’s durability, efficiency, and operational costs. Poorly chosen or maintained linings can lead to frequent repairs, unplanned shutdowns, and even safety hazards. Therefore, selecting the right material, like Castable Gunmix, and applying it correctly is crucial for optimizing furnace performance.

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What is Castable Gunmix?

Castable Gunmix is a type of monolithic refractory material designed for furnace lining. Unlike traditional refractory bricks, which are shaped and fired before installation, castable refractories are installed in a plastic or fluid state and then fired in place. This allows for a more seamless and uniform lining, which reduces the likelihood of weak points that can lead to premature failure.

Gunmix refers to a specific application method where the castable material is pneumatically applied to the furnace lining. This method is particularly effective for patching or lining areas with complex geometries that would be difficult to cover with bricks or other materials.

Benefits of Using Castable Gunmix for Cupola Furnace Lining

Enhanced Durability and Longevity

The Castable Gunmix used in cupola furnace linings offers exceptional durability. Its high resistance to thermal shock, abrasion, and chemical attack ensures that the furnace can operate under extreme conditions without frequent maintenance. This leads to a longer service life for the lining, reducing downtime and maintenance costs.

Improved Heat Retention and Efficiency

One of the key advantages of Castable Gunmix is its ability to retain heat within the furnace. This improved thermal efficiency results in lower fuel consumption and more consistent temperatures within the furnace, which is critical for producing high-quality cast iron. Better heat retention also means that the furnace can reach operating temperatures more quickly, further enhancing efficiency.

Ease of Application

The application of Castable Gunmix is relatively straightforward compared to traditional refractory bricks. The pneumatic gunning method allows for a more uniform and dense lining, which minimizes the risk of cracks and weak points. This method is also faster, reducing the time needed for repairs or initial installation.

Versatility in Application

Castable Gunmix is highly versatile and can be used for both complete furnace lining and patching. This versatility makes it an ideal solution for furnaces that require frequent maintenance or have areas with complex shapes that are difficult to line with bricks. Additionally, the material can be easily tailored to specific needs by adjusting the formulation of the castable mix.

Cost-Effectiveness

While the initial cost of Castable Gunmix may be higher than traditional refractory bricks, the long-term savings are significant. The extended lifespan of the lining, reduced maintenance frequency, and improved operational efficiency all contribute to lower overall costs. Furthermore, the faster application process reduces labor costs and minimizes furnace downtime, which is crucial for maintaining productivity.

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Key Considerations for Optimizing Cupola Furnace Lining with Castable Gunmix

To fully realize the benefits of Castable Gunmix in a cupola furnace, it’s important to consider a few key factors during the selection and application process.

Material Selection

Not all castable refractories are created equal. The specific formulation of the Castable Gunmix should be chosen based on the operating conditions of the furnace, including temperature, chemical exposure, and mechanical wear. Consulting with a refractory specialist can help in selecting the right material for the job.

Proper Application

The effectiveness of Castable Gunmix largely depends on proper application. The gunning process requires skilled operators to ensure a uniform and dense lining. It’s also important to follow the manufacturer’s guidelines for mixing, curing, and firing the material to achieve the best results.

Regular Maintenance

Even with the best materials and application techniques, regular maintenance is essential to keep the furnace lining in optimal condition. Regular inspections can identify areas of wear or damage early, allowing for timely repairs with Castable Gunmix to prevent more extensive and costly issues.

Environmental Considerations

The operating environment of the furnace, including temperature fluctuations and exposure to slag or other corrosive materials, should be taken into account when choosing and applying Castable Gunmix. Adjusting the composition of the castable material can improve resistance to specific environmental factors, further enhancing the longevity of the lining.

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Optimizing the Lining of a Cupola Furnace

Optimizing the lining of a cupola furnace is essential for maintaining efficiency, reducing operational costs, and ensuring safety. Castable Gunmix offers a modern solution to furnace lining challenges, providing enhanced durability, ease of application, and improved thermal efficiency. By carefully selecting the right material and applying it correctly, operators can significantly extend the lifespan of their furnace linings and improve overall performance. As the metalworking industry continues to evolve, the use of advanced materials like Castable Gunmix will play an increasingly important role in maintaining the reliability and efficiency of cupola furnaces.

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Aug 1 2024

How Insulation Ceramic Fiber Boards Enhance Thermal Resistance in Industrial Heat Treatment

In the ever-evolving landscape of industrial processes, efficiency, safety, and cost-effectiveness are paramount. One of the critical elements in ensuring these factors is the ability to control and manage heat within various industrial settings. This is where Insulation Ceramic Fiber Boards (ICFBs) come into play, particularly in the context of Industrial Heat Treatment. These boards are essential in enhancing Thermal Resistance, providing a reliable solution for industries that require precise temperature management.

Understanding the Role of Thermal Resistance in Industrial Heat Treatment

Industrial Heat Treatment involves heating and cooling processes used to alter the physical and sometimes chemical properties of materials, particularly metals. The primary goal is to achieve desired attributes such as hardness, strength, ductility, or corrosion resistance. The efficiency of these processes heavily depends on the materials’ exposure to controlled temperatures over specified periods.

Thermal Resistance is the property of a material that defines its ability to resist the flow of heat. In industrial heat treatment, maintaining consistent temperatures is crucial, as fluctuations can lead to defects or variations in the treated materials. Therefore, the insulation used in furnaces, kilns, and other heat-treatment equipment must possess high thermal resistance to ensure stable and uniform temperature distribution.

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The Unique Properties of Insulation Ceramic Fiber Boards

Insulation Ceramic Fiber Boards are a type of refractory material known for their exceptional thermal properties. They are made from high-purity alumino-silicate fibers, which are processed into a lightweight, rigid board. Here are some of the key properties that make these boards ideal for enhancing thermal resistance in industrial heat treatment:

High Thermal Resistance: ICFBs have a low thermal conductivity, meaning they are highly resistant to heat transfer. This property ensures that the heat remains within the desired areas, reducing energy loss and maintaining consistent temperatures within the heat treatment chamber.
Lightweight and Durable: Despite their lightweight nature, these boards are incredibly durable and can withstand high temperatures without breaking down. This makes them ideal for use in high-stress environments where both strength and thermal performance are required.
Excellent Insulation Performance: The fibers in ICFBs are designed to trap air, which acts as an insulator. This further enhances their ability to resist heat flow, making them an excellent choice for applications requiring prolonged exposure to high temperatures.
Chemical Stability: ICFBs are chemically stable, meaning they do not react with other materials at high temperatures. This is crucial in industrial heat treatment, where the introduction of impurities can compromise the quality of the treated materials.
Easy to Install and Shape: These boards can be easily cut and shaped to fit specific requirements, making them versatile and adaptable to various industrial applications.

The Role of Insulation Ceramic Fiber Boards in Enhancing Thermal Resistance

The integration of Insulation Ceramic Fiber Boards into industrial heat treatment systems offers several benefits that directly contribute to enhanced Thermal Resistance:

Consistent Temperature Control: By providing a highly effective thermal barrier, ICFBs help maintain uniform temperatures within heat treatment equipment. This consistency is vital for achieving the desired material properties and ensuring product quality.
Energy Efficiency: The high thermal resistance of ICFBs minimizes heat loss, leading to significant energy savings. In industries where heat treatment processes run continuously or for extended periods, these savings can translate into substantial cost reductions.
Protection of Equipment: ICFBs not only insulate the heat but also protect the structural integrity of the heat treatment equipment. By preventing excessive heat exposure to the equipment’s outer surfaces, these boards reduce wear and tear, thereby extending the lifespan of the machinery.
Reduction in Maintenance Costs: The durability and thermal stability of ICFBs mean that they require less frequent replacement compared to other insulation materials. This reduction in maintenance needs lowers operational costs and minimizes downtime in industrial processes.
Improved Safety: In high-temperature environments, safety is a top priority. ICFBs help reduce the risk of overheating and accidental fires by containing the heat within designated areas. This containment not only protects the equipment but also ensures a safer working environment for personnel.

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Applications of Insulation Ceramic Fiber Boards in Industrial Heat Treatment

Insulation Ceramic Fiber Boards are used in various industrial heat treatment applications, including:

Furnace Lining: ICFBs are often used as lining material in furnaces where precise temperature control is essential. Their high thermal resistance ensures that the heat is retained within the furnace, improving efficiency and product quality.
Kilns and Ovens: In kilns and industrial ovens used for processes like sintering, annealing, and drying, ICFBs provide the necessary insulation to maintain consistent internal temperatures, which is crucial for the integrity of the final product.
Heat Shields: ICFBs are used as heat shields in areas where protection from intense heat is required. This application is particularly important in environments where equipment or personnel could be exposed to high temperatures.
Casting and Molding: In casting and molding processes, maintaining the right temperature is key to ensuring the proper formation of the material. ICFBs provide the necessary insulation to keep molds and casts at optimal temperatures throughout the process.

Rongsheng Insulation Ceramic Fiber Boards for Sale

In conclusion, Insulation Ceramic Fiber Boards play a vital role in enhancing Thermal Resistance in Industrial Heat Treatment. Their unique properties, including high thermal resistance, durability, and energy efficiency, make them an indispensable component in modern industrial processes. By integrating ICFBs into heat treatment systems, industries can achieve more consistent temperatures, reduce energy consumption, protect equipment, and improve overall safety. As industrial processes continue to evolve, the use of advanced insulation materials like ICFBs will remain critical in driving efficiency and quality in heat treatment applications.

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Jul 18 2024

Low Cement Silicon Carbide Castable – High Spalling Resistance

Low cement castables are prone to bursting, peeling, lining peeling, and cracking during baking after demoulding and intermittent frequent furnace shutdown and opening, which affects the service life of low cement castables. Therefore, improving and enhancing the explosion-proof performance and thermal shock stability of low cement castables is of great help to the application of low cement castables. Low cement silicon carbide castables – high anti-stripping performance. Adding silicon carbide to low cement castables can improve the anti-stripping performance.

How to Improve the Explosion-Proof Performance of Low-Cement Castables?

In order to improve the explosion-proof performance of low-cement castables, we can add explosion-proof fibers to low-cement castables. When heated and baked after demoulding, the explosion-proof fibers in the explosion-proof low-cement castable shrink, melt, and form elongated pores in the castable. The number of open exhaust holes inside the castable is increased, and the air permeability of the castable is improved. This accelerates the discharge of water vapor, thereby improving the anti-burst performance of the castable and improving the explosion-proof performance of the castable.

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How to Improve the Spalling Resistance of Low Cement Castables?

In order to improve the spalling resistance of low cement castables, we can add a certain amount of silicon carbide to low cement castables. This can significantly improve the thermal shock stability of low cement castables in the face of rapid cooling and heating. Due to the high thermal conductivity of silicon carbide, the amount of silicon carbide added must be strictly controlled. When too much silicon carbide is added, the overall thermal expansion coefficient of the low cement castable will increase, which is not conducive to the thermal shock stability of the low cement castable. LOW CEMENT SILICON CARBIDE CASTABLE AL2O3 48%.SIC 30%. During construction, the amount of silicon carbide added needs to be strictly controlled. Reduce the thermal stress caused by the high thermal conductivity of silicon carbide on the low cement castable, so that the low cement castable has good thermal shock stability when subjected to thermal shock. Low cement silicon carbide castable-high spalling resistance.

Characteristics and Application of Low Cement Castables

Low cement castables, as the name implies, are castables with low cement content. Low cement dosage means low calcium content. Low calcium content means low pores and stronger corrosion resistance.

Low cement castables are divided into aluminum silicate, mullite, corundum, magnesium aluminum, quartz, carbon-containing and silicon carbide low cement castables. Low cement castables of different materials have different uses. Silicon carbide low cement castables are divided into furnace iron ditch castables and steelmaking ladle castables.

The most common low cement castable is aluminum silicate, that is, high aluminum low cement castable. The cement content of high aluminum low cement castable is between 3% and 6%. If the cement addition is 1%, it is an ultra-low cement castable. There is also cement-free castable.

Clay and high-alumina low-cement castables are mostly used in heating furnaces and soaking furnaces, and are also used in some parts of the lining of heat treatment furnaces and rotary kilns for building materials. Low-cement castables can also be used in high-temperature burner linings, heating furnace water cooling pipe wrapping linings, blast furnace tapping channels, cupola tapping troughs, integral powder spray guns for molten iron pretreatment, and other linings.

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Corundum and chromium-containing corundum low-cement castables are used for linings of certain parts of steel refining devices outside the furnace. They are also used for the lining of power frequency induction furnaces, high-temperature wear-resistant linings of petrochemical catalytic cracking reactors, etc.

Low-cement castables are also constantly updated by manufacturers to meet the actual needs of different furnace conditions. At present, many manufacturers use micro-powder and ultra-micro-powder technology. The result of cement combination and micro-powder technology is high strength. During use, as the heating temperature increases, the strength gradually increases.

It should be noted that the air permeability of low-cement castables is poor, and it is easy to cause peeling or cracking during baking. A reasonable baking system should be formulated according to its material, construction thickness and construction location. At the same time, metal aluminum powder, organic fiber, etc. can also be added to the castable. Make it easier to discharge moisture. Increase the service life of low-cement refractory castables.

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Improve the Fluidity of Low-Cement Castables

Low-cement castables are mainly divided into vibration type and self-flowing type. The ingredients of vibration type low-cement castables are 60%~70% refractory aggregate, 18%~22% refractory powder, 3%~7% calcium aluminate cement, and 3%~6% silica powder. The ingredients of self-flowing low-cement castables are similar to the former, but the difference is reflected in the particle size and micro-powder content. Generally speaking, too much micro-material will affect the physical properties of the castable, and the micro-powder content is suitable at 5%~6%.

SiC low-cement castable is a type of refractory castable with SiC as the main raw material and calcium aluminate cement as the binder. In low-cement castables, SiC can form a silicon oxide protective film on the surface in air with high oxygen partial pressure, with excellent performance and can be used as high-temperature structural materials. However, carbon-containing refractory materials used below 1550℃ use the characteristics of silicon carbide that is continuously oxidized under low oxygen partial pressure.

However, there are also the following problems in the production of low-cement castables containing silicon carbide.

Hydrophobicity. Silicon carbide in the castable will affect the fluidity and construction performance of the castable and reduce the density.
Difficult to sinter. When using silicon carbide with higher purity, it is difficult to sinter because silicon carbide is difficult to sinter. Therefore, it is not easy to obtain high strength.

Since the hydrophobicity of silicon carbide will have an adverse effect on fluidity, in order to improve the fluidity of refractory castables, it is necessary to select raw materials with little effect on fluidity for production. For example, by changing the shape of raw material particles and adjusting the type of water reducer, the fluidity of low-cement castables can be effectively improved.

To purchase high-quality low-cement refractory castables, please choose a powerful refractory manufacturer. Rongsheng Refractory Factory is a powerful refractory manufacturer. LOW CEMENT SILICON CARBIDE CASTABLE AL2O3 48%.SIC 30%. RS factory’s environmentally friendly, fully automatic monolithic refractory production line specializes in providing monolithic refractory services for high-temperature industrial furnaces. Customized lining materials. Contact us for free refractory lining solutions and quotes.

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Jul 4 2024

Refractory Brick Precast Blocks – Castable Precast Bricks

Refractory brick precast blocks are carefully prepared from refractory aggregates, powders, binders, additives, water, or other liquids, and are cast into unshaped refractory materials with a fixed shape. Monolithic vault for the furnace. According to the binding agent, it is divided into refractory cement bonding, phosphate bonding, water glass bonding, cementless bonding, etc. According to the material, it can be divided into high alumina, corundum, clay, mullite, etc.

Castable precast bricks can be prefabricated into various shapes, also called castable refractory precast shapes. Good thermal shock stability, high strength and good peeling resistance. No seams, good air tightness, less heat loss and energy saving. It can quickly repair the kiln and improve the furnace operation rate. It can realize direct hoisting and mechanized furnace construction, and the construction efficiency is high. Using Monolithic vault for the furnace can solve some technical problems in the furnace-building process for users. Rongsheng refractory material manufacturer can consider lining design and various construction plans for users according to their requirements and furnace type conditions.

Precast Shapes with Refractory Anchor Bricks

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Rongsheng Refractory Brick Precast Block Manufacturer

Rongsheng company has complete products and timely delivery. After-sales service is guaranteed. Castable refractory precast parts are gradually replacing the functions of refractory bricks with their irreplaceable advantages. Under the contemporary green environmental protection initiative, the production technology of refractory bricks is facing severe constraints of low-carbon environment. While the firing process is being updated and improved step by step from raw coal to coal-based gas, and then to natural gas, refractory materials are moving towards burning-free, lightweight, and high-usage production technology. As refractory products serve as high-temperature-resistant lining products in high-temperature industries, they serve the high-temperature parts of kiln linings such as steel, chemical industry, and thermal power. Therefore, continuous improvement and research and development are carried out to cope with the harsh working environment conditions of large furnace linings. This in turn increases the service life of the furnace lining. Its biggest advantage is that it can be pre-baked and directly hoisted, so the construction period is greatly shortened and the quality is stable. In recent years, the proportion of refractory brick precast shapes parts used in some special kiln parts is increasing. Monolithic vault for the furnace. Refractory brick precast parts are divided into small pieces in advance to be constructed in high-temperature kilns, and a special shape is designed. A mold is made according to the shape. The refractory castables and other materials are pre-cast, cured, and baked in the factory before being shipped to the factory. Use after hanging and assembling on site.

The baking of existing refractory brick prefabricated blocks generally adopts a temperature control method. During baking, several temperature measurement points are arranged in the drying kiln and a baking curve is preset. The baking curve includes multiple heating sections and holding sections. By monitoring the temperature of the temperature measurement point, the baking system is carried out according to the preset baking curve. This control method is simple and easy to implement, and is currently the main control method for baking refractory precast parts and even other materials. Refractory brick precast parts are prone to bursting during the baking process. It manifests as the castable suddenly and violently peeling off from its structural surface or exploding into several fragments. Higher or faster baking temperatures cause preforms to burst. In addition to the normal discharge of moisture during baking, due to the higher or faster baking temperature, a negative effect occurs, that is, excessive water vapor pressure causes the preform to burst.

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Burn-free Refractory Castable Precast Bricks

The compressive strength of unfired precast refractory bricks after demoulding can reach 55MPa. This is equivalent to the compressive strength of sintered high alumina bricks, which also has a certain degree of elasticity and toughness. The refractory resistance is the same as that of sintered refractory bricks, which can reach 1750°C, and can resist certain corrosion and penetration.

Refractory brick precast blocks can be used directly depending on the material. The creep performance changes as the furnace temperature increases to achieve a tighter use effect. Monolithic vault for the furnace. Castable precast blocks are divided into aluminate cement, water glass, aluminum phosphate, clay bonded and low cement precast blocks according to the binder. According to weight, they are divided into large, medium and small precast blocks. Precast shapes blocks are equipped with steel bars and anchors, so they are divided into ordinary precast shapes blocks, steel bar precast blocks and anchor precast blocks.

Differences between Castable Precast Block Furnace Cover and Refractory Bricks Furnace Cover

The traditional smelting electric furnace cover is made of about 30 kinds of special-shaped bricks and about 2,900 electric furnace top refractory bricks. The construction method using refractory bricks has the disadvantages of high construction difficulty, long construction period, serious deformation, poor thermal stability, and high energy consumption. The traditional high-alumina bricks for electric furnace lids can no longer meet the production application of high-power and ultra-high-power electric furnaces, and have become a “bottleneck” restricting production. Nowadays, cast-type electric furnaces cover precast bricks with high density, strong thermal shock resistance and good corrosion resistance are used as the main raw material. According to the size, thickness and shape of each electric furnace cover, high-aluminum castables are used for the furnace cover. After pouring, curing and baking, they are transported to the site for direct installation and use. Practice has proved that this kind of precast block shape made of refractory castables according to the overall size and shape of the furnace cover is not only easy to install, but also has good integrity, fast and efficient.

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Thermal Stress Distribution of Precast Furnace Cover Block

In the electric furnace production process, the period from the start of power supply to the time when all the charge is melted is called the melting period. During the melting period, more than 3/4 of the charge is melted, and the heat in the furnace can no longer be shielded by the charge. At this time, the arc high-temperature areas in the furnace have been connected into one piece, and the furnace cover is completely exposed to the hot molten metal and is subject to the greatest thermal shock. Most of the damage to the furnace cover and furnace walls occurs at this stage.

There is no direct contact between the furnace cover and the molten metal. At the end of the melting stage, the heat generated by the molten metal is transferred to the inner wall of the furnace lid through radiation. The outer wall is exposed to the air and transfers heat mainly through natural convection heat exchange with the air. Therefore, the thermal analysis temperature load and boundary conditions of the furnace cover mainly involve thermal radiation and convection heat transfer. During the analysis process, the thermal radiation effect on the inner wall of the furnace lid is equivalent to a temperature load of 1750°C, which is applied to the entire inner wall of the furnace lid. For the natural convection between the furnace cover and the air, the temperature of the air is taken to be 25°C, and the convection heat transfer coefficient with the air is set according to the value of l0-3/(ts K). Finally, it can be seen from the thermal analyzer that the temperatures of the refractory brick electric furnace cover and the castable precast electric furnace cover are equivalent. The temperature field changes of the electric furnace cover made of refractory bricks and precast blocks of cast furnace cover are smaller. And the highest temperature is distributed in the part of the inner wall of the furnace cover that is close to the molten metal, and the lowest temperature is distributed in the part where the central cover and the air convection heat exchange.

It can be seen from the thermal analyzer that the maximum thermal stress of the furnace cover is distributed in the center area of the vertical line with the molten metal, at the edge of the wall or the inner wall of the feeding hole, and at the bottom edge of the furnace cover. The minimum stress is distributed on the top of the center cover, and its average thermal stress pressure is about 3.5MPa. Far lower than AL2O3, the material’s yield stress meets the usage requirements. Therefore, the solution of using castable precast block furnace cover is feasible, and can greatly save installation time and reduce labor intensity.

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Conclusion on the Use of Precast Shapes Blocks for Furnace Cover

(1) There is little difference in the thermal stress level when using castable precast block furnace cover and refractory brick masonry furnace cover. But the former saves costs and has high installation efficiency.
(2) There are several points that need to be paid attention to when making furnace covers made of castable precast blocks. In the current experiment, high-aluminum castables of the same material as high-alumina bricks were used. However, during use, it was found that the furnace cover made of high-aluminum castables is relatively deficient in resistance to corrosion by molten metal and slag splash, thermal shock stability of the furnace cover, and resistance to corrosion by CO in the flue gas.
(3) The use of castable precast shapes furnace covers in electric furnace production fully demonstrates that under the same thermal stress distribution, the cost of use is lower than that of high alumina bricks. And in future development and applications, high-grade material castables can be used to make electric furnace cover bricks.

Rongsheng Refractory Materials is a refractory material manufacturer with rich production and sales experience. Our refractory products have been sold to more than 100 countries and regions around the world. In the production and use of unshaped refractory castables, we can customize lining material formulas for high-temperature industrial furnaces to effectively solve the problems of refractory linings. At the same time, our refractory precast shapes products also have many customer cases. Contact us to get a free quote and solution for Monolithic vault for the furnace.

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Jun 27 2024

Water Glass Combined Magnesium Monolithic Refractory Materials

In the refractory industry, water glass is mainly used to build fire mortar for magnesia refractory materials or medium and low-grade aluminum-silica refractory materials. Among them, the method of making magnesium iron refractory mortar for magnesia refractories is as follows.

Magnesium Iron Refractory Mortar for Magnesia Refractories

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Raw materials. Magnesia fines <1mm; 15%~20% magnesia fine powder remaining after 0.088mm sieve. <1mm iron ore or iron scale. Iron scale is the skin peeled off from rolling steel billet, so it is named because it resembles scales. Water glass with SiO2/Na2O molar ratio 2.2~2.9 and relative density 1.41~1.44.
Proportion. Magnesia fines: Magnesia fines: Iron ore fines = 1:1:1. Dilute the water glass to a relative density of 1.30~1.32. The dosage accounts for about 25% to 30% of the dry ingredients.
The mixed cement should have a masonry time of 30 minutes and a hardening time of 4 to 8 hours. Compressive strength of 5~10MPa after drying.
The hardening of cement is affected by temperature. If it hardens too quickly, water glass can be diluted. If the hardening is too slow, 0.5% ordinary cement can be used to accelerate hardening.
If the adhesiveness of the mortar is not strong, you can increase the proportion of fine powder as appropriate. If the refractory mortar joints are very wide, the amount or particle size of magnesia fine particles can be increased.
The refractory mortar can be used as needed. Do not mix too much at one time. The newly solidified cement can be diluted with water glass, or it can be poured back immediately and mixed with new materials before use.

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Characteristics of Magnesia Mortar

As we all know, refractory mortar is an accessory product used in building refractory bricks and furnace walls. It mainly includes four types: fireclay refractory mortar, high alumina refractory mortar, silica refractory mud, and magnesia refractory mortar. There is no doubt that magnesia mortar inherits the advantages and disadvantages of magnesia refractory materials and is used to build magnesia refractory bricks.

Advantages and Disadvantages of Magnesium Refractories

The melting point of MgO is as high as 2800°C, and the refractoriness of magnesia bricks is generally very high, up to more than 2000°C. Therefore, magnesia bricks have good high-temperature resistance, good stability in high-temperature vacuum, and strong resistance to alkaline slag. However, magnesia bricks have poor resistance to sulfate erosion, poor thermal shock stability, and are prone to hydration. In addition to traditional magnesia bricks, magnesia refractory materials also include forsterite refractory materials, magnesia-aluminum spinel refractory materials, magnesia-chromium refractory materials, white jade refractory materials, etc.

Advantages of Magnesia Mortar

Good plasticity and convenient construction.
High bonding strength and strong corrosion resistance.
High refractoriness, up to 1650℃±50℃.
Good resistance to slag invasion.
Good thermal peelability.

Disadvantages of Magnesia Mortar

Because magnesia refractory materials are easy to hydrate. At present, most of them have switched to the dry laying method to build magnesia refractory materials. However, for irregular parts, it is still necessary to use magnesia refractory mortar to adjust joints and pad bricks to alleviate stress concentration and increase the service life of the kiln lining.

Applications of Magnesia Refractory Mortar

Magnesia refractory mud is mainly used as a mortar filler for magnesia bricks, magnesia-alumina bricks, magnesia-chrome bricks, and other magnesia refractory bricks, and as a protective coating for magnesia masonry.

Buy high-quality magnesia refractory materials, magnesia bricks, magnesia chrome bricks, directly bonded magnesia chrome bricks, magnesia mortar, magnesia castables, and other unshaped refractory materials. Please choose Rongsheng refractory manufacturer. Rongsheng Manufacturer is a powerful manufacturer and seller of refractory materials. Our refractory products have been sold to more than 100 countries and regions around the world. The product quality is reliable, the delivery speed is fast, the customer reputation is good, and the service is guaranteed. Contact us for a free quote and solution.

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Jun 20 2024

The Magnesium Oxide Content of Alkaline Refractory Bricks

Alkaline refractory bricks are a kind of refractory material mainly composed of magnesia raw materials. They have excellent slag erosion resistance, thermal shock resistance and high temperature structural stability. In industries such as metallurgy, building materials, and chemicals, alkaline refractory bricks are widely used in the lining of high-temperature equipment such as furnaces, cement rotary kilns, and glass kilns. Rongsheng Refractory Materials Manufacturer has summarized a variety of commonly used alkaline refractory bricks based on years of production and sales experience. So, do you know the magnesium oxide content of alkaline refractory bricks?

Magnesite Bricks from Rongsheng Manufacturer

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Various Alkaline Refractory Bricks

Magnesia-Chrome Brick: Magnesia-Chrome Brick is an alkaline refractory brick made of magnesia and chromite as the main raw materials and sintered at high temperatures. Magnesia chrome bricks have the advantages of high melting point, high strength, and high resistance to slag erosion. Suitable for working conditions under high temperature, high pressure, and strong alkali environment.
Magnesia-alumina brick: Magnesia-alumina brick is an alkaline refractory brick made of magnesia and alumina as the main raw materials, adding an appropriate amount of additives, and sintering at high temperature. Magnesia-alumina bricks have good thermal shock resistance, slag erosion resistance, and high-temperature structural stability. Suitable for lining of high-temperature equipment such as cement rotary kilns and glass kilns.
Magnesia-calcium brick: Magnesia-calcium brick is an alkaline refractory brick made of magnesia and lime as the main raw materials, adding an appropriate amount of additives, and sintered at high temperature. Magnesia-calcium bricks have high thermal shock resistance and slag erosion resistance. Suitable for high-temperature equipment in steel, nonferrous metals and other industries.
Magnesia dolomite brick: Magnesia dolomite brick is an alkaline refractory brick made of magnesia and dolomite as the main raw materials, adding an appropriate amount of additives, and sintering at high temperature. Magnesium dolomite bricks have good thermal shock resistance, slag erosion resistance, and high-temperature structural stability. Suitable for lining of high-temperature equipment such as cement rotary kilns and glass kilns.

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Magnesium Content of Alkaline Refractory Bricks

Magnesia chrome bricks: The magnesium content of magnesia chrome bricks is generally between 60% and 80%, and the chromium content is between 20% and 40%. The magnesium content of magnesia-chrome bricks is high, which is beneficial to improving its resistance to slag erosion and high-temperature structural stability.
Magnesia-alumina bricks: The magnesium content of magnesia-alumina bricks is generally between 50% and 70%, and the aluminum content is between 20% and 40%. The magnesium content of magnesia-alumina bricks is moderate, which is beneficial to improving its thermal shock resistance and slag erosion resistance.
Magnesia-calcium bricks: The magnesium content of magnesia-calcium bricks is generally between 50% and 70%, and the calcium content is between 20% and 40%. The magnesium content of magnesia-calcium bricks is moderate, which is beneficial to improving its thermal shock resistance and slag erosion resistance.
Magnesium dolomite bricks: The magnesium content of magnesia dolomite bricks is generally between 50% and 70%, and the dolomite content is between 20% and 40%. The magnesium content of magnesia dolomite bricks is moderate, which is beneficial to improving its thermal shock resistance and slag erosion resistance.

Precautions

When selecting alkaline refractory bricks, the appropriate type and magnesium content should be selected based on specific working conditions and requirements.

When laying alkaline refractory bricks, attention should be paid to controlling the size of the brick joints, generally between 2-3mm. Excessive brick joints will lead to increased heat loss, while brick joints that are too small are not conducive to the expansion and contraction of the brick body.

During the masonry process, special anchors should be used to fix the refractory bricks on the base body to prevent the bricks from loosening and falling off. The selection and installation of anchors should comply with design requirements and construction specifications.

After the masonry is completed, the bricks should be trimmed and excess mortar should be removed to make the brick surface smooth and beautiful.

In short, alkaline refractory brick is a refractory material with excellent properties and is widely used in high-temperature equipment in metallurgy, building materials, chemical industry and other industries. When selecting and using alkaline refractory bricks, the appropriate type and magnesium content should be selected according to the specific working conditions and requirements to ensure the safe and stable operation of the equipment.

Rongsheng Checker Bricks for Glass Kilns — Rongsheng Checker Bricks

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Magnesite Checker Bricks for Glass Kiln

In the refractory industry, refractory bricks with MgO as the main component and periclase as the main crystal phase are collectively called alkaline refractory bricks. Alkaline refractory bricks are mainly used in thermal kilns used in cement, glass, ferroalloy and other industries.

In glass-melting furnaces, alkaline refractory bricks are mainly used as regenerator checker bricks. Its thermal conductivity is large, its service life is long, and its volume density is high, which increases the heat storage in the regenerator. The porosity of alkaline refractory bricks is low, and the thermal expansion coefficient increases linearly as the temperature rises. It is the largest among various refractory materials. Pay attention to leaving enough expansion joints during use.

Alkaline refractory bricks are non-insulators above 900°C and have very good electrical conductivity and cannot be used as high-temperature insulating materials.

Alkaline refractory bricks cannot be used in gas regenerators. And long-term contact with water vapor at 40~160℃ will cause hydration, which will cause the brick structure to become loose and damaged. So keep it dry during storage. Before laying the magnesite checkered bricks, the regenerator must be dried.

At present, including ordinary magnesia bricks, magnesia refractory materials also have the following types.

Ordinary magnesia bricks. It is made of sintered magnesite as raw material and sintered. The content of MgO is about 91%. It is a magnesium refractory product directly combined with silicate and is widely produced and used.
Directly bonded magnesia bricks. It is made of high-purity sintered magnesia as raw material and sintered. The content of MgO is more than 95%. It is a magnesia refractory product directly bonded between periclase grains.
Magnesia silica brick. It is made of high-silicon sintered magnesite as raw material and sintered. SiO2 content is 5%~11%, it is a magnesia refractory product combined with forsterite.
Forsterite Bricks. Forsterite refractory material is a refractory material with forsterite as the main crystal phase. It is mostly made of peridotite and pure peridotite as the main raw materials, and the formed products are called forsterite bricks.

Buy high-quality alkaline refractory bricks, magnesia bricks, magnesia checker bricks for glass kilns, metallurgical kilns, etc. Please choose Rongsheng refractory material manufacturer. Rongsheng manufacturer, product quality is reliable and delivery speed is guaranteed. Moreover, comprehensive customer service effectively guarantees the service life of the refractory furnace lining and saves production costs for customers.

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Apr 12 2024

Spraying Construction Method of Rongsheng High Temperature Refractory Coatings

Refractory spray paint is used to spray new linings and can also be used to repair furnace pipes. Spraying construction method of Rongsheng high-temp refractory coating. It is an effective unshaped refractory material that is easy to construct, extends the service life of the kiln, and reduces the consumption of refractory materials. The material composition of refractory spray paint is basically similar to that of refractory castables of the same type. The difference is that the critical particle size of refractory aggregate is smaller, generally 3~5mm, and is constructed using spraying methods. The dosage of refractory powder, ultrafine powder, and binder is relatively large, generally 35~45%.

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Spraying Process of Refractory Coating

Spraying is carried out using a spray machine or spray gun. The material obtains considerable speed with the help of compressed air and is sprayed onto the sprayed surface through the nozzle, forming a strong spray layer. The key technologies of refractory spray coatings are mainly adhesion, bonding, strength, and sintering. This is also the basic characteristic that the material should have, otherwise the service life of the spray coating will be reduced. These characteristics are not only related to the quality of the material itself, but also affected by the spraying equipment, construction technology, and the state of the sprayed body.

The particles of refractory spray paint cannot be larger than 5mm. Because when it is larger than 5mm, the spray gun will be blocked and normal construction will not be possible. During construction, the refractory spray coating is sprayed 40-50mm into the pipe, and the spray coating can be quickly formed. Generally speaking, the rebound rate of refractory spray coatings produced by refractory spray coating manufacturers is 10%.

In refractory spray coatings, medium and fine particles can greatly improve the adhesion rate, but will increase peeling during drying. Coarse particles can make the repair layer more stable, but too many coarse particles will lead to a high rebound rate and increase the amount of material used. Therefore, the particle gradation must be reasonable and cannot exceed 5mm. Because it exceeds 5mm, the spray gun cannot spray. Reasonable gradation can best improve the construction and use performance of spray coatings.

High-Temperature Refractory Coatings

Refractory spray coatings are divided into light spray coatings and heavy spray coatings. The materials selected according to different use environments include corundum, high alumina, mullite, clay, SiC, magnesium, etc. Mainly used in hot blast furnaces, heating furnaces soaking furnaces, blast furnaces, flues and chimneys, etc. However, lightweight refractory spray coatings are relatively more expensive than heavy refractory spray coatings.

The density of heavy refractory spray paint is generally 1.6-1.8g/cm3. However, there are different requirements in different furnace pipelines. Especially the sintering machine pipes must be made much better than other parts. In other words, this part needs to use refractory spray paint with a density of 2.2g/cm3. Of course, the price of refractory spray paint for sintering machines will be much higher than that of refractory spray paint for other parts.

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What is Refractory Coating?

(1) Heavy refractory spray paint

The bulk density of heavy refractory spray coatings is generally greater than 1.8g/cm3. Refractory aggregates and powders generally use aluminum silicate materials, with a critical particle size of 5 or 10 mm. Particle composition: 3~5mm is about 30%, 1~3mm is about 30%. Less than 1mm is about 40%. The binding agent is aluminate cement and water glass, plus additives. Generally, semi-dry method or false dry method is used for construction.

Main properties of heavy refractory castables. The medium temperature strength of CA-50 cement spray coating is reduced. However, water glass and phosphate spray coatings increase with the increase of heating temperature, and their bulk density is slightly lower than the same type of refractory castables produced by vibration molding.

In recent years, medium-heavy refractory spray coatings with a bulk density of 1.8~2.1g/cm3 have been developed. That is, on the basis of heavy materials, 3% to 6% expanded perlite or 5% to 20% porous light clinker is added. It is mainly used on the heat insulation layer of kilns and has good heat preservation effect.

(2)Lightweight refractory spray coating

There are many varieties of lightweight refractory spray coatings, mainly including clay, ceramsite, perlite and other refractory spray coatings. Lightweight refractory spray paint is mainly used for the thermal insulation layer of kilns, and can also be used for the working layer of tubular heating furnaces, flues and chimneys.

The critical particle size of refractory aggregate for lightweight refractory spray paint is 5mm. The particle gradation is: 3~5mm, about 19%~30%. 0.6~3mm is about 8%~14%. 0.088~0.60mm is about 30%~40%, and less than 0.088mm is about 25%~35%.

The main properties of lightweight refractory spray coatings. During the spraying construction process of refractory spray paint, the original particle gradation will be greatly changed due to the rebound and scattering of refractory aggregates and the splashing of refractory powder. Therefore, when the aggregate size requirements of the refractory spray coating are certain, in order to make the aggregate gradation of the actual spray coating meet the requirements, the original gradation before spraying must be adjusted to meet the requirements after spraying.

coating material — refractory spray coating

Spraying construction of Rongsheng Refractory Spray Coating

Before spraying paint, test spraying should be carried out in accordance with the construction instructions provided by the manufacturer for the brand of spray paint. To determine the appropriate parameters, such as wind pressure, water pressure, etc.

Several commonly used spray coatings

(1) When spraying clay materials at room temperature, the aggregate particle size should be below 3.5mm. When the spray paint lacks viscosity, 2% clay should be added to improve its construction performance.
(2) When spraying high-aluminum materials at room temperature, additives should be added to prevent falling and increase the density of reinforced metal parts.
(3) When lightweight insulation materials are used for spraying, lightweight aggregates with higher strength should be used, and appropriate amounts of asbestos and clay should be added. Aggregates with low strength, brittle under pressure and friction, or elastic aggregates are not suitable for spraying. The volume density of lightweight thermal insulation spray paint should be between 0.7~1.3t/m3.

Reinforcement metal parts

Spraying construction must be reinforced with metal supports. Metal supports should have the characteristics of simple shape, small size, and reliable performance. Generally, it should be made of round steel.

When the thickness of the spray coating is 35~75mm, metal mesh should be used for reinforcement. The diameter of the metal mesh is Φ3.2~4.2mm, and the mesh size should be 1.5 times the thickness of the spray coating. And it is fixed on the furnace wall by welding, binding, and crimping.

When the spray thickness is more than 100mm, round steel of 4~8mm should be used to make V-shaped or Y-shaped metal parts and welded to the furnace shell.

The installation distance of metal parts: the side wall part should be 3 times the thickness of the spray coating, and the top part should be 1.5~1.8 times the thickness of the spray coating. The distance from the front end of the metal anchor to the surface of the spray coating should be 50mm for the side wall and 25~30mm for the ceiling.

Process inspection before spraying

The following process inspections should be carried out before spraying refractory spray paint:

(1) Before spraying, the installation position, spacing size, and welding quality of the metal supports should be checked and cleaned.
(2) When there is a fixed steel wire mesh on the support frame, check whether the anchoring quality of the steel wire mesh meets the requirements. The upper, lower, left, and right sides of the steel wire should overlap one grid. The overlap shall not exceed three layers and the fasteners shall be oriented toward the non-working layer.
(3) Check the sprayed surface. There should be no floating rust, dust accumulation, oil stains, or water immersion on the sprayed surface.

Spraying operations and adjustments

Refractory spray paint is sprayed onto the sprayed surface with a spray gun. Materials constructed by spraying are called refractory spray paint. Spraying is carried out using spray machines and spray guns. The refractory spray paint uses compressed air or mechanical pressure in the pipeline to obtain sufficient pressure and flow rate. Spray onto the sprayed surface through the nozzle to form a solid spray layer.

The spraying methods of refractory spray coatings are divided into three categories: wet method, dry method, and flame method. When constructing refractory spray coatings, appropriate construction plans for high-temperature coatings and refractory coatings can be specified based on actual working conditions. To extend the service life of the kiln lining.

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Mar 8 2024

How to Choose Honeycomb Ceramic Regenerator?

In recent years, honeycomb regenerative furnaces have developed very rapidly. Since the regenerator can be miniaturized and integrated with the burner, and each burner maintains its independence, it becomes a regenerative burner. It truly achieves extreme waste heat recovery and ultra-low NOX emissions. The energy-saving effect brought by regenerative combustion technology is very obvious. It can absorb the heat of high-temperature flue gas to the maximum extent and avoid heat waste. Honeycomb ceramic regenerator is the key and core component of regenerative high-temperature combustion technology.

RS Honeycomb Ceramic Regenerator for Sale

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How to Choose the Honeycomb Ceramic Regenerator?

The selection of a honeycomb ceramic regenerator is very critical. Improper selection will cause blockage, burning, collapse, and other phenomena during use, causing the furnace temperature to rise slowly, failing to reach the temperature, and in serious cases causing furnace shutdown accidents. It affects production and increases gas consumption.

Therefore, when selecting a honeycomb body, in addition to considering the rapid cooling and rapid heating resistance of the honeycomb ceramic regenerator, load softening temperature, compressive strength, thermal expansion coefficient thermal shock resistance, and other indicators. The heat release characteristics of the honeycomb ceramic regenerator also need to be considered. It is necessary to select a honeycomb ceramic regenerator made of materials with a large specific surface area, large blackness, large heat capacity, and fast thermal conductivity. In this way, the honeycomb ceramic heat storage body absorbs and releases heat faster and more, and can effectively absorb the heat of the flue gas. Significantly increase the preheating temperature of gas and air, increase the combustion temperature of the heating furnace, and achieve the purpose of reducing gas consumption.

Silicon Carbide Honeycomb Ceramic Regenerator

The silicon carbide honeycomb ceramic regenerator is an improvement based on the formula of the corundum-mullite honeycomb ceramic regenerator. A certain amount of high-purity silicon carbide is added to improve the performance of the original honeycomb ceramic regenerator. Silicon carbide honeycomb ceramic regenerator combines the advantages of silicon carbide, zirconium chromium corundum, and other materials. It has the characteristics of good antioxidant, slag resistance, high-temperature resistance, high blackness, and fast thermal conductivity. Its high-temperature strength can be maintained up to 1600°C, making it the material with the best high-temperature strength among ceramic materials. Due to its fast thermal conductivity and high blackness, it has better energy-saving properties than a corundum-mullite honeycomb ceramic regenerator. According to relevant customer usage statistics, the use of silicon carbide honeycomb ceramic regenerators can significantly reduce the exhaust temperature of exhaust gas and reduce gas energy consumption by more than 5-10% compared with other honeycomb ceramic regenerators. Silicon carbide honeycomb ceramic regenerator is mainly used as the heat exchange medium for high-temperature regenerative industrial kilns above 1250°C.

Large Holes Honeycomb Ceramic Regenerator

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Large Holes and Big Eyes Honeycomb Ceramic Regenerator

The hole shapes of honeycomb ceramic regenerators often include square holes, round holes, hexagonal holes, etc., and the hole spacing is usually between 3-6mm. Among them, the hexagonal hole surface layout is more uniform and the structure is more stable. It is currently the most commonly used hole type. In addition to matching the medium pressure, flow rate, burner combustion capacity, and other factors, the selection of hole type and aperture should also pay attention to the actual medium quality conditions. For exhaust gas with high dust content, the hole diameter and wall thickness should be appropriately increased. Choose a honeycomb ceramic regenerator with large holes and large eyes to reduce the clogging and corrosion hazards caused to the honeycomb ceramic regenerator.

The honeycomb ceramic regenerator with large holes and large eyes is mainly used to deal with the harsh working environment of some industrial furnaces and the high dust content in the flue gas. During use, the small holes of the honeycomb ceramic regenerator often become blocked. After the small holes of the honeycomb ceramic regenerator are blocked, not only will its heat storage and smoke exhaust performance be significantly reduced. It also causes smoke exhaust and uneven heating of the honeycomb ceramic heat storage body, which is prone to cracks and aggravates its damage. In regenerative industrial furnaces with harsh working environments and high dust content in flue gas, the use of honeycomb ceramic regenerators with large holes and large eyes can effectively avoid clogging the small holes of conventional honeycomb ceramic regenerators.

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RTO Incinerator Honeycomb Ceramic Regenerator

The honeycomb ceramic regenerator of the RTO incinerator has the characteristics of high softening temperature under load, small expansion coefficient, strong resistance to rapid cooling and rapid heating, and long service life. The basic principle of an RTO incinerator is to oxidize organic waste gas at high temperatures (>760℃) to generate CO2 and H2O. The use of honeycomb ceramic regenerators can maximize the recovery and reuse of heat energy, with a heat recovery rate greater than 95%. The geometric characteristics of the RTO honeycomb ceramic regenerator are generally made into columnar regenerators with dimensions of 150mm×150mm×150mm and 150mm×150mm×300mm and are integrated into the RTO regenerator. The number of holes in the cross-section of a piece of packing that airflow passes through is called the hole density, also expressed by the number of holes per square inch (CSI). Usually from 13×13 (number of holes 169) to 60×60 (number of holes 3600).

The greater the hole density, the larger the surface area per unit volume, which can provide a larger heat transfer area and thereby improve the heat transfer efficiency. The organic waste gas is heated to above 760°C, causing the VOC in the waste gas to oxidize and decompose into carbon dioxide and water. The high-temperature gas generated by oxidation flows through the special ceramic heat storage body, causing the ceramic body to heat up and “storage heat”. This “heat storage” is used to preheat the subsequent incoming organic waste gas. This saves fuel consumption for exhaust gas heating.

The honeycomb ceramic regenerator of the RTO incinerator should be divided into two or more zones or chambers. Each regenerator goes through the procedures of “heat storage-heat release-cleaning” in turn, starting over and over again and working continuously. After the regenerator “releases heat”, part of the clean exhaust gas that has been processed should be introduced immediately, and the regenerator should be cleaned to ensure that the VOC removal rate is above 95%. Only after cleaning is completed can the “heat storage” program be entered.

Honeycomb Ceramic Regenerator from Rongsheng

Corundum Mullite Cordierite Honeycomb Ceramics

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Honeycomb ceramic regenerator is the key material of regenerative industrial kilns, and it is the heat exchange medium of regenerative industrial kilns. The honeycomb ceramic regenerator absorbs and stores the heat from the waste gas in the industrial kiln, and then uses the stored heat to heat the air and fuel. This not only increases the calorific value of the fuel, lowers the emission temperature of exhaust gas, and saves energy, but also reduces the emissions of CO2 and NOX, which is helpful for environmental protection. The cross-sectional holes of honeycomb ceramic regenerators mainly have square, regular hexagonal, and circular three-hole structures. Moreover, the pores are straight channel structures that are parallel to each other. This structure greatly reduces the resistance of the pores to flow through and greatly improves the single-hole volume heat transfer efficiency of the honeycomb ceramic regenerator. The main materials of the honeycomb ceramic regenerator of the RTO incinerator are dense cordierite, high alumina, corundum mullite, chromium corundum, zirconium corundum, silicon carbide, etc. Contact us for a free quote.

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Yearly Archives: 2024

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What is Castable Gunmix?

The Role of Castable Gunmix in Furnace Patching

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The Maintenance Benefits of Using Castable Gunmix

Importance of Furnace Maintenance

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Understanding Ceramic Fiber Boards

The Role of Ceramic Fiber Boards in High-Temperature Applications

Energy Efficiency

Thermal Stability

Resistance to Thermal Shock

Lightweight and Easy Installation

Versatility in Application

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Enhancing Energy Efficiency with Insulation Ceramic Fiber Boards

Reduced Heat Loss

Improved Process Control

Extended Equipment Lifespan

Environmental Impact

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Selecting the Right Insulation Ceramic Fiber Boards

Temperature Rating

Density

Chemical Compatibility

Installation Requirements

Exceptional Thermal Insulation of Ceramic Fiber Boards

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Understanding Cupola Furnace Lining

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What is Castable Gunmix?

Benefits of Using Castable Gunmix for Cupola Furnace Lining

Enhanced Durability and Longevity

Improved Heat Retention and Efficiency

Ease of Application

Versatility in Application

Cost-Effectiveness

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Key Considerations for Optimizing Cupola Furnace Lining with Castable Gunmix

Material Selection

Proper Application

Regular Maintenance

Environmental Considerations

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Optimizing the Lining of a Cupola Furnace

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Understanding the Role of Thermal Resistance in Industrial Heat Treatment

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The Unique Properties of Insulation Ceramic Fiber Boards

The Role of Insulation Ceramic Fiber Boards in Enhancing Thermal Resistance

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Applications of Insulation Ceramic Fiber Boards in Industrial Heat Treatment

Rongsheng Insulation Ceramic Fiber Boards for Sale

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How to Improve the Explosion-Proof Performance of Low-Cement Castables?

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How to Improve the Spalling Resistance of Low Cement Castables?

Characteristics and Application of Low Cement Castables

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Improve the Fluidity of Low-Cement Castables

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Rongsheng Refractory Brick Precast Block Manufacturer

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Burn-free Refractory Castable Precast Bricks

Differences between Castable Precast Block Furnace Cover and Refractory Bricks Furnace Cover

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Thermal Stress Distribution of Precast Furnace Cover Block

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Conclusion on the Use of Precast Shapes Blocks for Furnace Cover

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Characteristics of Magnesia Mortar

Advantages and Disadvantages of Magnesium Refractories

Advantages of Magnesia Mortar

Disadvantages of Magnesia Mortar