2024 - RS Kiln Refractory Bricks

Application of magnesia-alumina spinel bricks in cement kilns. At present, the chromium-free measures taken by the new dry process cement kiln are mainly to replace magnesia-chrome bricks with magnesia-dolomite bricks, magnesia-alumina spinel bricks, and magnesia-iron-alumina spinel bricks (referred to as magnesia-iron bricks). Its kiln lining performance is very outstanding, and it is the best material to replace magnesia-chrome bricks in domestic cement kilns.

Rongsheng Magnesia Aluminum Spinel Bricks for Cement Kilns

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The magnesia-alumina spinel bricks produced by introducing ferroalumina spinel into magnesia refractory materials provide a new lining concept for cement rotary kilns. Its good structural flexibility and excellent kiln lining performance provide it with high adaptability. In recent years, magnesia-alumina spinel bricks have been fully used in the high-temperature zone of cement rotary kilns. Rongsheng refractory manufacturer can provide high-quality magnesia refractory brick products for cement kilns, including magnesia-dolomite bricks, magnesia-alumina spinel bricks, and magnesia-alumina spinel bricks. Contact Rongsheng for a free quote.

Material Properties of Magnesia-Alumina Spinel

Magnesia-alumina spinel is one of the most important refractory materials in the steel and cement industries. It has gradually replaced chromium spinel and is also a popular refractory material in the above fields. However, magnesium-chromium alloys and Al2O3-chromium alloys are gradually decreasing due to the environmental hazards of hexavalent chromium. Magnesium-alumina spinel has excellent refractory properties such as high refractoriness, moderate thermal expansion, thermal shock stability and resistance to slag erosion.

The densification of spinel by primary firing requires very high temperatures (>1700℃) because the oxide composition is accompanied by a 7% volume expansion during the spinel formation process. On the other hand, the expansion during the spinel formation process is beneficial for Al2O3-MgO-C (AMC) bricks. Because the expansion during the in-situ spinel formation process minimizes the gaps between bricks and prevents metal infiltration.

The formation and sintering of spinel have been studied by different researchers by changing the raw materials and processing steps. Mansour et al. pointed out that the most spinel is formed when the calcination temperature of raw materials MgCO3 and Al(OH)3 is 900℃ and 1100℃ respectively. Gray believes that hydroxide contributes to the formation of spinel and the densification of magnesium-aluminum spinel. Kostic et al. found that fine grinding of raw materials will increase its specific surface area and increase its structural defects, which will lead to the formation of low-temperature spinel.

Magnesia-Rich Magnesia-Alumina Spinel

Magnesia-rich magnesia-alumina spinel is mainly used in cement kilns because of its compatibility with the products of cement formation process. Compactness of MgO-rich magnesia-aluminum spinel. Alper in the study of MgO-Al2O3 binary system showed that the solubility of MgO in the spinel phase was 39%. Bailey et al. found that the presence of excess MgO in the spinel phase would restrict the growth of spinel grains and promote sintering. Cooper et al. found that 40% MgO in magnesia spinel bricks would improve its thermal and corrosion properties. India has a large reserve of magnesia ore, which contains impurities such as CaO, SiO2 and Fe2O3 that limit its application at high temperatures. In the present study, natural magnesia ore has harmful impurities SiO2 and CaO. As a magnesia-rich magnesia-alumina spinel aggregate, it was developed and compared with the aggregate prepared by synthetic calcined magnesia.

Dense Magnesium Aluminate Spinel

Through various experiments, researchers have a unique understanding of dense magnesium aluminate spinel bricks.

1) The density of sintered spinel generated by Salem magnesite (SS) increases sharply between 1400℃ and 1500℃, followed by a slight decrease at higher temperatures due to liquid phase sintering. The spinel generated by caustic magnesia (NS) densifies slowly below 1500℃, followed by an improvement in density at 1600℃. The NS sample is densified by solid phase sintering.

2) X-ray diffraction analysis of the SS sample sintered at 1600℃ shows that spinel and periclase are the main phases, and forsterite is the secondary phase. This is because SiO2 exists in natural magnesite, while the NS sample only contains periclase and spinel phases.

3) As the temperature increases from 1500℃ to 1600℃, the flexural strength of the NS sample increases due to its more compactness. However, compared with the SS sample sintered at 1500℃, the flexural strength of the SS sample sintered at 1600℃ is lower, which is due to the presence of the low melting point phase and the uneven particle size distribution.

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Blog Ceramics Refractories

Nov 1 2024

How to Choose Cordierite Slab as Baking Board?

Because of its low price and strong thermal stability, cordierite baking slabs have shown explosive growth in recent years, defeating competitors such as ceramic slabs and volcanic slabs, and becoming the first choice for home and commercial pizza and bread baking.

“Slate” is passed on by word of mouth among baking enthusiasts, but most people don’t know how to distinguish it. Some are much cheaper, but they are quite heavy to pick up, and you think the quality is good. In fact, as long as you look at the appearance carefully, you can see a lot of differences.

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How do you Identify High-Quality Cordierite Baked Slabs?

There are certain processes in the manufacture of cordierite slabs, from raw material processing and mixing to pressing, drying, firing, and later grinding packaging, and other processing. The differences in processing in these aspects by different manufacturers determine the different costs. RS manufacturers provide high-quality cordierite slabs for wholesale sales. The price is fair.

Differences in raw material quality and mix ratio

The main raw material content of cordierite slabs is of course cordierite, and some clay mineral soils are also mixed to form and improve properties. Cordierite with a very low thermal expansion coefficient plays a vital role in the thermal stability of the slab. Therefore, the quality and amount of cordierite largely determine the refractoriness of the slab.

The raw material cordierite needs to be sintered. The higher the sintering temperature, the higher the cost, and it will look whiter after firing.

After mixing with other materials (usually colorants are added), pressing and sintering, the color of cordierite can no longer be distinguished. Moreover, the impact on refractoriness is not as obvious as reducing the content of cordierite. Simply put, the addition of additives will not directly affect the refractoriness of cordierite slabs.

Generally, the temperature used by home users is limited and the frequency of use is not high. Therefore, some manufacturers will reduce costs by reducing the amount of relatively expensive cordierite. This will directly lead to a decrease in refractoriness, easy cracking during rapid cooling and heating, and faster aging of the slab.

Raw material processing process

Before mixing various raw materials, some processing is required. For example, one step that has a greater impact on the appearance of the finished product is to remove the larger iron impurities in the raw materials. Because iron impurities have a greater impact on the appearance of the finished product, it is difficult to completely remove them using a simple process, and generally the larger particles are isolated.

Since iron impurities are difficult to completely remove, even if the surface of the product is relatively clean after iron removal, it is inevitable that there will be some black spots after high-temperature firing. Therefore, some manufacturers will skip the iron removal process to save some time and labor costs. However, if large iron impurities are not removed, dense iron particles will appear on the surface of the product after firing.

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Firing temperature and firing time

Firing is a very important process in the manufacture of stone slabs, which has a great impact on the quality of the product. Sufficient firing time and appropriate firing temperature (generally 1200 degrees Celsius) can make the stone slab fully sintered, harder, and more refractory.

The surface of the fully sintered stone slab is firm and flat.

The powder on the surface of the unsintered stone slab will fall off, and the particles on the surface seem to fall off easily. The so-called powder loss is the foreign dust accumulated on the surface, which will disappear after washing. However, the powder loss caused by insufficient sintering is the shedding of the material of the stone slab itself.

Some unsintered products have particularly serious powder loss.

Shortening the firing time and lowering the temperature can reduce fuel consumption. More finished products can be fired in the same time, which can naturally reduce costs. That’s why some stone slabs can be sold at very low prices. The cordierite slabs of RS manufacturers are of reliable quality, factory direct sales, and guaranteed after-sales service. Contact RS for free samples and quotes.

Subsequent grinding and packaging

Mineral powder is very soft and needs to be stamped into shape with a large-tonnage press. Different shapes and sizes require different molds. The mold consists of several parts. The upper and lower mold cores and the frame form a closed shape. There is a certain gap between the frame and the core, so the edge of the stamped embryo will be rough. The embryo is very soft before firing and is inconvenient to grind. It can only be done after sintering and forming with hardness. Whether it is semi-automatic machine grinding or manual grinding, it is a time-consuming and labor-intensive process.

Of course, not grinding can also save some costs. Some manufacturers will not grind at all to save labor costs.

Through the above description, I believe that you will soon find out whether the cordierite slab you bought is the one with the highest cost performance. Identifying the differences and differences in the quality of cordierite slabs will also understand the difference of “you get what you pay for”. I hope you can buy a product that suits your taste.

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Blog

Oct 10 2024

Application of 7-Hole, 19-Hole, 31-Hole and 37-Hole Checker Bricks in Hot Blast Furnaces

Lattice brick, this term may not be common in the daily life of ordinary people, but in the iron-making industry, it is widely recognized and accepted as a heat transfer and heat storage body with many superior thermal characteristics such as strong heat exchange capacity, large heat storage area, smooth ventilation, and low resistance. Rongsheng Checker Bricks, English name Lattice brick, is a heat transfer medium, mainly used in the upper and middle parts of the heat storage chamber of the hot blast furnace to store heat. In the process of heating cold air into hot air, lattice brick plays an extremely important role.

7-Hole, 19-Hole, 31-Hole and 37-Hole Hot Blast Furnace Checker Bricks

Checker bricks, the name may sound a bit mysterious, but it actually plays a very important role in industry. In hot blast furnaces, glass kilns and coke oven regenerators, it is like a passionate heat transfer messenger, helping hot and cold gases to complete heat exchange.

Rongsheng Checker Bricks for Glass Kilns — Rongsheng Checker Bricks

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So, what is so special about checker bricks? First of all, its design is very clever, with bricks with grid holes arranged in an orderly manner. These grid holes allow hot and cold gases to pass freely, thereby achieving efficient heat exchange.

The characteristics of checker bricks are also quite significant:

Strong heat exchange capacity: can quickly transfer heat to cold gas.
Large heat storage area: store more heat and reduce energy consumption.
Smooth ventilation: ensure smooth passage of gas without affecting heat exchange.
Good volume stability: can maintain the shape even at high temperatures.
High-temperature load creep performance: the performance remains stable under high temperatures and high load.

According to the material classification, checker bricks can be divided into clay, high alumina, mullite, silica and sillimanite and other types. And according to the specification classification, there are 7 holes, 19 holes, 31 holes and 37 holes and other options.

Whether in hot blast furnaces, glass kilns or coke oven regenerators, checker bricks are an indispensable part. It not only affects the operating efficiency of the entire system, but also directly affects the safety and stability of production. Therefore, choosing the right checker brick is a crucial decision for every industrial producer.

Checker Refractory Bricks Used in Blast Furnace

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The Volume Stability of the Hot Blast Furnace Checker Brick is Good

The checker brick has multiple transparent grid holes parallel to the side surface, as well as positioning protrusions and positioning grooves on two parallel surfaces. These designs not only make it ventilated smoothly and with low resistance, but also greatly enhance its heat exchange capacity and heat storage area. In addition, the checker brick has good volume stability, excellent high temperature load creep performance, high density and low porosity, which enables it to maintain excellent performance under high temperature and high pressure working environment.

Blast furnace hot blast furnaces usually adopt a checker brick regenerator structure, which transfers heat to the checker bricks by passing the high temperature flue gas after combustion through the holes of the checker bricks. Then during the air supply period, the cold air is heated into hot air through the checker bricks, and then sent to the blast furnace through the hot air pipe for combustion reaction. The aperture and heating area of the checker bricks have a direct impact on the performance of the hot blast furnace. The old blast furnace hot blast furnace uses standard checker bricks with an aperture of 40 mm and a heating area of 32.7 square meters per cubic meter. The Kalugin top-fired hot blast furnace uses checker bricks with smaller apertures and larger heating areas, such as checker bricks with an aperture of 30 mm and a heating area of 48 square meters per cubic meter, and checker bricks with an aperture of 20 mm and a heating area of 64 square meters per cubic meter. These improvements not only improve the thermal efficiency of the hot blast furnace, but also significantly reduce the amount of refractory materials used and investment costs of the hot blast furnace.

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With the technological development of the ironmaking industry in the metallurgical industry, increasing the air temperature of the hot blast furnace has become an important measure. The technological development of the Kalugin top-fired hot blast furnace has enabled the maximum air temperature of the blast furnace hot blast furnace to reach 1350 degrees. Under this trend, 20 mm aperture checker bricks have become the first choice for modern hot blast furnaces due to their higher heating area and lower dosage. In blast furnace hot blast furnaces in Russia, China, Kazakhstan, Ukraine and other places, 20 mm aperture checker bricks have been widely used.

The application of checker bricks is not limited to blast furnace hot blast furnaces, it is also used in other industrial fields such as flame furnaces. According to different temperature zones and technical requirements, checker bricks of different materials are generally selected, such as siliceous checker bricks, clay bricks, high alumina bricks, mullite bricks, sillimanite bricks, etc. These checker bricks provide strong heat exchange and heat storage capacity for industrial production with their unique structure and performance.

In general, checker bricks have become an indispensable and important material in the ironmaking industry with their superior thermal properties and wide application fields. Its design and application not only reflect the continuous exploration and innovation of human beings in industrial technology, but also provide more possibilities and opportunities for our future industrial production. Contact Rongsheng for more information.

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Blog Cement Kiln Refractory

Sep 19 2024

Manufacturer of Magnesia Alumina Spinel Bricks for Cement Kilns

Magnesia-alumina spinel bricks are made of high-purity magnesia sand and pre-synthesized magnesia-alumina spinel as the main raw materials and are made after reasonable grading, high-pressure molding, and high-temperature firing. Rongsheng is a manufacturer of magnesia-alumina spinel bricks for cement kilns. Magnesia-alumina spinel bricks are characterized by high purity, high strength, corrosion resistance, low linear expansion coefficient, and good thermal shock resistance. They are ideal refractory materials for the transition zone of cement rotary kilns.

Rongsheng Magnesia Aluminum Spinel Bricks for Cement Kilns

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Production of Magnesium Aluminum Spinel Bricks

The amount of magnesium aluminate spinel added to the ingredients of magnesium aluminate spinel brick production is not the more the better. With the increase of spinel amount, the thermal shock resistance becomes better. However, due to mismatched expansion, the strength (especially flexural strength) will decrease. Taking Al2O3 as the standard, the Al2O3 in the product should not be greater than 15%~20%, and 10%~18% is preferred. The main impurity in magnesium aluminate spinel bricks is SiO2, which should not be greater than 1.5%.

Over the past thirty years, people have been pursuing technologies to replace magnesium chrome bricks to eliminate hexavalent chromium pollution, and first placed their hopes on periclase spinel bricks. When spinel bricks entered China with the introduction of six new dry kilns at a price of more than $1,000 per ton, China saw a fever for spinel bricks. The initial reports were optimistic, but gradually different news came from the cement plants: “It can’t hold the kiln skin.” It turns out that the eutectic temperature of spinel bricks and cement is close to (slightly lower) the firing temperature of cement, which is fatal. Therefore, spinel bricks retreated 15~20m in the lining of Chinese cement kilns and reached the upper transition zone. They occupied the position of high-alumina bricks or ordinary magnesia-chrome bricks.

Regardless of M-A series or M-K series products, the academic community agrees that Fe2O3 affects the product’s resistance to atmosphere changes. One of the explanations for the superiority of spinel bricks over magnesia-chrome bricks in the upper transition zone is that the Fe2O3 content is lower than that of M-K series products. However, Yoshiki Tsuchiya of Japan added 4% Fe2 O3 to spinel bricks to improve the brittleness of the bricks. The expansion rate is only 1.13% at 1000℃, the flexural strength is 12MPa, and the wear is 30mm in 8 months in the area of 3840m of φ5.0SP kiln. The wear of commonly used spinel bricks is 80~120mm, and it is said that this high iron brick can hang on the kiln skin when used in the firing zone.

Magnesia Aluminum Spinel Bricks Advantages

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Performance Advantages of Spinel Bricks

Spinel bricks are better than ordinary magnesia-chrome bricks in thermal shock resistance, R+ alkali corrosion resistance, acidic gas corrosion resistance, and atmosphere change resistance. However, for refractory bricks used in transition belts and unloading belts on cement kilns, should also have low thermal conductivity, good wear resistance, and high shear fracture resistance. It determines the availability of spinel bricks. China has been using spinel bricks for about 20 years. The most basic problem exposed is the high cylinder temperature. The cylinder temperature of a 200~220mm thick kiln lining will rise to 350℃ or even close to 400℃ within 100 days of operation. The wear resistance is poor, and it is rare to be able to operate stably for more than 8 months on a 2500t kiln.

The ingredients of periclase spinel bricks in my country use sintered high-purity magnesia sand, medium-grade magnesia sand, and synthetic spinel sand (SiO2 0.6%~2.0%). The thermal shock resistance index is generally more than 10 times, and the best ones are more than 20 times. However, the high-temperature flexural strength is low (1400℃, 0.5h), which is roughly 23MPa, and most products are less than 3MPa. This is a technology that spinel bricks need to improve. Spinel bricks for cement kilns. Magnesium-aluminum spinel bricks for cement kilns.

The advantages of spinel bricks are good thermal shock resistance. During use, they react with clinker to form a very thin calcium aluminate protective layer on the surface of spinel bricks. It makes the liquid phase difficult to penetrate, and the anti-stripping performance is better than that of directly bonded magnesia-chrome bricks. When used in the cooling zone and transition zone of the cement kiln, the service life is doubled compared to that of directly bonded magnesia-chrome bricks. However, it is slightly inferior to directly bonded magnesia-chrome bricks in terms of corrosion resistance. At the same time, spinel bricks are easy to hydrate, have a large thermal conductivity, and the kiln shell temperature is higher than when using directly bonded magnesia-chrome bricks.

Spinel Refractory Bricks for the Transition Zone

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Application of Rongsheng Magnesium Aluminum Spinel Brick in the Transition Zone of Cement Rotary Kiln

Magnesium aluminum spinel brick is a product made of high-purity magnesia sand and pre-synthesized magnesium aluminum spinel as the main raw materials, after reasonable grading, high-pressure molding and high-temperature firing. It is characterized by high strength, corrosion resistance, low linear expansion coefficient, and good thermal shock resistance. It is an ideal refractory material for the transition zone of cement rotary kiln.

Bauxite-based sintered magnesium aluminum spinel uses high-quality alumina with an Al2O3 content of more than 76% and high-quality light-burned magnesium powder with an MgO content of more than 95%. After a multi-stage homogenization process, it is sintered at a high temperature of more than 1800°C in an ultra-high temperature tunnel kiln. It has a large volume density, a high mineral phase content, good grain development, uniform structure, and stable quality. Magnesium aluminum spinel has good erosion resistance, strong corrosion and spalling ability, good slag resistance, abrasion resistance, good thermal shock stability, and high temperature resistance. It is a magnesium aluminum spinel brick for the high temperature zone of the rotary kiln for producing cement. It is also an ideal raw material for refractory products such as ladle lining bricks and ladle castables. Magnesium-aluminum spinel is widely used in refractory materials, steel smelting, cement rotary kilns and glass industrial kilns.

It has good erosion resistance, abrasion resistance and thermal shock stability. Its main uses: First, it replaces magnesia-chrome sand to make magnesia-aluminum spinel bricks for cement rotary kilns, which not only avoids chromium pollution, but also has good spalling resistance. Second, it is used to make ladle castables, which greatly improves the erosion resistance of steel plate linings. It is widely used in refractory materials for steelmaking.

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Product Characteristics of Rongsheng Magnesium Aluminum Spinel Bricks

Excellent kiln skin performance.
Low thermal conductivity (1000℃, 2.27w/m·k), small thermal expansion coefficient.
Excellent structural flexibility. The alkali salts of K2SO4, Na2SO4, NaCl, and KCl decomposed from cement materials have strong anti-corrosion and anti-penetration capabilities.
High load softening temperature and excellent thermal shock resistance. Suitable for key parts of SP and NSP kilns with high kiln temperature, fast rotation speed, strong alkali corrosion ability, and heavy mechanical load. It can effectively extend the life of the furnace lining and maintain a low kiln shell temperature.

Rongsheng Magnesium Aluminum Spinel Brick for Sale from Manufacturer

Rongsheng Refractory Manufacturer, Magnesium Aluminum Spinel Brick is a refractory material with a high melting point, small thermal expansion coefficient, low thermal conductivity, good thermal shock stability and strong corrosion resistance. Magnesium aluminum spinel brick belongs to isometric crystal system minerals, and high-purity magnesium aluminum spinel brick is colorless. Magnesium aluminum spinel crystals formed under natural conditions have good chemical stability, so they are commonly found in drifting sand deposits. Magnesium aluminum spinel crystals with pure composition do not hydrate or react with acid. Magnesium aluminum spinel bricks are made of light-burned magnesium powder, industrial alumina, or high-quality inkstone clay, and are made after cooperative melting, cooling and crushing. The advantages of magnesium aluminum spinel bricks are good crystal development, large grain size, dense structure, and strong corrosion resistance. To purchase high-quality magnesium aluminum spinel bricks for cement rotary kilns, please contact Rongsheng for free samples and quotations.

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Sep 5 2024

How Castable Gunmix Does Furnace Patching and Maintenance

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.

High-Temperature Ceramic Insulation Board

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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.

Gunning Mixes — Rongsheng Castable GunMix for Sale

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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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Yearly Archives: 2024

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Material Properties of Magnesia-Alumina Spinel

Magnesia-Rich Magnesia-Alumina Spinel

Dense Magnesium Aluminate Spinel

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How do you Identify High-Quality Cordierite Baked Slabs?

Differences in raw material quality and mix ratio

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Firing temperature and firing time

Subsequent grinding and packaging

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7-Hole, 19-Hole, 31-Hole and 37-Hole Hot Blast Furnace Checker Bricks

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The Volume Stability of the Hot Blast Furnace Checker Brick is Good

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Production of Magnesium Aluminum Spinel Bricks

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Performance Advantages of Spinel Bricks

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Application of Rongsheng Magnesium Aluminum Spinel Brick in the Transition Zone of Cement Rotary Kiln

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Product Characteristics of Rongsheng Magnesium Aluminum Spinel Bricks

Rongsheng Magnesium Aluminum Spinel Brick for Sale from Manufacturer

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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