High-strength Corundum Castable RS Refractories Manufacturer

High-strength Corundum Castable are fire-resistant crafts with Al2O3 content exceeding 90%, with corundum as the main crystal phase, and blended with appropriate thickeners, coagulants, stainless steel plate chemical fibers, and compounded according to strict secret recipes. It has many characteristics such as good high temperature compressive strength, wear resistance, erosion resistance, high heat transfer, thermal shock resistance, corrosion resistance, good air tightness and early strength by the High-strength Corundum Castable RS Refractories Manufacturer. Email us for more details.

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High-strength Corundum Castable Description

Corundum series castable refractory products are a type of unshaped refractory insulation materials that are relatively common in production and application at this stage. Corundum is a high-strength abrasion-resistant and refractory castable raw material. The key is to use corundum as the stone and particulate material plus some fusion agent to prepare the refractory castable. Compared with high aluminum refractory castable and mullite refractory castable, it has higher impact toughness and cavitation resistance. It is mainly used as lining raw materials for various furnaces such as heating furnaces, hot blast furnaces for ironmaking blast furnaces, heat treatment furnaces, and porcelain kiln. The castables are mainly used in metallurgical industry and industrial furnaces, and are also widely used in crude oil, chemical plants, decorative building materials, electrical engineering and mechanical equipment industrial furnaces and thermal insulation equipment. It is mainly used to construct a variety of general buildings such as heat treatment furnace linings.

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High-strength Corundum Castable Uses

(1) Adding steel fiber and water reducing agent to the castable can produce steel fiber castable with good heat resistance and strong wear resistance. Mostly used for heat treatment furnace hearth, tapping trough and cement rotary kiln mouth.

(2) According to customer requirements, using this series of product castables can be used to produce and process a variety of prefabricated components.

High-strength Corundum Castable Physical and Chemical Indicators

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Instructions for use of High-strength Corundum Castable

1. Before construction of the refractory castables project, be sure to check whether the nails are firmly welded. Use high temperature resistant nails at around 500 ℃. The surface of the nails should be coated with paint or plastic tape to buffer the surging ground stress after heat.
2. The pouring material should be stored in a warehouse with a cover to prevent the return of moisture. The storage period cannot exceed six months.
3. It can be applied in the working temperature range of -5 ℃ ~ 30 ℃.
4. In the application, be sure to use a forced mixer or mortar mixer to mix materials, and do not use manual service to mix materials. The mixing utensils need to be cleaned and tidy in advance. Do not infiltrate other dirt such as lime powder, grit, fly ash cement.
5. Be sure to use clean drinking water for mixing, strictly control the water demand, and perform measurement verification.
6. Add the big bag material first, then the small bag material, and then add the water. The water flow rate refers to the water demand of each model. After mixing with water for 3 minutes, tap water can be removed from the blender by holding the ginseng pellets. Under the condition that the slurry can be shaken, tap water is required to achieve higher compressive strength.
7. During the application, all the raw materials in the bag should be cleaned, and some of the applications cannot be removed. It is forbidden to mix different types of castables.
8. The construction time can be up to 30 minutes. The solidified blocks can not be mixed with water and used, and should be abolished. Large and medium-sized stirring rods are used to vibrate, which exceeds the compaction density. The massage stick must be reserved. In case that the massage stick is abnormal, the reserved stick can be turned on immediately.
9. The lining can be dismantled every day after construction, and it can be maintained in natural gas every day. If it needs to be delivered, it can be baked.

Production and Application of Sillimanite Bricks for Blast Furnace

Due to the characteristics of its raw materials, sillimanite bricks have a low thermal expansion rate, resistance to metallurgical slag and various glass liquids, and high temperature abrasion resistance. Therefore, the physical and chemical properties of sillimanite bricks are better than those of high-alumina bricks, with a fire resistance of 1770 ～ 1830 ℃ and a load softening starting point of 1500 ～ 1650 ℃. It is mainly used for forming the liquid hole of the glass pool kiln, the lining of the blast furnace, the throat and the ceramic industrial kiln furniture.

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Sillimanite Bricks Manufacturer #1

The blast furnace sillimanite bricks produced by the plant are based on sillimanite and mullite, alumina clinker and cokestone clinker as aggregates. It is made by adding an appropriate amount of bound clay and mixing with the granules at an appropriate ratio, after mixing, high pressure molding and proper firing temperature.

Physical and Chemical Index of Sillimanite Bricks for Blast Furnace

The Main Chemical Composition of Sillimanite Bricks Raw Materials

Production Process of Sillimanite Bricks for Blast Furnace

The firing temperature of sillimanite brick is between 1350 ~ 1400 ℃. This is a major feature of process parameters. Firing is performed in a tunnel kiln. And in summary, the addition of sillimanite to high-alumina materials (such as rocky soil, mullite, etc.) can produce high-quality refractories.

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Sillimanite Bricks Manufacturer #2

Sillimanite bricks for blast furnaces. The parts used are furnace bottom protection brick, furnace throat lining and tuyere combination brick.

The brick is made of sillimanite, andalusite and sintered mullite as the main raw materials, and some ultrafine powders and binders are added. The bricks are fired in a tunnel kiln by high pressure molding or vibration pressure molding. The firing temperature is 1390 ~ 1400 ℃, and the heat preservation time is 10 ~ 16h.

The proportion of sillimanite bricks: sillimanite 30% to 40%, andalusite + mullite 35% to 55%, super alumina 10% to 15%, raw clay 5% to 10%.

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Physical and Chemical Index of Sillimanite Bricks for Blast Furnace

The sillimanite bricks produced by the plant use sillimanite and andalusite composite materials. Particle size of sillimanite concentrate: 0.250 ~ 0.149mm, about 10% ~ 20%, 0.149 ~ 0.104mm, about 27% ~ 60%, 0.104 ~ 0.074mm, about 12% ~ 28%, and less than 0.074mm, about 30% ~ 48%. This particle size is used as an intermediate particle when making bricks.

The decomposition temperature of andalusite is different from that of sillimanite. At the calcination temperature of about 1400 ° C, the sillimanite crystals in the product have not been transformed, and the transformation of andalusite crystals is not complete. Therefore, during use, these crystals continue to undergo the micro-expansion accompanied by mullite , Which is enough to offset the shrinkage caused by the increase of the liquid phase amount of the product at high temperature, and improve the load softening temperature of the product. At the same time, high pressure molding plays a role in reducing porosity and increasing strength.

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Conclusion

In summary: Over the years, users have reported good use and can better meet the needs of the light industry, building materials, and metallurgical industries. Due to the good physical and chemical properties, low cost, and significant economic and social benefits of Sillimanite Bricks products, its development prospects are very broad. The Sillimanite Bricks products need to further improve its physical and chemical properties.

Low Cement Castable Properties

Low cement castable, also named as low cement castable refractory, is a kind of unshaped refractory castable. This Low cement castbales are made of superfine power, aluminate cement, anti detonant and water reducer. RS Kiln Refractory Manufacturer supply customers with high quality castable refractory, Email to us for the free quote, and you will get the lower price here!

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Low Cement Castable Properties

Low-cement, ultra-low cement refractory castables refer to castable refractories with a calcium aluminate cement addition of less than 8%. According to the American ASTM regulations, the CaO content in low cement castables is less than 2.5%, generally between 1.0% and 2.5%. When the CaO content is less than 1.0%, it is called an ultra-low cement castable. Unlike ordinary refractory castables, some or most of the calcium aluminate cement in the matrix of low cement and ultra low cement castables is replaced by ultrafine powder with the same or similar chemical composition as the main material. At the same time, an appropriate amount of dispersant (water reducing agent) and a certain delayed coagulant are added.

Low cement castables refractory material has the merits of high density, low porosity rate, good hot strength, high refractoriness and high refractoriness under load. Besides, the low cement refractory castable has strong mechanical spalling resistance, shock resistance and corrosion resistance ability. 

• High density
• Low porosity rate
• Good high temperature strength
• High refractoriness
• High refractoriness under load
• Strong in mechanical spalling resistance, shock resistance and corrosion resistance.

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Low Cement Castables Physical & Chemical Index

Low Cement Castables Application

Due to the Properties of Low cement castable high alumina, it is widely used in the following thermal equipments. Such as heating furnace in metallurgical industry, boilers in power industry and building material industrial furnace.

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Low Cement Castable Manufacturers

RS refractory manufacturer is a professional supplier of refractory castable for steel industry, petrochemical industry, cement industry, glass industry,  etc. We RS Refractory Factories, produced not only various refractory bricks, also own the newly established castable refractory production line, 150 tons per day. If you are looking for high strength castables, low cement castables refractory density, mullite refractory castable, lightweight insulation castables, etc. Please quote us by filling the message box or to the contact us page. Make an ideal purchase plan for refractory castables, Rongsheng will never let you down!

Lightweight Insulating Castable Refractory

The Lightweight Castable Refractory is a castable unshaped refractory material prepared by adding water or a solution containing a binder during construction by using light refractory aggregate, refractory powder, binder and admixture. It is generally used as a thermal insulation lining for thermal equipment to reduce energy consumption by heat preservation. Therefore, it is also called Lightweight Insulating Castable Refractory.

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Lightweight Insulating Castable Refractories Features

Lightweight Insulating Castable Refractories have good thermal insulation properties due to their small bulk density and low thermal conductivity. At the same time, lightweight insulation refractory castables have other unique features for thermal insulation lining of various thermal equipment, and some lightweight castables can also be used directly for work lining.

• Feature 1: Light weight, high compressive strength, acid and acid gas corrosion.
• Feature 2: heat insulation, heat preservation, low water absorption
• Feature 3: Simple construction, it is the most ideal product for the construction of alkali corrosion resistant parts under high temperature.
• Feature 4: Good workability, strong adhesion, long initial setting time and long operation time, strong strength growth, strong impermeability, no need for acid treatment, easy to ensure the dense and fullness of masonry gray joints, can significantly improve The airtightness and integrity of the lining wall of the chimney and the corrosion resistance of the lining are ideal cementing materials for high chimneys, high temperature flue and duct lining, and can also be used for acid resistant pools in petroleum, chemical, nonferrous metallurgy and other industries. Acid resistant engineering such as tanks.

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Lightweight Insulating Castable Refractory can be classified according to the use temperature:

• Low temperature lightweight refractory castable with a temperature of 600-900°C;
• Medium temperature lightweight refractory castable with a temperature of 900-1200°C;
• High temperature lightweight refractory castable, use temperature greater than 1200°C.

This kind of lightweight insulation castable has the properties of lightweight, good performance of insulation, and low thermal conductivity.

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Rongsheng Lightweight Insulating Castable Refractory Manufacturer

The refractory castable production line of Rongsheng Refractory Manufacturer has been fully put into operation. The daily production capacity is 150 tons. In addition to the visible production strength, Rongsheng’s technical strength cannot be underestimated. Rongsheng’s technical team will consolidate the customized castable refractory lining according to the working conditions of the customer’s thermal equipment to improve the use of refractory materials, extend the life of the lining of the kiln, and greatly save costs and energy consumption.

If you are in need of refractory castables, such as Lightweight Insulating Castable Refractory, please contact us and we will provide you with more choices, lower prices, and faster delivery!

Castable Refractory Cement Manufacturer

The raw materials of high-quality bauxite and high-quality lime are mixed in a certain proportion; after sintered, the clinker with aluminate as the main component is obtained; the clinker is further ground into fine powder; Finally, a fire-resistant hydraulic cementitious material called Castable Refractory Cement is produced. Refractory Cement has a refractoriness of not less than 1580°C. According to the composition, it can be divided into alumina refractory cement, low calcium aluminate refractory cement, calcium magnesium aluminate cement and dolomite refractory cement.

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Use of Refractory Cement

Refractory cement is also be called furnace cement. Refractory cement can be used to bond various refractory aggregates (such as corundum, calcined high alumina bauxite, etc.) into refractory mortar or concrete for lining of cement rotary kiln and other industrial furnaces.

Precautions after Construction of Refractory Cements Lining

After the refractory cement lining is completed, an boiler-drying is required to evaporate excess water. Avoid the explosion of the boiler when start-up operation, and extend the service life of the refractory lining.

When the refractory cement lining is on baking, it should be slowly heated to avoid excessive temperature rise to prevent local bursting. When it comes to cooling of the refractory cement lining, it should also be slow, and avoid forced ventilation.

Castable Refractory Cement Manufacturer

Rongsheng Castable Refracory Cement Manufacturer has experienced more than 10 years in the refractory industry and currently has a refractory brick production plant and a castable production plant, and a separate office. RS unshaped refractory production line has been put into production, fully automatic, efficient production process, to provide you with high quality refractory cement and other castable products. To get Castable Refractory Cement Price, please contact our sales manager, Make a free quote.

The Application of Corundum Castable

Corundum castable is made from corundum aggregate, fines, binders and additives. Corundum castable has the advantages of high mechanical strength, excellent abrasion resistance, high refractoriness, good slag corrosion resistance, low creep rate and so on. Al2O3 content in corundum castable is above 90%. Raw materials used for corundum castable production are: tabular corundum, white corundum, brown corundum and so on. Composite corundum castable such as chrome corundum castable, application of corundum castable, zirconia corundum castable are widely used in different industrial furnaces areas.

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Corundum castable used in heating furnace tapping spout are composed of fused corundum( brown corundum or sub-white corundum) aggregate, fused corundum powder, a-Al2O3 micro powder, SiO2 micro powder, Cr2O3 micro powder( or zircon micro powder) and high purity calcium aluminate cement.

Application of Corundum Castable

Corundum refractory castable  is widely used in steel ladle working lining, sliding nozzle valve, tapping nozzle, electric arc furnace cover triangle zone and so on. Besides, corundum castable are also used in places where need good abrasion resistance, for example, rotary kiln, coal injection tube, circulating fluidized bed boiler, RH furnace immersion tube outer lining, petrochemical industry high temperature catalytic cracking reactor working lining, etc.

Sometimes, black silicon carbide is added into corundum castable raw materials, so the wearing resistance is greatly improved, it is very suitable for CFB boilers.

Corundum Castable Physiochemical Index

Corundum Castable Manufacturer Supplier

RS Group Kiln Refractory Bricks is the manufacturer & supplier of corundum castable. Our corundum castable is with high quality and competitive price. Contact RS Group for more details.

RS Group GIFA 2019 Exhibition Time

After intense preparations, RS Group’s exhibition staff arrived at GIFA 2019. We are ready to show the world the advantages of RS refractory products and our production technology. The following is the RS Group GIFA 2019 Exhibition Time.

RS Group exhibition site uses the Chinese red witch is the characteristics of Chinese. Our refractory bricks models and RS products brochures are on display. Welcome the you from all over the world to get a glance of RS refractory products.

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At our exhibition, Rongsheng Group will welcome visitors with the fullest enthusiasm. Our products, such as firebricks, unshaped refractories, graphite electrodes, insulating refractories and so on are with competitive. Our service, contains the customization, refractory products cn be designed for the special working conditions. Our technology, with refractory projects design, construction and maintenance, etc.

In 25th, yestory, at RS Group booths, there have been many visitors. Under the guidance of our booth staff, the visitors learned more about RS Group’s refractory products and then took photos with them. We look forward to the more visitors in the next following days!

If you are attending or want to attend GIFA 2019 in Exhibition center in Dusseldorf, Germany. Don’t miss us, RS Group, Booth No.: Hall 4 – C39. Date: June25 ~ 29, 2019.

Noranda Furnace Refractory

Noranda furnace is formerly called Noranda reactor, it is horizontal cylindrical bath smelting furnace. Copper concentrate ore, copper containing material, flux and fuel are proportionally mixed and loaded into furnace by thrower. Oxygen rich air are blasted into furnace from tuyere, which makes the molten bath in a stirring state, raw material can have desulfurization reaction and slag making reaction, and produce matte with about 70% copper content.

Noranda furnace has strong adaptation to raw material, large capacity and high efficiency, flue gas SO2 concentration is high and can meet the requirement of sulfate acid making. It is also self heating smelting furnace, with low energy consumption. Noranda furnace copper smelting belongs to oxygen-rich bath smelting. It can realize drying, sintering, smelting and blowing smelting slag making at the same time, with high smelting intensity, intense bath agitating. To ensure the smooth going of smelting process and the service life of furnace, furnace lining refractory should have very high performance.

The most vulnerable parts of Noranda furnace are tuyere, furnace mouth, material loading-end combustor and furnace cylinder top corresponded to slag discharging end combustor, sediment zone slag line upper and lower part wall and slag-end wall. 

At tuyere zone, large amount of oxygen enriched air enters into furnace, accompanied with fierce agitating and spraying, chemical reaction is intense, corrosion is severe, meanwhile, furnace temperature will fluctuate frequently and cause thermal shock, mechanical abrasion is also happened when poking tuyere. So the working atmosphere is very harsh, damage speed is quick. It directly determined the service life of Noranda furnace. Furnace mouth would suffer high temperature smoke current scouring, mechanical impaction during cleaning slag, is also easy to be damaged.
Sediment zone slag line upper and lower cylindrical wall and slag-end wall are exposed in high temperature, and as slag layer will frequently change position during slag discharging and copper discharging, this part will suffer severe erosion and high temperature current scouring, is also vulnerable.

Material loading end wall and loading mouth. As material is water containing, cold air will also enter furnace from loading mouth, the furnace lining of material loading mouth will deform and form bump.

Feeding end combustor and slag discharging end combustor surrounding furnace top lining mainly suffer the direct scouring of flame, local thermal load is overlarge and with the coaction of large amount cold air, thermal shock is very severe.

According to the production condition of Noranda furnace, refractory materials used in it should have high purity, good slag corrosion resistance, high mechanical strength, good scouring resistance, abrasion resistance, good thermal stability. Earlier, furnace lining where suffers severe damage is mainly built by fused cast magnesia chrome bricks, other parts are built by direct bonded magnesia chrome bricks. The quantity of fused cast magnesia chrome bricks accounts for 30%~40% of the total firebricks consumption. With the improvement of furnace design, the damage degree of the damage tending parts is greatly reduced, along with the enhancement of firebrick quality, now fused grain rebonded magnesia chrome bricks have replaced fused cast magnesia chrome bricks. Although fused cast bricks have good abrasion resistance, erosion resistance and mechanical scouring resistance, their thermal shock resistance is poor and it is also expensive. The rest parts still use direct bonded magnesia chrome bricks.

Special Grade Phosphate Bricks

Special Grade Phosphate Bricks Description

Phosphate bricks have been recognized as high quality linings for cement kilns and lime kilns. Phosphate bricks include two types: one is phosphate bonded high alumina brick (referred to as phosphate brick), and the binder is phosphoric acid solution with a concentration of 42.5% ~ 50%; the other is phosphate bonded high alumina wear resistant bricks ( wear-resistant bricks), and the binder is aluminum phosphate solution prepared from industrial phosphoric acid and industrial aluminum hydroxide. Among them, phosphate brick has good chemical stability, high thermal strength and good wear resistance. It is often used at expansion port of machine shaft kiln and high temperature zone kiln lining, rotary cement kiln cooling zone and transition zone. The corrosion resistance of wear-resistant bricks is better than that of phosphate bricks. It is commonly used in areas of machine shaft kiln where abrasion is severe,  as well as cooling machine an and kiln preheating parts of the rotary kiln.

Special grade high alumina bricks contain zirconium, their thermal shock stability and anti-stripping property are good, Special grade phosphate brick is developed and produced in recent years. Special grade phosphate brick is made from phosphate solution binder with a concentration of 42.5%~50%, alumina clinker aggregate calcined above 1600 °C in rotary kiln. During the application of the special grade phosphate brick, the phosphoric acid and the calcined bauxite fine powder react with the refractory clay to form a bond mainly composed of cristobalite-type orthophosphate.

Special Grade Phosphate Bricks Characteristics

High normal temperature compressive strength, good thermal shock stability, high Refractoriness under load temperature, accurate dimensions, large bulk density and good wear resistance.

Special phosphate brick has the advantages of ordinary phosphate brick: high normal temperature compressive strength, good wear resistance, refractoriness under load temperature is basically equivalent to semi-direct combined magnesia chrome brick, superior to anti-spalling high alumina brick, and has good thermal shock stability.

For transition zone with large temperature fluctuation, special grade phosphate bricks have obvious performance advantages: high temperature strength and strong resistance to thermal stress and mechanical stress in the kiln, excellent adaptation to cylinder body ellipticity changes at wheel belt parts.

Secial grade phosphate brick has higher bulk density and lower permeability, which greatly improves its thermodynamic performance and chemical corrosion resistance. The harmful components in coal powder fluctuate greatly, especially the SO3 component is high and unstable. Special grade phosphate brick is almost neutral and not sensitive to alkali corrosion, so it is more suitable for the transition zone where lining coating is frequently sprayed and damaged.

Special Grade Phosphate Bricks Physiochemical Index

Special Grade Phosphate Bricks Applications

Special grade phosphate bricks are suitable for transition zone kiln mouth of rotary kiln and other parts that firebricks are easy to fall off, and are suitable for sintering zone. The use of special phosphate bricks in the transition zone, the service life of the bricks is basically matched with the magnesia chrome bricks.  Special grade phosphate bricks are also used in mechanical shaft kiln, lime kiln, carbon industry rotary kiln and so on.