Blog Archives - Page 6 of 9 - RS Kiln Refractory Bricks

The temperature of the carbon brick in the furnace hearth is too high, the working conditions of the lining deteriorate, and the damage is accelerated, which affects the long life of the blast furnace and the safe operation of the equipment. For the damage and repair of carbon brick lining in the furnace hearth, all manufacturers are looking for effective measures to curb the rising temperature of carbon bricks. Govern at the early stage of hidden dangers to ensure safe and efficient operation of equipment and strengthen smelting.

Blast Furnace Carbon Bricks — Blast Furnace Carbon Brick Lining

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Analysis of the Damage to the Lining of Blast Furnace Carbon Brick

After the blast furnace was put into production for a period of time, due to the consumption of ceramic coasters, the carbon brick lining in the hearth directly suffered the erosion of the molten iron, which may be partially damaged. The bottom of the hearth is recessed and cracked in the shape of a garlic head so that the temperature gradient in the carbon brick increases and the high-temperature area moves outside the furnace.

In addition, the carbon ramming mass material filled between the ring-shaped carbon brick and the stave may shrink after a long time of carbonization. Especially when the blast furnace is built, the charcoal ramming material is not compacted, and it is more likely to be loose. A gas gap is formed in the carbon ramming layer, which seriously affects the cooling effect of the cooling wall on the carbon brick. The thermal resistance of the gas is 200 times that of the dense carbon ramming.

Excluding the damage to the cooling stave, the reason why the monitoring temperature of the thermocouple built in the carbon brick is higher than the normal temperature is mainly caused by the following two situations. In general, by observing the temperature difference between the cooling wall inlet and outlet water, the reason for the local temperature rise of the carbon brick lining can be roughly judged. If the temperature difference between the incoming and outgoing water is higher than the normal part, it should be caused by the carbon brick being eroded and thinned to increase the intensity of the heat flow. When the temperature difference between the incoming and outgoing water is lower than the normal part, it should be caused by the shrinkage of the carbon ramming material and the increase in thermal resistance caused by the gas gap. When both factors are combined, changes in the temperature difference between the incoming and outgoing water may cancel each other out and the changes are uncertain.

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Repair of the Damaged Carbon Brick Lining of Blast Furnace

For the former case, it should be recommended to adopt vanadium-titanium ore protection measures in blast furnace production operations. Increasing the viscosity of the solution in the hearth will help to form a protective layer with a certain thickness on the surface of the carbon brick, to avoid the high-temperature area caused by the further erosion of the carbon brick lining moving in the direction of the furnace. For the latter case, the cooling wall hot surface grouting measures can be taken to eliminate the gas gap in the carbon ramming layer and improve the cooling effect of the cooling wall on the carbon brick. When necessary, the two measures are adopted at the same time to achieve the purpose of reducing the temperature of the furnace carbon brick.

The grouting measure for the hot surface of the cooling stave is to find out the filling position of the iron filings between the two cooling studs at the part where the temperature of the carbon brick in the hearth is too high. After drilling holes in the furnace shell with a magnetic drill, drill through the iron filings layer with an impact drill to reach the carbon ramming layer. Then use a negative pressure ejector to suck out the debris clogged in the hole to make the grouting pipeline unblocked. A high thermal conductivity furnace and a special carbonaceous bottom of the furnace are used to press the slurry into the cold and hot surface of the cooling wall and grouting at the same time. To fill the air gap of the carbon ramming mass layer on the hot surface of the cooling stave to improve the cooling strength of the stave on the carbon brick.

Rongsheng Refractory Bricks Manufacturer

Rongsheng has extensive experience in the production and sales of monolithic refractory materials and refractory bricks. Rongsheng’s fully-automatic unshaped refractories production line, with an annual output of 80,000 tons. And our refractory materials products have been sold to more than 60 countries around the world. Such as Malaysia, South Africa, India, Indonesia, Pakistan, Netherlands, Kuwait, Kenya, Russia, United States, Philippines, Vietnam, etc. To purchase high-quality carbon bricks and high-quality ramming mass materials, please leave your specific needs on the message form of this website. We will reply to you as soon as possible.

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Jul 1 2020

What Details Should be Paid Attention to When Using Refractory Mortar?

Refractory mortar is a bonding connection material for building refractory bricks. Proper selection of refractory mortar is very important for the integrity and tightness of the refractory brick combined with the high temperature in the later period and the lining of the kiln. In the construction process of refractory materials, what details should be paid attention to when using refractory mortar can not be ignored. Rongsheng’s high-quality refractory bricks and supporting refractory mortar of the same material are used.

RS High Quality Refractory Mortar — RS High-Quality Refractory Mortar

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Details to be Noted When Using Refractory Mortar

When using refractory mortar, it needs to be paid attention: The performance of the refractory mortars used for building refractory bricks should be compatible with the physical and chemical properties of the refractory bricks used. The types and indicators of refractory mortars are determined by the material and temperature of the refractory bricks used in industrial kilns.

When the refractory mortars are used in combination with refractory bricks, the fineness of the refractory mortar must be kept above 160 mesh, otherwise, it will dry too quickly and the adhesion will not be strong. Before using refractory mortar, it is necessary to determine the viscosity of the refractory mortars and the amount of liquid added. (Water binding, phosphoric acid-binding, resin binding). The bonding time of refractory mortar must meet the construction requirements of refractory bricks. The bonding time of refractory mortar depends on the material, size and difficulty of construction of refractory bricks. Generally speaking, the bonding time is 1-1.5min. It will not dry too fast or too slow. Too slow to condense. Too fast refractory bricks and refractory bricks are not bonded together.

When the refractory mortars are prepared, choosing the water as the liquid, clean industrial water is used, and the PH value is between 6-7. Do not use industrial water containing harmful substances and oil stains. It is particularly worth reminding that when preparing refractory mortar in coastal areas, the water used must be strictly tested, and the concentration of chloride ions cannot be greater than 300mg/L. Springwater can not be used when constructing near a mountain. The PH value of spring water is 11, so it cannot be used.

Phosphoric acid is added to the refractory mortar during its preparation, and it must be carried out in strict accordance with the instructions of the refractory mortars manufacturer. The amount of phosphoric acid added should not be too much or too little, too thin, or too thick are not conducive to the bonding strength of refractory mortar.

There are many varieties of refractory mortars, and various varieties and brands can not be mixed. The best prepared refractory mortar on the day is best used on the same day, not used the next day. The rational use of refractory mortar is based on the material of the refractory brick and the temperature of the construction is closely combined.

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Rongsheng Refractory Manufacturer

Rongsheng is an experienced refractory manufacturer. Rongsheng’s refractory products have been sold to more than 60 countries and regions around the world. Such as Malaysia, South Africa, India, Indonesia, Vietnam, Pakistan, Netherlands, Kuwait, Kenya, Russia, United States, etc. Rongsheng also has production lines for refractory bricks and refractory castables. Advanced production equipment and experienced technical team escort our refractory products. For more information about Rongsheng refractory bricks and refractory castables, please contact us. We will provide you with high-quality refractory service.

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Jun 20 2020

How to Choose Refractory Lining for Blast Furnace?

How to choose refractory lining for blast furnace? In the design of refractory materials for blast furnaces, the different working conditions and erosion mechanisms of each part of the blast furnace should be fully considered, combined with the conditions of the original fuel, and the refractory materials should be selected in a targeted manner. The high-quality Refractory Lining for Blast Furnace, which can not only improve the service life of the blast furnace but also greatly save the production cost.

Construction Refractory Lining for Blast Furnace

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Therefore, according to the different working conditions of different parts of the blast furnace, the selection of refractory lining for blast furnace used in each part is as follows.

(1) Furnace bottom, hearth, taphole area, and tuyere belt.

The development of longevity technology in the hearth and hearth bottom has gone through a long process. The mainstream models of the entire hearth and hearth bottom structure are the “carbon + ceramic composite hearth and hearth bottom” structure and the “carbonaceous hearth + integrated hearth bottom” structure, these two technical systems.

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The heat-resistant castable is used below the furnace bottom water-cooling pipe centerline to the elevation of the heat-resistant foundation pier top. Carbon refractory ramming material is used between the centerline of the furnace bottom water-cooled pipe and the first layer of fully covered carbon brick. The first, second, and third layers are covered with semi-graphite carbon blocks, and the fourth layer is covered with microporous carbon bricks. There are also carbon bricks and ultra-microporous carbon bricks, the bottom of the furnace is made of two layers of ceramic pads, and the hearth is made of ceramic walls. The ceramic is beneficial to the heat preservation of the hearth slag and is conducive to saving the coke ratio and active hearth.

By adopting strong cooling measures in which the furnace bottom water cooling tube is buried under the furnace bottom brick, and the building method of the carbon furnace and ceramic. The goal of reducing erosion rate and longevity of blast furnace can be achieved.

The taphole area is built with carbon composite bricks. A composite brown corundum combined brick structure is adopted in the tuyere area. Its anti-slag iron corrosion and thermal shock resistance are good, the overall performance is good, and it has good protection for the tuyere-cooler casings. At the same time, it supports the refractory brick lining of the furnace belly.

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(2) The area of furnace belly, furnace waist, and furnace body.

A thin furnace lining structure with an integrated refractory brick wall is adopted, and the lining of cast iron cooling plate refractory brick is integrated with the cooling wall by cold setting. The production practice of the steel mill proves that this design structure can fully meet the normal service life of the blast furnace for 12-15 years.

The furnace belly, furnace waist, and lower part of the furnace body are inlaid with silicon carbide bricks combined with silicon nitride. The middle of the furnace body is made of fired microporous aluminum carbon brick. The middle and upper parts of the furnace body are lined with phosphoric acid-impregnated high-density clay bricks.

(3) Refractories for furnace throat

Furnace throat plays a role in protecting furnace lining and reasonable cloth. This area is mainly affected by direct impact and friction from blast furnace incoming materials. Because the temperature of this part is not high, about 400~500℃, the refractory materials used are mostly dense clay bricks, high alumina bricks, and sillimanite bricks. But the service life is still short, so it is also protected by wear-resistant and impact-resistant cast steel bricks.

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(4) Furnace top and riser.

Spraying materials with strong CO corrosion resistance and high thermal flexural strength.

(5) Between the cooling stave and the furnace shell.

The grout is pressed into the refractory mortar without water.

Rongsheng refractory brick manufacturer

Rongsheng is a refractory manufacturer with more than ten years of production and sales experience. Our refractory brick and refractory castable production lines are equipped with advanced production equipment. Moreover, our experienced technical engineers of refractory materials always pay attention to the development of refractory materials and customize refractory products for customers’ refractory linings. Our refractory products have been sold to more than 60 countries around the world, such as Malaysia, South Africa, India, Indonesia, Pakistan, Netherlands, Kuwait, Kenya, Russia, United States, etc. If your blast furnace needs refractory bricks or refractory castables. Please contact us with your details requirements, we will provide you with efficient refractory service.

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Jun 9 2020

Performance of High-Quality Alumina Bubble Castable

As we all know about the alumina bubble bricks. Have you ever heard about the alumina bubble castable? The answer is Yes! Alumina Bubble Castable is a lightweight refractory castable prepared with alumina hollow balls as aggregate and industrial alumina or corundum powder as powder. The binders used in this kind of lightweight refractory castables are mainly CAC (CA-70C, CA-80C) cement, aluminum phosphate, and aluminum sulfate. The particle size of the alumina hollow ball aggregate in the castable is 5mm, and the natural particle size or graded gradation is usually used. At the same time, additives are also added to improve the Performance of High-Quality Alumina Bubble Castable.

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Performance of Alumina Bubble Refractory Castable

The bulk density of alumina hollow spheres is 0.5~0.8g/cm-³. The true density is 3.94g/cm-³. The melting point temperature is 2040°C. The thermal conductivity is 0.46W·(m·k)-1 at 1100℃. The crystal form is α-AL2O3. The content of AL2O3 is greater than 99%. So is the Alumina Bubble Castable’s performance index as the following:

Items		CA-70C			Low Cement	Aluminum Sulfate
Crushing Strength (MPa)	110 ℃	27.1	19.0	15.9	9.7	7.4
Crushing Strength (MPa)	1500 ℃	32.2	22(1000℃)	13.3	26.6	21.2
Bending Strength (MPa)	110 ℃	9.1	5.4	8.0	4.0
Bending Strength (MPa)	1500 ℃	10.8
Refractoriness Under Load (℃)	0.2MPa, 0.6%	＞ 1600
Thermal Conductivity (W/m·k)	1000 ℃	0.80	0.82	0.82	0.65	1.76
Chemical Composition (%)	Al2O3	94.8	80.8	93.7	95.4	95.8
	Fe2O3		0.6	2.66(Cr2O3)	0.13
	CaO	3.4	3.3	3.17	2.18
Bulk Density (g/cm3)		1.6	1.46	1.64	1.58	＜1.3
Working Temperature (℃)		1800	1600	1800	＞1600	＞1600

Silicon Carbide Alumina Bubble Castable

(1) Adding silicon carbide in an appropriate amount is beneficial to increase the volume density, room temperature compressive strength, and thermal shock stability of low cement combined alumina bubble castable. The excessive addition of silicon carbide will destroy the matrix structure of the castable. When the amount of silicon carbide added is 6%, the bulk density of the alumina bubble castable sample reaches 1.5g/cm3, and the retention rate of normal temperature compressive strength is 92.3%. At this time, the alumina hollow ball castable exhibited the best thermal shock stability.

(2) As the firing temperature increases, the bulk density of this kind of castable and the normal-temperature compressive strength before and after thermal shock increase gradually. When the firing temperature is 1 450 ℃, the bulk density of the sample reaches 1.48g/cm3, and the retention rate of compressive strength at room temperature is the highest, reaching 95.3%. The ability of the alumina bubble castables to resist temperature changes is enhanced.

Features and Applications of Alumina Bubble Castable

The characteristics of alumina bubble castable are high load softening temperature, high strength, and good heat insulation performance. The operating temperature is generally 1600℃~1700℃. It is an ideal thermal insulation material for carbon black reaction furnace and special high-temp permanent layer lining. Alumina bubble refractory castables are mainly used in thermal furnaces such as metallurgy, ceramics, refractory, petrochemical, and carbon black. It can meet the development needs of new processes and technologies, save energy, and has outstanding economic and social benefits.

RS Refractory Materials Manufacturer

As one of the refractory manufacturers, RS has more than 10 years of experience, and the refractory materials have been delivered to more than 60 counties and areas. Such as Malaysia, South Africa, India, Indonesia, Pakistan, Netherlands, Kuwait, Kenya, Russia, United States, etc. If you are looking for the alumina hollow ball bricks and the alumina bubble castables, please leave us your detailed requirements, so that we can according to your furnaces’ working conditions to provide you the suitable refractory materials.

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May 27 2020

Difference Between High Alumina Bricks and Fire Clay Bricks

When buying refractory bricks, some customers may consider whether to buy high alumina bricks or fire clay bricks. This is based on the customer’s actual thermal furnaces’ working conditions, taking the difference between high alumina refractory bricks and fire clay bricks as a reference. High alumina bricks are close to alkaline, and clay fire bricks are close to acid, which is the most essential difference between them.

Fire Clay Bricks - T19 (Aluminum 48%) — Fire Clay Bricks – T19

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High Alumina Bricks

High alumina refractory brick is an aluminum silicate refractory with an alumina content of more than 48%. It is formed and calcined by alumina or other raw materials with high alumina content. The high alumina bricks have high thermal stability, and the refractoriness is above 1770 ℃. Slag resistance is better. It is mainly used for lining blast furnace, hot blast stove, electric furnace top, reverberatory furnace, and rotary kiln, etc. In addition, high alumina bricks are also widely used as open-hearth regenerative checker bricks, plugs for pouring systems, nozzle bricks, etc.

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Fire Clay Bricks

The Al2O3 content of the fire clay bricks is 30% ~ 40%. Fire clay bricks are kind of weak acid refractory brick products, which can resist the erosion of acid slag and acid gas. They have weaker resistance to alkaline substances. Clay fire bricks have good thermal properties and are resistant to rapid cooling and heat.

Clay fire bricks are mainly divided into clay fire bricks for blast furnaces, clay refractory bricks for hot blast stoves, and large clay fire bricks for glass kilns according to their uses.

Due to the low load softening temperature of fire clay bricks, shrinkage occurs at high temperatures, the thermal conductivity is 15% to 20% lower than that of silica bricks, and the mechanical strength is also worse than that of silica bricks. Therefore, clay bricks can only be used for secondary parts of coke ovens, such as regenerator wall sealing, small flue lining bricks and regenerator bricks, furnace door lining bricks, furnace roof, and riser lining bricks.

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Advantages of Fire Clay Bricks

Fire clay bricks are weak acid refractory materials and have a certain degree of corrosion resistance to acid slag. Its application is widely, and it is also the refractory material with the largest production volume.
The price is cheap. Because it mainly uses refractory clay as the raw material, the production cost will be much lower than the refractory bricks using other raw materials.
Low refractoriness. It can be used in the high-temperature kiln places where do not belong to the high-temperature zone, or other parts that are not important.

Clay Fire Bricks Performance

The fire resistance of clay bricks is comparable to that of silica bricks which can up to 1690 ~ 1730 ℃. But the softening temperature under load is 200 ℃, lower than that of silica bricks. Because the clay brick contains mullite crystals with high refractoriness, it also contains nearly half of the low-melting amorphous glass phase.

In the temperature range of 0 ~ 1000 ℃, the volume expands of clay fire bricks uniformly with increasing temperature. Its linear expansion curve approximates a straight line. The linear expansion rate is 0.6% to 0.7%, only about half of the silicon brick. When the temperature reaches 1200 ℃, and then continue to heat, its volume will begin to shrink from the maximum expansion. The residual shrinkage of clay bricks leads to the cracking of the masonry gray joints, which is a major disadvantage of clay bricks. When the temperature exceeds 1200 °C, the low melting point in the clay brick gradually melts. Due to the surface tension, the particles are very close to each other, resulting in volume shrinkage.

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Conclusion

In general, the chemical pH value of high alumina bricks belongs to neutral refractory bricks. Fire clay bricks are neutral refractory bricks that tend to be acidic. High-alumina refractory bricks, all physical and chemical properties except thermal shock resistance, are superior to clay fire bricks. In the construction of kilns lining and other thermal equipment, if the clay refractory bricks are capable of the working environment, it is not necessary to use high alumina bricks.

Of course, due to the limitations of the working conditions of industrial kilns, under certain conditions, certain types of clay bricks or certain types of high-alumina bricks must be used. Under such conditions, to meet the production conditions of industrial kilns as the standard, we will provide customers with high-quality clay bricks and high-alumina bricks. From this point of view, the performance of some clay bricks will be better than that of high alumina bricks.

Want to get the prices of fire clay bricks, and lightweight fire clay bricks, please contact Rongsheng Refractory Bricks Manufacturer. Rongsheng has just delivered 750t low creep low porosity fire clay bricks to customers.

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May 16 2020

Correctly Use of Refractory Mortar

The use of refractory mortar is suitable for building flue, kiln tunnel, kiln wall, and firebox of kilns, which greatly benefited us in reducing the cost of masonry kilns. The use of Refractory Mortars can also called use of fire brick mortar, they can be applied as a protective coating for linings by smearing or spraying.

Because of its good thermal exfoliation, Refractory Mortar is mainly used in coke ovens, glass furnaces, blast furnace hot air furnaces, and other industrial furnaces. At the same time, because almost all the refractory raw materials can be made into a powder used to prepare high-temperature mortar, be used as joint material for refractory bricks. So that called fire brick mortar. Refractory mortar appears in which refractory bricks are needed. Therefore, the use of Refractory Mortar is also widely in thermal engineering equipment in metallurgy, building materials, machinery, petrochemicals, glass, boilers, electricity, steel, cement, and other industries.

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Problems Encountered in the Use of Refractory Mortar

Due to the different refractory bricks and the different working conditions of different kilns, the requirements for the use of refractory mortar are also different. If not used properly, the refractory lining is prone to problems. For example, in the preparation of clay refractory mortar, only refractory clay is used without mixing with cement, and the viscosity and strength of the heat resistant mortar are not good. Moreover, because of its high temperature, it loses its binding effect and becomes powdery, which is poured out from the brick joint, causing the brick body to loosen and the number of bricks dropped frequently. Seriously affect production. A factory dropped bricks 4 times a month, making it impossible to operate normally. To deal with this situation, the only way is to adding iron plates or knocking down the heavy blocks.

Basic Use of Refractory Mortar

Before using the Refractory Mortar, firstly, clean the furnace, and use refractory cement, also called aluminate cement, to hang the slurry in the furnace once or twice. After drying, use refractory cement and refractory sand, adjust it according to 1: 1, and make up a part of it in the furnace. Then tap lightly with a small rubber hammer. After the entire furnace is tapped and filled, then hang the slurry with refractory cement once or twice and let it dry for about a week. Use this method to make up the furnace, under normal circumstances, there is no crack in the furnace!

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Configuration and Use of Refractory Mortar

Refractory Mortar consists of refractory powder, binder, and admixture. Almost all refractory raw materials can be made into a powder used to prepare refractory mortar. The common refractory mortar is made of refractory clinker powder plus an appropriate amount of plastic clay as a binder and plasticizer. Its ordinary temperature strength is low, and the ceramic bond at high temperatures has high strength. The chemically bonded high-temperature mortar with hydraulic, gaseous, or thermosetting bonding material as the bonding agent will produce a certain chemical reaction and harden before the temperature below the ceramic bonding temperature.

Firstly, When making Refractory Mortar, the powder is wetted in advance to saturate the water. Then, mix it very carefully in a refractory mortar mixer.

Preparation of Clay Refractory Mortar

The content of Al2O3 in clay refractory mortar is less than 40%. Use high-grade cement or high-alumina cement and clay refractory soil to dry mix evenly, with a mass ratio of (cement: fire mud) of 1: 2 or 1: 3, add water and stir to adjust to a thick paste-free.

High-alumina Fire Mortar Prepared by Water Glass

Add 17.5 ~ 20 kg of water glass for every 50 kg of high alumina fire mortar. Add the firing mortar to the water glass and mix well to use. This kind of fire mortar is used for LZ70 high aluminum brick masonry.

Phosphoric Acid Formulated High Alumina Fire Mortar

Add 8 kg of water per kg of 85% phosphoric acid to obtain a 42.5% phosphoric acid solution. Add 42.5% phosphoric acid solution 20 ~ 25 kg for every 50 kg of high-aluminum fire mortar, and mix well. It can be used above twelve hours. This fire mortar is used to build composite bricks.

After that, when pouring refractory mortar, a mold is used, and the high-temperature mortar is tamped by an air hammer or by hand.

Then, the thickness of the refractory filling layer should not exceed 100 mm each time, and the appropriate temperature for pouring heat resistant mortar is 20 degrees.

Lastly, in the construction of kilns, in order to make fire brick mortar play a greater effect, it must be used with refractory pain. Apply them to the surface of refractory brick masonry, which greatly improves the use and reduces the work of masonry maintenance. The paint is sprayed with compressed air or applied manually, and its thickness is 4-5 mm.

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Tips:

The particle size of refractory mortar varies according to the requirements of use. The limit particle size is generally less than 1mm, and some are less than 0.5mm or finer.
When choosing the material of refractory mortar, it should be considered to be consistent with the material of refractory products of masonry. In addition to being used as a jointing material, refractory mortar can also be used as a protective coating for linings by smearing or spraying.

Contact with RS Refractory Castable Factory — RS Refractory Castable Factory

Rongsheng Refractory Manufacturer is a manufacturer specializing in providing refractory services for various kiln equipment. Our factory has a reliable reputation and high product quality. Our factory also has very strong strength, we also have a refractory brick factory and refractory castables factory. Our customers also cover more than 60 countries and regions in the world. If you need to buy Refractory Mortar, please contact us, our refractory service will not let you down.

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May 4 2020

What’s the Principle of Selection Rotary Kiln Refractory Lining?

Refractory material is an important material to ensure the normal operation of cement rotary kiln. Its performance, design level and masonry process will affect its service life, kiln operation rate and clinker quality. Many factors, such as the stress experienced by the refractory material during the operation of the cement kiln system, will affect the refractory used in rotary kiln. Generally, the design of rotary kiln refractory lining in the rotary kiln firing system needs to be selected according to certain principles according to the variety and performance of the cement kiln refractory materials.

Castable Refractory Lining for Rotary Kiln

A castable refractory lining configuration with a working layer, insulating layer, and a ceramic fiber backing.

Refractory Bricks Lining for Cement Rotary Kiln

A typical refractory brick lining configuration with a working layer and an insulating layer.

The selection principles of Rotary Kiln Refractory Lining are as follows:

① Choose refractory materials according to the production method and kiln type.

② Use refractory materials according to the specifications of the kiln.

③ Select refractory materials according to the nature of the raw materials and fuels used.

④ Choose refractory materials according to the heat load in the kiln.

⑤ Select refractory materials according to the stress distribution and thermal distribution in the kiln.

Cement rotary kiln is the most advanced rotary kiln on the market. After years of technical innovation and practical application, the selection of refractory used in rotary kilns has also accumulated rich experience. More refractory products for the rotary kiln refractory lining, such as spinel refractory, dolomite refractory. Please Contact RS for more details.

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Apr 15 2020

Where to Buy Refractory Cement for Boiler?

Refractory cement for boiler, when the boiler is repaired, the models and specifications of refractory concrete are also different according to the different parts used. For example, when repairing the furnace wall, 0-3mm high-aluminum aggregate and refractory cement are mixed 1: 1. If your thermal equipment needs refractory cement, where to buy refractory cement for boiler? Rongsheng refractory cement manufacturer will serve you wholeheartedly.

RS Refractory Cement for the Refractory Lining Construction

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Refractory Cement Uses and Specifications

As a monolithic refractory, refractory cement is often used as a refractory lining and also as a castable refractory cement. Refractory cement is mainly used in coke ovens, glass furnaces, blast furnace hot air furnaces and other industrial furnaces. Application industries include: metallurgy, building materials, machinery, petrochemicals, glass, boilers, electricity, steel, cement, etc.

In the boiler industry, 0-3mm high-aluminum aggregate and refractory cement are mixed 1: 1 when repairing the furnace wall. Among them, high-aluminum aggregates are also called refractory aggregates and powders. The furnace arches are made of refractory concrete with 4-15mm mixed aggregate. The refractoriness of the mixed refractory castable can reach 1700 degrees. The level of refractoriness is closely related to the aluminum content of refractory aggregates. The amount of refractory cement depends on the tonnage of the boiler. The larger the tonnage, the greater the amount. A 10-ton coal-fired boiler or hot water boiler uses approximately 5 tons of refractory cement.

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Where to Buy Refractory Cement

Generally speaking, as long as it is a refractory dealer or a refractory manufacturer, it will sell refractory cement. If your boiler has a large demand for refractory cement, you can directly contact the refractory manufacturer. If your demand is not very large, you can directly contact your local dealer to purchase. If you buy a small amount of refractory cement through the manufacturer, it is not cost-effective in terms of freight.

Rongsheng is an experienced manufacturer of refractories. Our refractory products, including castables, refractory cement, and refractory bricks, have been exported to more than 60 countries and regions around the world. In the Philippines, Laos, Vietnam, Canada, Australia, and other places, we have our refractories project.

As a refractory cement manufacturer, Rongsheng’s refractory bricks and castable products can reach the international quality level. In addition, Rongsheng has an independent production plant for refractory bricks and castables. Our workshop is equipped with advanced production equipment and an experienced technical R & D team. If you need to build new boiler equipment or refurbish the refractory lining of the boiler equipment, please contact us.

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Get the Price of the Refractory Cement for Boiler

Refractory cement for a boiler is also divided into many types, mainly because the aluminum content is different. Generally, the price of CA-50 refractory cement is around 1500, and the cheaper one can reach around 1200. The price of the most expensive refractory cements, CA-80 and 70, can reach 56,000 tons. The prices of refractory cement listed here are from the Internet and are for reference only. The specific price is subject to the time of purchase. For cheap refractory cement Philippines, please contact Rongsheng Refractory Cement Manufacturer.

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Mar 28 2020

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

Chemical Composition(％)	AL2O3≥	70	75	80	85
	SiO2≤	26	21	16	11
	CaO≥	2.5	1.5	1.2	1.0
Modules of Rupture（MPa）	110℃×24h≥	8	11	12	13
	815℃×3h≥	9	12	13	14
	1100℃×3h≥	10	13	14	15
Cold Crushing Strength（MPa）	110℃×24h≥	70	80	85	90
	815℃×3h≥	80	85	90	95
	1100℃×3h≥	85	90	95	110
Bulk Density (g/cm3)		2.75	2.85	2.9	2.95
CC ≤		7	6	6	5
Thermal Shock Resistance （900℃water quenching），cycle ≥		25	20	25	20
Features		Abrasion resistance, erosion resistance, high use temperature, long life and easy construction.

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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.

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Blog

Dec 7 2019

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

Items	Sillimanite Bricks (#1)
Apparent Porosity (%)	15.3
Bulk Density (g/cm3)	2.58
Cold Crushing Strength (MPa)	120.9
Refractoriness (℃)	＞1810
Refractoriness Linear Change (%) (1500℃, 2h)	+0.17
KD	1590
T2	1660
Thermal Shock Resistance (1000,WaterQuenching, Cycle)	＞15

The Main Chemical Composition of Sillimanite Bricks Raw Materials

Items	Al2O3	Fe2O3	TiO2	K2O+Na2O
Sillimanite	57.33	1.71	0.91	0.49
Grade II bauxite clinker	67.68	1.30	1.65	0.30
Grade I bauxite fines	82.50	2.40	–	–
Mullite	76.17	0.40	0.27	0.50
Flint Clay Clinker	44.61	1.20	–	–

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

Items

Refractoriness(℃)

Apparent Porosity (%)

Bulk Density (g/cm3)

Cold Crushing Strength (MPa)

T2

Thermal Shock Resistance

(1000,WaterQuenching, Cycle)

Al2O3

Fe2O3

Refractoriness Linear Change (%)

(1500℃, 2h)

Thermal Expansion (1000℃,%)

Sillimanite Bricks (#1)

＞1790

13

2.58

99.6

1610

＞30

61.28

0.86

0

–

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.

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