Blog Archives - Page 5 of 9 - RS Kiln Refractory Bricks

The traditional way of lining the chimney is to use acid-resistant cement to build acid-resistant bricks. However, in the masonry mode of acid-resistant brick masonry, the horizontal and vertical joints of the brick are full, which will make the airtightness of the masonry poor. In addition, the dampness of the thermal insulation castable of the thermal insulation layer will cause the thermal insulation performance to decrease. The damage of the heat-insulating castable and the imperfect combination of bricks and bricks will cause corrosive smoke to penetrate the masonry and the insulation layer and corrode the outer cylinder wall. Therefore, the use of lightweight acid-resistant castables for integral casting has also accounted for a certain proportion.

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Masonry of the Inner Wall Lining of the Chimney

It is very inconvenient to construct the chimney with the method of heat insulation castable and lined bricks. Practical problems such as the setting of heat-insulating castables, the treatment of the gaps between the bricks, and the moisture-proof measures, have seriously affected the service life of the chimney.

If the thermal insulation castable and the lining of the anticorrosive brick masonry are combined into one. Lightweight or ultra-lightweight acid-resistant castables with strong corrosion resistance, good heat insulation, and high strength are used to make light acid-resistant castable linings by casting. Thermal insulation and corrosion resistance are combined into one, and the overall airtightness has been greatly improved.

Due to the sulfur dioxide in the flue gas in the chimney, there is water in the flue and chimney to form dilute sulfuric acid, and the acid will corrode the acid-resistant castable. Aluminate cement cannot be used as a binder for light acid-resistant castables. Acidic cement will crack and break the lining castables. Therefore, the acid-resistant castable for the chimney lining needs water glass as the binder and aluminate as the cementing agent, which is severely damaged under the action of sulfuric acid.

Acid-resistant Castable for Chimney Inner Wall Lining

Lightweight acid-resistant castables are mainly composed of raw materials and curing agents. The curing agent adopts ammonium phosphate or ammonium chloride or sodium fluorosilicate, which shall not be crushed and used. After stirring, the light acid-resistant castable with a specific gravity of 0.8-1.0. The initial curing time of the light acid-resistant castable is 40 minutes. It is poured into the template and formed in 2 hours. After 24 hours, it is demoulded and then dried naturally. Because the lightweight acid-resistant castable has good sulfuric acid corrosion resistance, it can fully meet the anti-corrosion requirements of the chimney for lining materials.

The light acid-resistant castable is cast as a whole, which can make the lining integrated and airtight, and has a light volume, and also reduces the weight pressure of the chimney.

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Advantages of Acid-Resistant Castable

Acid-resistant castables have good strength and stability when immersed in acid. Generally, the compressive strength increases as the immersion time increases. The advantages of acid-resistant castables are as follows.

Good heat resistance. Lining in the titanium dioxide rotary kiln, the service temperature is as high as 950℃-1000℃.
The acid-resistant castable has stable performance in various concentrations of organic acid and inorganic acid, especially in dilute acid, industrial water, and neutral aqueous solution without crystal salt. Has high impermeability.
Acid-resistant castable adopts a non-toxic curing agent, which is non-toxic to operators and construction personnel. Approved by the medical and health department, it can be used in anti-corrosion engineering of food, medicine, and other equipment.
Curing at room temperature, simple construction, convenient use, easy to transport, and moisture-proof storage. Compared with organic acid-resistant materials, acid-resistant castables are inexpensive. In addition to having the same properties as organic acid and corrosion resistance, it also has the unique performance of resistance to strong oxidizing media.

Acid-resistant castables are suitable for the lining of petrochemical and corrosive equipment. It can fully resist the erosion of acid gases and solutions and is widely used in equipment such as steel chimney lining, flue sulfuric acid tank lining, blast furnace hot blast stove top protective layer, and other equipment.

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Rongsheng Acid-resistant Castable Manufacturer

Purchase high-quality acid-resistant castables for chimneys from Rongsheng refractory manufacturers. Rongsheng’s advanced environment-friendly and fully automatic unshaped refractory production line have an annual output of tons. If you need to buy various unshaped refractory lining materials, please contact us. We will provide you with high-quality refractory castable products suitable for your production needs according to your specific needs.

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Jan 9 2021

The Influence of Certain Oxides on the Performance of Magnesia Chrome Bricks

In the production process of magnesia chrome bricks, there will be a variety of additives. For example, chromium oxide, aluminum oxide, zirconium oxide, iron oxide, etc. These additives have a very important influence on the performance of magnesia chrome bricks. The Rongsheng refractory manufacturer will make the following specific analysis on the influence of these four oxides on magnesia-chrome bricks.

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The Influence of Chromium Oxide on Magnesia Chrome Refractories

Chromium oxide is one of the main components of magnesia-chromium refractories. Appropriate addition of chromium oxide components with high purity and small particle size to magnesia-chromium refractories has the following three main effects on magnesia-chromium refractories.

(1) Increase the direct binding rate

When the content of Cr203 in periclase increases, the dihedral angle between silicate melt and periclase increases. This principle also leads to poor wettability between silicate and magnesia-chromium spinel compared to silicate and magnesia-iron spinel. This phenomenon also causes the silicate to be distributed only in the form of islands between the magnesia-chromium spinels, and the direct bonding in the magnesia chrome bricks body increases.

(2) Improve strength

During the sintering process, the periclase solid solution in the magnesia-chromium refractory material has the dissolution and re-dissolution of spinel during the re-dissolution of silicate. Because of their similar crystal structure, spinel can form a large amount of secondary spinel around the periclase crystal, which improves the strength of the product and the slag resistance. The addition of high-purity small particles of chromium oxide to the magnesia chrome brick can promote the formation of spinel and promote the formation of secondary spinel.

(3) Increase slag viscosity

When the magnesia-chromium refractory contains more chromium oxide components, due to the low chemical activity of the chromium oxide components when chromium oxide is present in the slag, the viscosity of the slag component increases.

The Influence of Alumina on Magnesia Chrome Refractory Bricks

The addition of alumina to magnesia chrome refractory bricks has different effects depending on the raw materials used. The raw materials contain more impurity components such as CaO and SiO2. The addition of appropriate alumina components can promote the sintering of magnesia chrome refractory bricks, and the brick structure will become denser. This is because alumina can form low-melting substances with calcium silicon and other components in the refractory bricks. The formation of these low-melting substances accelerates the sintering and densification process.

However, due to the different content of CaO and SiO2 in the raw materials, the influence of the crystal structure of periclase and other crystalline materials in the raw materials causes differences in the content and diffusion of CaO and SiO2 in the brick body. When the amount of CaO and SiO2 diffused to the boundary is not enough to meet the reaction rate of alumina, the remaining alumina will react with MgO in the periclase crystals. The reaction equation is as follows:

MgO+Al2O3=MgO·Al2O3

That is, spinel is generated at the grain boundary and other positions in the brick body, and the volume and density of the magnesia-aluminum spinel, which is the reaction product of MgO and Al2O3, is quite different. Therefore, this reaction is accompanied by a larger volume expansion. This hinders the sintering reaction of the magnesia-chrome brick body to a large extent, which increases the pores in the brick body and reduces the strength.

In other words, to add alumina to the magnesia-chromium refractory bricks, it is necessary to consider the CaO and SiO2 components in the raw material, and appropriately add alumina. If most of Al2O3 is added, it can react with the silicon-calcium component in the brick body to form a low melting phase, and it can present a continuous distribution in the brick body. At this time, due to the increase in the amount of liquid phase during the sintering process, it can promote the material transfer during the sintering process, promote the sintering of the brick body, and increase the density of the product. On the contrary, if the content of CaO and SiO2 is too low, it is not enough to meet the conditions of consuming Al2O3 to generate the liquid phase. Because the Al2O3 at this time will react with the MgO component in the brick body to form a spinel. The volume expansion caused by the formation of spinel cannot be well alleviated, the density of magnesia chrome bricks products will be reduced, and the compressive strength at room temperature will be affected.

The Influence of Zirconia on Magnesia-Chromium Refractory Materials

The addition of zirconia can improve the performance of magnesia-chromium refractory materials to a certain extent.

(1) ZrO2 has strong chemical stability. It shows good chemical inertness to general glass melts and acids and bases and is not easy to be wetted by metal solutions.

(2) ZrO2 can change the aggregation state and grain shape of the crystal grain boundary phases in the magnesia-chrome refractory materials, and reduce the dihedral angle between the crystals, and promote the bonding between the crystals.

However, the addition of too much ZrO2 is detrimental to magnesia chrome refractory materials. This is because ZrO2 has a small solid solubility in magnesium oxide. If an excessive amount of ZrO2 is added, the residual ZrO2 will remain between the crystal grains, hindering the mass transfer during sintering, and is not conducive to the densification of the brick body.

The Influence of Iron Oxide on Magnesia Chrome Bricks

Due to the presence of magnesia-iron spinel, iron oxide can promote the sintering of magnesia chrome bricks to a certain extent. However, due to the valence of iron oxides, the solid solubility of the two oxides FeO and Fe2O3 in periclase is slightly different. For this reason, magnesium-chromium products with high iron oxide content are not suitable for copper smelting production with an unstable atmosphere and unstable temperature.

If a magnesia chrome brick with higher iron content is used in a copper converter, it may generate a bulging and loose layer due to the following phenomena. In the case of high-temperature reduction, Fe2O3 in the periclase solid solution will be reduced to FeO and low-iron spinel in the brick body. In the lower temperature or oxidizing atmosphere, the low-iron spinel will be oxidized again to generate MgOFe2O3. In this process, the volume changes, which will cause the explosion of magnesia chrome refractory and the formation of evacuation layers.

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The above-mentioned substances have not only their own influence on magnesia chrome refractory materials during the use of the copper smelting process. Its interaction with iron-silicon slag and SO2 atmosphere is also worth noting.

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Dec 15 2020

Emergency Measures for Ladle Leakage

During the smelting period of the refining furnace, along with the continuous increase in the temperature of the molten steel, the ladle refractories are corroded to varying degrees, and other reasons eventually cause the molten steel to penetrate the ladle wall, and the molten steel overflows. Especially during the period from the completion of smelting to continuous casting, if the ladle is worn through, the damage will be very serious. The staff and production equipment under the lifting route will suffer serious casualties and damage. Bring huge property losses to the steel company. Following, let’s learn about Emergency Measures for Ladle Leakage.

Possible Causes of Ladle Leakage Accidents

During the smelting period, the temperature of the refining furnace continues to rise, and the corrosiveness to the ladle continues to increase, resulting in redness of the ladle wall. If it is not found in time and cooling measures are taken, it is very easy to cause steel ladle leakage, and then cause production safety accidents.
The oxidation of molten steel is too strong, and the slag brought from the furnace will also have high oxidation. The high oxygen content of molten steel and high (FeO) steel slag will cause the corrosion rate of refractory materials to accelerate, and will also cause Ladle Leakage.
The quality of refractories is not good. The refractoriness, load softening point, and other indicators do not meet the standard requirements, and under normal molten steel conditions, corrosion will accelerate and cause Ladle Leakage.
Ladle lining masonry quality is not good. Ladle masonry does not meet the specification requirements, especially if the refractory brick for the ladle lining joints are too wide, the brick joints are not staggered, the brick joints are not evenly coated and other defects, it is easy to cause the molten steel to penetrate into the brick joints and cause the refractory bricks to fall off and float up to cause the Ladle Leakage.
Overuse causes ladle leakage also. In the process of using the ladle, it has been found that the lining of the ladle has a large erosion, and there is a risk of leakage.

Possible Signs before Ladle Leakage Accident

The furnace lining is severely corrosive.
The wall of the ladle is red and deformed.
The temperature of molten steel is abnormally high.
The surface of molten steel fluctuates abnormally.

Emergency Treatment Measures for Ladle Leakage Accidents

Measures to be taken when ladle leakage accidents are encountered at the smelting position of the refining furnace, hoisting, etc.

If undesirable phenomena such as excessively high molten steel temperature in the ladle or redness of the ladle wall are found, the team leader and dispatch should be notified immediately. The production technology department is notified by the dispatcher to jointly study preventive measures and report to the company leaders in time. At the same time, except for the personnel of rescue agencies and those who must insist on production, other personnel are not allowed to approach the bottom of the refining furnace, and no one is allowed to stand within 20 meters of the lifting route.
The furnace head immediately took measures to cool down. And immediately notify the workshop director and dispatcher, and the dispatching office will notify the Technical Quality Department to jointly study preventive measures. Report to company leaders in time.
Except for personnel from rescue agencies and those who must insist on production, all other personnel on the site are not allowed to approach the furnace bottom or within 20 meters of the lifting route.
After discovering that the wall of the package is red or burned through, the furnace supervisor on duty should immediately take measures to cool down and lift the safety ladle to the accident package area to prepare to turn the package. At the same time, an alarm was issued and other personnel was notified to evacuate. The dispatcher informs the chief surveyor, the safety department, the security department, the hospital, and the fire brigade, and activates the emergency plan. The on-duty dispatcher and the squad leader in front of the furnace must stick to their posts and quickly evacuate the scene after the accident is handled.
After the accident caused casualties, the furnace supervisor on duty organized personnel to carry out rescue work while handling the lifting of the ladle. Move the wounded to safety.
After receiving the notice, the Safety Section rushed to the scene immediately. Assist the workshop to seal off the scene, maintain the order of the scene, and assist rescuers in the rescue.
The dispatcher is responsible for contacting the ambulance and cooperating with the doctor to send the wounded to the hospital. At the same time, escorts are arranged.
Other personnel shall be uniformly organized and arranged by the headquarters. When gas leaks are found in gas equipment, gas pipelines, and ancillary facilities, they should immediately report to the workshop leader. The discoverer should be on guard to prevent unrelated persons from entering the gas leak area. If the leakage area is large, the gas protection station must be notified, and the safety department will send personnel to evacuate and guard the leakage area.

After receiving the notification, the production dispatching office will immediately notify the production office, safety department, emergency rescue team personnel, general dispatcher, security department, hospital, and fire brigade of the on-duty dispatcher. The company leaders ordered the launch of an emergency plan.
After receiving the notice, the electrical department will immediately switch on and off all electrical equipment on site. Eliminate secondary casualties due to leakage.
The captain on duty in the continuous casting process immediately organized personnel to close and remove the on-site gas blind valve, butterfly valve, oxygen point valve box valve, and other flammable and explosive gas valves and equipment.

Rongsheng refractory manufacturer reminds steel mill customers that security is no small matter. It is our vision to ensure the economic benefits of the enterprise under the premise of safe production. In the production and sales of refractory materials for refining furnace ladle, Rongsheng refractory manufacturers always put production safety first. Bulk supply kinds of refractory materials for the ladle refining furnace, such as refractory bricks and monolithic refractories, etc. To get the price of refractory materials for high-quality thermal furnace equipment for free, please contact us. We will provide you with refractory products that best suit your production needs according to your specific needs. There are various refractory materials for refining furnace walls.

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Nov 26 2020

Is High Alumina Refractory Mortar the Same as High Alumina Cement?

High alumina refractory mortar is prepared from high alumina bauxite clinker, binding agent, and admixture. It is usually delivered in bulk and dry, with water added for reconciliation.

The role of high alumina refractory mortar additives

Soft clay is added to high alumina refractory mortar to improve work abilities, such as spreadability and adhesion. Using soot silica powder instead of soft clay can lower the sintering temperature. Additives mainly include precipitation agents, stabilizers, plasticizers, and anti-shrinking agents. The role of the precipitation agent is to reduce the amount of water added. The stabilizer prevents the solid-liquid separation phenomenon of the adjusted refractory mud during the standing process. Adding plasticizers improves the spreadability of the mud and prevents flow. The anti-shrinking agent is to prevent cracks or peeling caused by volume shrinkage after sintering.

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Advantages of high alumina refractory mortar

(1) Good plasticity and convenient construction.
(2) High bonding strength and strong corrosion resistance.
(3) High refractoriness, up to 1750℃.
(4) Good resistance to slag invasion.
(5) Good heat peeling.

Use of high alumina refractory mortar

The high-alumina refractory mortar is correctly configured according to the materials of the bricks. Usually, it is mainly used for laying high alumina bricks and corundum bricks.

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How to use high alumina refractory mortar

When selecting fire mortar, the chemical composition similar to that of refractory bricks should be considered, so that the thermal expansion of the mud is consistent with the thermal expansion of the bonded refractory bricks to ensure that the masonry can be reliably bonded. It should have good masonry performance and high-temperature performance to bond the refractory bricks into a dense overall furnace lining.

The masonry performance of mortar refers to the work performance of refractory mortar in the masonry process, which is beneficial to ensure the quality of masonry. If there are good fluidity and plasticity. It has certain water retention performance and can maintain a uniform state without segregation and precipitation. It has proper consistency and viscosity during masonry and does not dry up during the brick kneading time, so as to achieve the required thickness of the brick joints, and the mortar in the brick joints is full.

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Is high alumina refractory clay the same as high alumina cement?

High alumina refractory clay is different from high alumina cement. Although both high-alumina refractory clay and high-alumina cement are powdered materials, there is a big difference between high-alumina refractory clay and high-alumina cement. High-aluminum refractory mortar is a synthetic material made by processing high-aluminum particles into powders smaller than 180 mesh and adding some binders and coagulants. The high alumina cement is the finished material after calcining bauxite and lime.

High-alumina refractory clay is a refractory material used in the joints of refractory bricks. The powder is high alumina powder plus a certain proportion of binding agent and coagulant. After adding water or adding a liquid binder, stir it into a slurry and apply it to the surface of the refractory brick to adjust the size deviation. It can make the refractory bricks form a tight whole to prevent the damage of high temperature and external force. That is to say, it is the fire clay for bricklaying, which is a kind of finished solid powder.

High alumina cement is a kind of binder in refractory applications, and high alumina cement is also called aluminate cement. It is a clinker with 50% alumina content calcined with bauxite and lime. Aluminate cement is yellow or brown, and high-grade alumina cement is white. The labels are 625#, 725#, 925#, and CA70, CA80.

High-alumina cement is closely related to refractory materials and can be used as a binder for various castables. In addition, some 525# and 425# cement are equipped with gypsum bauxite for construction and special projects. High-alumina cement has a good coagulation effect in the castable, which will make the castable have high-temperature resistance and good strength. It is a raw material for refractory materials.

The high-alumina refractory mortar is also divided into multiple grades, which can be used in conjunction with the construction of refractory bricks of various materials. It is divided into the high-aluminum refractory mortar, phosphoric acid combined with high-aluminum refractory mortar.

Therefore, high-alumina cement and high-alumina refractory mortar are completely different products, but they are closely related to refractory materials. They are also two of the most widely used materials in refractory products.

Contact with RS Refractory Castable Factory — RS Refractory Castable Factory

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Rongsheng unshaped refractory manufacturer

Rongsheng is a refractory sales manufacturer with an advanced and fully automatic unshaped refractory production line. Rongsheng’s refractory materials have been sold to more than 60 countries around the world. For example, Russia, South Africa, Kazakhstan, Philippines, Chile, Malaysia, Uzbekistan, Indonesia, Vietnam, Kuwait, Turkey, Zambia, Peru, Mexico, Qatar, etc. And got the customer’s continuous return orders. Rongsheng’s unshaped material production line has an annual output of 80,000 tons. Not only can we customize refractory materials according to your specific furnace conditions and production conditions. And can provide you with a refractory solution for the overall kiln lining. If you need to buy unshaped refractory materials, such as high alumina refractory mortar, high alumina refractory castable, high alumina cement, etc. Please contact us. We will provide you with services according to your specific needs.

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Oct 10 2020

Non-Burning Bricks for Ladle

Non-burning bricks for ladle include alumina-magnesia bricks, alumina-magnesia-carbon bricks, and magnesia-alumina-carbon bricks. The difference between their fired bricks is that they use water glass or phenolic resin as the bonding agent and undergo low-temperature treatment after molding. During the use of non-fired bricks for ladle, the alumina and magnesia in the matrix form spinel, and the carbon in the graphite and resin binder forms a carbon chain network structure. Therefore, the strength, slag resistance, and thermal shock resistance of refractory bricks for ladle are further improved. To get the price of refractory bricks for ladle for free, please contact Rongsheng refractory brick manufacturer. Next is the introduction of unburned bricks for a ladle.

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Alumina-Magnesia Brick and Alumina-Magnesia-Carbon Brick

First of all, let’s learn about the non-burning bricks for ladle combined with water glass, including alumina-magnesia brick and alumina-magnesia-carbon brick. The aggregate of the alumina-magnesia brick is generally first-grade bauxite, and the powder is super-grade bauxite clinker powder and first-grade magnesia powder. Use high modulus water glass as the bonding agent. After pressing, the finished product is treated at a low temperature of 150°C. The refractory brick is used on the large and medium-sized die-cast ladle, and its life span is generally 60 to 90 times.

Alumina-magnesia-carbon bricks are successfully manufactured on the basis of alumina-magnesia bricks and magnesia-carbon bricks, and the production process is similar to that of magnesia-carbon bricks. Water glass is combined with alumina-magnesia-carbon bricks, and primary and secondary alumina clinker is used as a refractory aggregate. The first-grade or super-grade high-alumina powder is used as refractory powder, and 8%~13% of the first and second-grade metallurgical magnesia powder is blended. The carbon material adopts electrode powder, earthy graphite, or flake graphite, the amount of which is 3%~8%, and the water glass solution (m=2.4~3.0) is used as the binding agent. After forming, the finished product is processed at a low temperature of 200~250℃. The refractoriness of the water glass bonded alumina-magnesia-carbon brick is 1770℃, and the 4% load softening temperature is 1320~1340℃, which is caused by more Na2O in the binder. If high modulus sodium silicate is used to bring in less Na2O, the load softening temperature will increase to 1410℃, and the refractoriness will be 1790℃. This kind of refractory brick is widely used in medium and small ladle due to its better performance and low price. The refractory brick is applied to the mold-cast ladle, and the slag line area is built with magnesia carbon bricks, and its life span is 50-100 times.

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Resin-Bonded Alumina Magnesia Carbon Brick

The raw materials of resin-bonded alumina-magnesia-carbon bricks use first-grade or super-grade bauxite clinker, white corundum, sub white corundum, and magnesia-alumina spinel as aggregates and powders. The magnesia powder is made of high-quality sintered magnesia or fused magnesia with Mg>95%, and mixed with flake graphite, high-quality silicon carbide and alumina powder or SiO2 powder. The phenolic resin binder is used for high-pressure molding, and the bricks are then processed at a low temperature of about 200°C to become the finished product. The refractory brick has the advantages of excellent strength, corrosion resistance, peeling resistance, thermal shock resistance, and non-sticky slag. However, the thermal conductivity is relatively large, and heat insulation measures must be taken during use.

It is better to directly add an alumina-magnesia spinel compound fired material into the alumina-magnesia-carbon bricks than doping with magnesium oxide. Because magnesia oxide can form spinel with alumina during use. Synthetic alumina-magnesia spinel should generally be sintered in a rotary kiln at a temperature greater than 1600°C. The higher the temperature, the better the quality. Its bulk density is 2.95~3.10g/cm3, and its content of alumina and magnesia should be greater than 91%. The fused magnesia-alumina spinel is more expensive. To ensure the quality of refractory bricks, suitable magnesia-alumina spinel should be selected.

Resin-bonded alumina-magnesia-carbon bricks have been widely used in the continuous casting ladle of many steel plants. On the 50-100t steel ladle for continuous casting, mid-grade alumina-magnesia-carbon bricks are used as lining. The slag line area is built with high-quality magnesia carbon bricks, and the service life is generally 50 to 80 times, up to 100 times.

In the 1990s, a large number of high-quality alumina-magnesia-carbon bricks and magnesia-carbon bricks for slag line areas were used in the lining of refining furnaces. The service life of the refining bag is more than 30 times, and the service life of LF(V) of 40~90t is about 50 times.

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Magnesia Alumina Carbon Brick

The production process of magnesia-alumina-carbon brick and alumina-magnesia-carbon brick is basically the same. It is the pre-synthetic spinel mixed with fused magnesia, and the difference in linear expansion coefficient between the two forms micro-cracks during high temperature and cooling use to buffer the thermal stress generated by temperature changes and reduce thermal spalling. Because the elastic modulus of spinel (MA) and periclase (M) are quite different, the former (0.012~0.022)×106MPa, the latter (0.059~0.49)×106MPa. Tough spinel helps to improve the thermal shock resistance of refractory bricks. In addition, the carbon material is added to the periclase-spinel, and about 10% graphite is added. After making it evenly distributed in the refractory brick body, the carbon atoms form a staggering network structure at high temperature, so that the material has a good high-temperature performance. In addition, graphite has high surface tension and a small wetting angle, which can effectively prevent the penetration of molten slag.

For example magnesia-alumina-carbon bricks for 75t LF lining of a steel plant. MgO 71%, Al2O3 13%, C 10%, apparent porosity 3%, bulk density 3.08g/cm3, compressive strength 50MPa, high temperature flexural strength (1400°C) 8MPa. The slag line uses high-quality MgO-C bricks, with a service life of more than 50 furnaces.

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Rongsheng Refractory Brick Manufacturer

Rongsheng is an experienced refractory manufacturer. Rongsheng’s refractory brick products have been recognized by customers in more than 60 countries around the world. Rongsheng’s project of refractory materials for ladle also has very strong competitiveness. If you need to buy refractory materials for ladle, please contact us. We will provide you with services according to your specific needs. You are welcome to consult and learn more about non-burning bricks for ladle.

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Sep 15 2020

Several Different Types of “T” Refractory Bricks

T19 refractory bricks also called ax bricks. The size of the T19 mullite brick is 230×114×65/55mm. The country stipulates the size of bricks in order to facilitate calculation and save resources. There are many types of refractory bricks, and their shapes and sizes are quite complicated, but they all stipulate a unified brick number. People with rich experience and knowledge of refractory bricks can know its purpose, even shape, size, and weight from the brick number. For example, bricks with the prefix “T” are commonly used in general industrial furnaces. From “T-1” to “T-105”, there are more than 20 shapes and 105 brick numbers (specifications). Another example is the bricks with the prefix “G” are used for blast furnaces. There are two shapes and 8 specifications from “G-1” to “G-8”. The size of the T19 refractory bricks produced and processed by Zhengzhou Rongsheng Refractories is strictly implemented in accordance with the standard size, and customers are welcome to come and inspect. Next, let’s learn more about the “T” refractory bricks.

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Several Different Types of “T” Refractory Bricks

The cylindrical lining uses T3 bricks to match T38 bricks and T39 bricks (thicker lining). Or use T3 bricks with T19 bricks and T20 bricks (thin lining) for masonry. When designing, we must go through strict calculations to ensure that the “T” refractory bricks joints are basically the same.

T3 is a standard brick with dimensions (length×width×height): 230×114×65.
T38 and T39 are wedge-shaped bricks, also called knife-shaped bricks, with dimensions (length×width×height) respectively: 230×114×65/55 and 230×114×65/45.
T19 and T20 are called ax-shaped bricks, and the dimensions (length×width×height) are 230×114×65/55 and 230×114×65/45, respectively.
The thickness of T38 and T39 is gradually reduced from 65 to 55/45 in the length (230) direction.
The thickness of T19 and T20 is gradually reduced from 65 to 55/45 in the width (230) direction.

One Kind of Refractory Bricks — One Kind of “T” Refractory Bricks

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T19 Mullite Bricks

T19 mullite bricks are mainly used in metallurgical hot blast furnaces with high blast temperature above 1400℃. The parts and slag lines of the torpedo car hit by molten iron. The roof of the steel-making electric arc furnace, the forehearth of the glass melting furnace, the regenerator arch, and the upper structure. Ceramic sintering kiln, ceramic roller kiln, tunnel kiln, electric porcelain drawer kiln, dead corner lining of petroleum cracking system, glass crucible kiln, and various electric furnaces, etc. The wall of the clarifier, cement and lime rotary kiln lining, etc. They can be directly contacted with flame.

Mullite bricks are aluminum-silicon refractory products with mullite as the main crystal phase. Because the main crystal phase of mullite brick is mullite. Therefore, the properties of mullite bricks are as follows: the high-temperature resistance of mullite bricks can reach above 1790℃, the starting temperature of load softening is 1600-1700℃, and the compressive strength at room temperature is 70-260MPa. Good thermal shock resistance, high strength, low high temperature creep rate, low expansion coefficient, low thermal coefficient, and acid slag erosion resistance. It can also greatly reduce the weight of the high-temperature furnace body, transform the structure, save materials, save energy, and improve production efficiency.

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Rongsheng Refractory Bricks Manufacturer

The mullite bricks produced by Zhengzhou Rongsheng Refractory Bricks Manufacturer are mainly divided into lightweight mullite bricks and corundum mullite bricks. Lightweight mullite bricks use imported tabular corundum and high-purity fused corundum as the main raw materials. It is made by applying advanced superfine powder adding technology, mixing, drying, forming, and firing in a high-temperature shuttle kiln. Corundum and mullite refractory bricks are made of dense fused corundum and alumina powder as the main raw materials, which are mechanically mixed and high-pressure forming and high-temperature firing. Through the purity of the corundum sand and the process formula to meet the requirements of different corundum products using temperature.

Zhengzhou Rongsheng Kiln Refractory Material Co., Ltd. produces and processes various types of refractory materials. If you have a demand for T19 refractory bricks, T19 mullite bricks, etc. Rongsheng Company can provide you with high-quality products. For more information, please contact us. We will provide you with services according to your specific needs.

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Sep 9 2020

Corundum Bricks on the Tapping Channel of the Heating Furnace

In the small and medium-sized steel rolling heating furnace with side discharge, the tapping trough is an important part of the heating furnace. The structure of the tapping trough is directly related to the energy consumption and service life of the heating furnace. Because corundum bricks such as chrome corundum bricks and zirconia corundum bricks have good high temperature wear resistance and slag resistance. As a result, it has gradually replaced water-cooled cast iron tapping channels and has been widely used in small and medium-sized steel rolling furnaces. Rongsheng refractories manufacturer provides you with high-quality refractories for steel rolling furnaces, such as corundum bricks on the tapping channel, etc.

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Factors Affecting the Service Life of Corundum Bricks on the Tapping Channel

In actual production, improper construction and use often reduce the service life of corundum bricks on the tapping channel of the heating furnace. Therefore, it is of great significance to analyze the factors that affect the service life of corundum bricks and discuss measures to improve the service life of corundum bricks. To analyze the service life of corundum bricks on the tapping channel of the heating furnace, it is necessary to conduct a dialectical analysis from the characteristics of the corundum brick itself and the working conditions of the tapping channel of the heating furnace.

(1) Due to the high density of corundum bricks, thermal stability is poor. Therefore, it is easy to burst when the temperature changes sharply, especially near the tap hole. When the furnace pressure fluctuates frequently, the door of the furnace may burst into flames and sometimes suck cold air. As a result, the surface temperature of the corundum bricks fluctuates up and down, forming large internal stress. This causes the surface of the corundum brick to peel off and crack.

(2) The gap between the corundum bricks is not tightly sealed, and the oxide scale or its melt enters the gap and adheres to the upper oxide scale, forming a solid whole with the corundum brick. As a result, it is difficult to remove the oxide scale on the surface, and it must be removed with a big steel hammer. Doing so is easy to cause damage to the corundum brick, often cracked or knocked off.

(3) The masonry of the refractory bricks at the bottom of the corundum bricks must be smooth, and castables can be used to level them when they are uneven. It is not allowed to use loose thermal insulation materials, and it is not allowed to pay only part of it. In other words, the corundum bricks must be cushioned with hard refractory materials. Only in this way can it be ensured that the corundum bricks will not loosen when the billet slides on the corundum bricks. The loosening of corundum bricks will cause two undesirable consequences. One is to make the upper surface of the corundum bricks uneven, which affects the sliding of the billet and the elimination of oxide scale and reduces its service life. Second, the gaps filled with magnesia powder appear again due to the loosening of the corundum bricks, and the oxide scale will fall into it, which will cause difficulty in removing the oxide scale and reduce the service life of the tapping trough.

(4) Avoid “cutting” of corundum bricks by continuous casting billets. Most of the small and medium-sized steel billets have irregular shear sections. If the billet moves in the direction of the tapping channel, the surface of the corundum brick will be cut, which reduces the service life of the corundum brick. Therefore, when the billet enters the furnace, the placement of the billet should be adjusted to avoid the cutting of the corundum brick by the billet when it moves in the tapping trough, which can increase the service life of the tapping trough. Expansion joints or improper setting of expansion joints will make it have no room for expansion when heated, which will easily cause great internal stress, leading to premature damage to the corundum bricks and reduced service life.

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How to extend the service life of corundum bricks on the tapping channel of the heating furnace?

(1) Reasonably control the furnace pressure so that the furnace pressure is always slightly positive. Especially when the steel rolling production is abnormal, attention should be paid to adjusting the flue gate at any time to keep the furnace pressure in a slightly positive state. Ensure that no cold air is sucked at the door of the tapping furnace so that the surface temperature of the corundum brick near the tapping port will not change frequently.

(2) The masonry gap between corundum bricks must be as small as possible. After the masonry is completed, the gaps must be filled and compacted with magnesia powder. Leave 30-50mm expansion joints at both ends of the tapping trough, which are filled with alumina silicate refractory fiber felt and covered with 30mm thick magnesia powder. In this way, the longitudinal expansion stress of the corundum bricks on the tapping channel can be eliminated, and the oxide scale can be prevented from falling into the expansion joints. The expansion joints on both sides of the tapping trough are the same as the two ends, but the expansion joint width is 10mm.

RS Refractories Bricks for Kinds of the Heating Furnaces

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Rongsheng Refractory Bricks Manufacturer

Rongsheng is an experienced corundum refractory brick manufacturer. Rongsheng’s refractory products have been sold to more than 60 countries and regions all over the world. For example, Thailand, UAE, Turkey, Kuwait, South Africa, Malaysia, Vietnam, Netherlands, Philippines, Singapore, Egypt, Russia, etc. Rongsheng’s refractory technology team aims to provide the most suitable refractory materials for the refractory lining of various thermal furnace equipment, including refractory bricks and refractory castables. If you need refractory equipment on your heating furnace equipment, please contact us. We will provide you with services according to your specific needs.

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Aug 31 2020

Characteristic Analysis of High-strength Wear-Resistant Castables for Waste Incinerators

High-strength wear-resistant castable is a widely used castable refractory for furnaces. High-strength wear-resistant castables can be used in circulating fluidized bed boilers, corrosion-resistant liners in the chemical industry, wear-resistant liners in the coal industry, blast furnace linings in the steel industry, and garbage incinerator linings. The Rongsheng refractory manufacturer analyzed the characteristics of high-strength wear-resistant castables for waste incinerators based on the characteristics of waste incineration. And specially developed wear-resistant refractory castables for garbage incinerators.

Application of High-strength Wear-Resistant Castables

Generally, high-strength wear-resistant castables for circulating fluidized bed boilers use corundum, silicon carbide, and special grade bauxite as the main raw materials, with superfine powder and compound additives. It has the characteristics of high strength at early medium temperature, good high-temperature performance, stable volume, strong resistance to slag penetration and erosion, erosion resistance, convenient construction, and strong integrity of the lining structure. It is a good wear-resistant material currently used in CFB boilers.

High-strength wear-resistant castables for waste incinerators, low-aluminum mullite, and SiC are selected as aggregates, silica sol, and pure calcium aluminate cement are used as binders, and ultrafine powder and water reducer are added. The sample is mixed according to the ratio of aggregate and powder 67:33, the critical particle is 5mm, and the binder and water reducer are added to the powder. According to the principle of first coarse and then fine, pour it into a mixer, pre-mix for 3 to 5 minutes, then add an appropriate amount of water, stir for 3 minutes, take it out and pour it into the triple test mold, vibrate and shape, and cure, dry and fire.

High-strength Corundum Castable — High-strength Wear Resistance Castable

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Characteristic analysis of high-strength wear-resistant castable for a waste incinerator

The following characteristics of high-strength wear-resistant castables for waste incinerators are tested as a reference for the analysis.

Determine the fluidity of the castable;
Measure its physical and chemical indexes at room temperature after treatment at various temperatures, as well as alkali resistance and abrasion resistance;
The acid test is carried out according to the crucible erosion method to detect Cl2 erosion. The test was carried out at 1000 ℃ for 48 h, and humid acid Cl2 gas was introduced to analyze the corrosion surface changes and microstructure of the sample.
The effects of Al2O3/SiO2 value, binder addition, SiC addition, and superfine powder addition on the properties of the castable were studied, and the optimal addition amount was optimized.

The results show:

When the value of Al2O3/SiO2 in the castable is about 0.8, the acid and alkali corrosion resistance of the sample is the best;
Cement-silica sol compound addition and the addition amount is 5%, the effect is the best;
Wear-resistant castables added with SiC have higher drying strength. Although the intensity of medium temperature (1100 ℃) fluctuates, it also maintains a relatively high value. When used at around 1300°C, the oxidation resistance and wear resistance will be effectively improved;
When the addition amount exceeds 15%, due to the fineness of SiC, a continuous phase is formed in the matrix, which can significantly improve the thermal conductivity of the castable. So that the castable has better thermal shock resistance;
When a proper amount of silicon powder is added, the specific surface area of the silicon powder is large, the activity is higher, and the silicon powder has the effect of filling and promoting sintering. In this way, only a small amount of water is needed to make the castable have better rheology and improve the high-temperature strength of the castable.

Application of high-strength wear-resistant castables for a garbage incinerator

By analyzing the characteristics of high-strength wear-resistant refractory castables for tie incinerators, Rongsheng refractory manufacturers, combined with the actual working environment and operating temperature, developed high-strength wear-resistant castables for garbage incinerators. The high-strength wear-resistant castable is used in the garbage incinerator and is mainly used in the wear-resistant parts such as the hearth and the roof of the gasifier. Through many years of operation, no product quality problems occurred in the middle, and the garbage incinerator is operating in good condition. Another incinerator project also used Rongsheng’s high-strength wear-resistant castables. It has been in operation for nearly 2 years without any obvious damage.

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Rongsheng refractory castable manufacturer

Rongsheng is an experienced refractory castables manufacturer. Rongsheng’s refractories have served customers in more than 60 countries. Through continuous accumulation and research and development, Rongsheng has built a new unshaped refractory production line with an annual output of 80,000 tons. Provide high-quality unshaped refractory materials for Rongsheng customers. The Furnaces we serve covers CFB boilers, gasifier equipment in the chemical industry, etc. At the same time, Rongsheng specially developed refractory materials for garbage incinerators by studying the working characteristics of garbage incinerators. For more information about high-strength wear-resistant castables for waste incinerators, please contact us. We will provide you with services according to your specific needs.

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Jul 24 2020

Rongsheng Refractory Cement for Sale in Philippines

Refractory Cement for Sale is also called bauxite cement, high alumina cement, aluminate cement. According to the national standard GB201-2000, refractory cement is also collectively referred to as CA50 aluminate cement. In order to distinguish the strength of cement, such symbols are often used to indicate: CA50-A600, CA50-700, CA50-A900, etc. Refractory cement is a fast-setting, fast-hardening, high-strength high-temperature binder. The initial setting time is generally about 2 hours. The final setting time is generally about 4 hours. The strength can reach 70% within three days, and the strength can reach 100% of the overall strength within 28 days. Refractory cement, high alumina fine powder, high alumina aggregate, and other additives are formulated into refractory castables according to a certain particle gradation. Rongsheng Refractory Cement for Sale, Its refractory temperature can reach 1500 degrees Celsius, and it is widely used in high-temperature furnace engineering.

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Classification of Refractory Cement for Sale

Refractory cement is one of the main materials for making high-temperature furnace linings. It is Refractory Cement for Sale with refractoriness not lower than 1580°C. According to different compositions, it can be divided into aluminate refractory cement, low calcium aluminate refractory cement, calcium magnesium aluminate cement, and dolomite refractory cement.

Aluminate cement can be divided into four categories according to Al2O3 content:

CA-50, 50%≤Al2O3＜60%
CA-60, 60%≤Al2O3＜68%
CA-70, 60%≤Al2O3＜77%
CA-80, 77%≤Al2O3

The Main Components of Refractory Cement

Refractory cement refers to cement with calcium aluminate as the main component. Refractory Cement for Sale is the basic bonding agent of unshaped refractory-casting refractory. Its chemical composition is mainly Al2O3 and CaO, and some also contain quite a lot of Fe2O3 and SiO2. The mineral composition consists of the following three kinds of minerals, CaO·Al2O3 (CA), CaO·2Al2O3 (CA2), 12CaO·7Al2O3 (C12A7) three compounds. And it is composed of 2CaO·Al2O3·SiO2 (C2AS) containing inclusions and 4CaO·Al2O3·Fe2O3 (C4AF).

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Properties of Refractory Cement

The properties of Refractory Cement for Sale mainly depend on its mineral composition. The main mineral of refractory cement is monocalcium aluminate (CA), which has a high hydraulic activity and coagulates. Although it is not very fast, it hardens quickly, and the hardening time does not exceed one day. It is the main source of the strength of high alumina cement, especially the early strength. Calcium aluminate (CA2) has slower hydration and hardening, with lower early strength and higher late strength. the C12A7 has the characteristics of fast hydration and fast setting, but the strength is not high. In ordinary high alumina cement containing inclusions ( C2AS and C4AF), C4AS plays a role in hardening the cement as soon as possible. In high-grade high-alumina cement, C12A7 plays a hardening role. As for C2AS, basically it does not produce hydration, so it cannot show its strength.

Refractory cement contains 5 kinds of calcium aluminate minerals, and these calcium aluminates will show intense heat generation as the hydration reaction proceeds. Ordinary high-alumina cement contains 53-55% Al2O3. After 5-8 hours, the temperature reaches a peak value of 80-90℃. The high-alumina cement containing 70% Al2O3 will reach the peak temperature after 10-12h and the high-alumina cement containing 80% Al2O3 after 8-10h, which are 80 ℃ and 70 ℃ respectively.

The heating temperature and the time to reach the maximum temperature of a single cast of different types of high alumina cement are determined by the heating characteristics and content of the calcium aluminate contained.

Rongsheng Refractory Cement Manufacturer

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How to Use Refractory Cement

The use of refractory cement is very simple, it can harden after adding water and mixing. Generally, there is no need to add other binders, but some refractory aggregates and powders can be added. If only refractory cement is used, a lot of cracks will occur after high temperature. It can be used to cement various refractory aggregates, such as corundum, calcined high alumina bauxite, etc. It is made into the refractory mortar or refractory castable, which is used as lining of cement rotary kiln and other industrial kilns.

Precautions for Refractory Cement

Many people tend to confuse refractory cement with refractory soil. If refractory cement and refractory soil are used together, the use-value of refractory cement will be greatly reduced. It is equivalent to mixing refractory cement and loess together. The solidification strength and marking of refractory cement will be much lower. It is recommended that workers who have been engaged in furnace construction for a long time, in refractory construction, use refractory cement and refractory soil rigorously.

High Alumina Castable Refractory Cement — Rongsheng High Alumina Refractory Cement for Sale

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Refractory Cement for Sale Price

Because refractory cement has the following characteristics, the consideration of the Refractory Cement for Sale price also needs to be analyzed according to specific working conditions.

Refractory cement is a bonding agent used in thermal kilns or wall linings.
This type of cement is different from other types of cement, it still maintains a firm bond under high-temperature conditions.
Refractory cement will have a certain strength at room temperature, which is used to ensure the hardened shape of the preform.
In addition, refractory cement solidified at room temperature has some physical and chemical advantages. For example, through the cement solidification process, the internal moisture of the cement product can be quickly precipitated, or the internal structure can be tightly reinforced.

The price of commonly used refractory cement is generally 1800 yuan per ton. Some users need a small amount of refractory cement to make small furnaces, and the price at this time is calculated according to the price of each bag.

What is the price of refractory cement for boilers? There are also many types of refractory cement for boilers, mainly because of the different aluminum content. The general CA-50 is about 1500, the cheaper one can reach about 1200, and the most expensive CA-80 and 70 can reach 5 to 6 thousand tons. The refractory cement prices listed in this article come from the Internet and are for reference only. The specific price is subject to the price provided by the supplier at the time of purchase. Get more details on refractory cement Philippines for sale. Please leave us your requirements.

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Jul 17 2020

Learn More About Refractory Plastics

Refractory plastics are made of refractory aggregates and powders, raw clay and chemical compound binders, and additives. After preparation and mixing, it is extruded into a brick shape. After the package is stored for a certain period of time, it still has good plasticity and can be constructed by tamping. But the plastic-refractory has better thermal shock resistance and easy construction. Applicable to various heating furnaces, soaking furnaces, annealing furnaces, hot air furnaces, etc. It can also be used in furnace cover of a small electric arc furnace, burner of the high-temperature furnace, and other parts.

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Classification of Refractory Plastics

Refractory plastics can be divided into clay, high-alumina, mullite, corundum, chromium, silicon carbide, and zirconium-containing refractory plastics according to the variety of refractory aggregates. According to the type of binder, it can be divided into refractory plastics combined with aluminum sulfate, phosphoric acid, phosphate, water glass, and resin.

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Properties of Refractory Plastic

Workability of refractory plastic.

Generally, plastic refractory should have high plasticity. And after a long period of storage, it still has a certain plasticity. If the plasticity of the plastic refractory is not significantly reduced during its storage period, hydraulic binders cannot be used. If an air-hardening binder is used, sealing measures must also be taken during storage. However, since some of the binding agents may gradually coagulate, the plasticity is gradually lost. When the plastic refractory has high water content, it is also easy to become hard due to the loss of water retention, which makes the water dispersed and lost. In order to keep the plasticity of refractory plastics unchanged during storage for a long time, retarding measures must be taken.

The hardening and strength of refractory plastics.

Ordinary refractory plastics are hard. Since there is no chemical binder in it, the strength before unsintering is very low. However, at a certain temperature, the strength increases with increasing temperature. After sintering at high temperatures, the cold strength greatly increased. The hot state strength decreases with increasing temperature at a high temperature.

Refractory plastics added with sodium silicate have a relatively fast strength change after construction. To properly control the drying speed, it is not easy to produce shrinkage cracks. The mold can be removed quickly after construction. Refractory plastics containing this kind of binder are suitable for large kilns with long construction periods.

Refractory plastic shrinks during heating.

But plastic refractory contains more clay and moisture, and it often shrinks greatly during drying and high-temperature heating. Generally speaking, because plastic refractory contains a considerable amount of clay, its deformation under high-temperature load will be higher than other unshaped materials. So for plastic refractory, its volume stability is often used as an important technical indicator. (National regulations: the shrinkage of high-grade clay refractory plastic after heating to 1400°C should be no more than 4%. The shrinkage of special-grade clay refractory plastics after heating to 1600°C should be less than 2.5%)

The thermal shock resistance of refractory plastics.

Compared with sintered refractory products of the same material and uncustomized refractory materials of other materials, refractory plastics have better thermal shock resistance. Due to the high thermal shock resistance of refractory plastic, it is better to be used where the temperature fluctuation is large.

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Uses of Refractory Plastics

Refractory plastics are mostly used in boiler walls and roofs of boilers. It is also used in a heating furnace, soaking furnace, and annealing furnace. But the plastic refractory has a low bulk density and good thermal shock resistance. When used in the heating process and high temperature, it will not cause serious deformation due to crystal phase change. The mineral composition near the heating surface is mullite and cristobalite crystallites, and the glass phase is less. Therefore, refractory plastic is particularly suitable for furnace walls with large temperature fluctuations and high-temperature furnace roofs that receive flame impact or radiation. Learn more from Rongsheng Refractory Materials Manufacturer.

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Masonry of the Inner Wall Lining of the Chimney

Acid-resistant Castable for Chimney Inner Wall Lining

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Rongsheng Acid-resistant Castable Manufacturer

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Rongsheng unshaped refractory manufacturer

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Rongsheng Refractory Brick Manufacturer

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Rongsheng Refractory Bricks Manufacturer

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Rongsheng Refractory Bricks Manufacturer

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Application of High-strength Wear-Resistant Castables

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Characteristic analysis of high-strength wear-resistant castable for a waste incinerator

Application of high-strength wear-resistant castables for a garbage incinerator

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Rongsheng refractory castable manufacturer

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Classification of Refractory Cement for Sale

The Main Components of Refractory Cement

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Properties of Refractory Cement

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How to Use Refractory Cement

Precautions for Refractory Cement

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Refractory Cement for Sale Price

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Classification of Refractory Plastics

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Properties of Refractory Plastic

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Uses of Refractory Plastics

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