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How High Alumina Refractory Balls Improve Thermal Efficiency in Industrial Applications

2023-03-20 by globalrefractory

In the world of industrial manufacturing, maximizing thermal efficiency is key to maintaining productivity and profitability. One way that companies achieve this is by using high alumina refractory balls. These small but mighty balls are an essential component in many high-temperature processes, from steel manufacturing to petrochemical refining.

How do high alumina refractory balls improve thermal efficiency in industrial applications?

So, how exactly do high alumina refractory balls improve thermal efficiency in industrial applications? Let’s take a closer look.

Firstly, high alumina refractory balls have excellent thermal insulation properties. Their high alumina content, typically above 90%, means they have a low thermal conductivity. This means they are able to retain heat and prevent heat loss, which is particularly important in high-temperature processes where energy efficiency is critical.

Secondly, high alumina refractory balls are extremely durable. They can withstand temperatures up to 1800°C without any significant deterioration, making them an ideal choice for use in furnaces, kilns, and other high-temperature applications. Their durability means they require less frequent replacement than other refractory materials, resulting in reduced downtime and maintenance costs.

Furthermore, high alumina refractory balls have excellent chemical resistance. They are able to withstand exposure to harsh chemicals, acids, and alkalis without any significant degradation. This makes them particularly useful in industries such as petrochemical refining, where exposure to corrosive substances is common.

Finally, high alumina refractory balls are able to promote thermal uniformity. They are able to distribute heat evenly, reducing hot spots and ensuring that heat is transferred evenly throughout the process. This helps to reduce thermal stress and minimize the risk of damage to equipment, ultimately resulting in improved safety and efficiency.

In conclusion, high alumina refractory balls are a crucial component in many industrial applications, particularly those involving high-temperature processes. They improve thermal efficiency by providing excellent insulation, durability, chemical resistance, and thermal uniformity. By utilizing these powerful little balls, companies are able to achieve optimal productivity and profitability, while also reducing their environmental impact by using less energy and producing fewer emissions.

What are high alumina ceramic balls?

High alumina ceramic balls are small spherical objects made from a high-purity alumina ceramic material. They are typically used as a type of advanced ceramic material in a variety of industrial applications that require high-temperature resistance, wear resistance, and chemical resistance.

High alumina ceramic balls are produced by processing high-purity alumina powder through several stages, including mixing, molding, sintering, and grinding. The sintering process involves heating the molded ceramic balls at high temperatures, which causes the individual alumina particles to fuse together, resulting in a dense and uniform material with excellent mechanical properties.

One of the primary benefits of high alumina ceramic balls is their high-temperature resistance. They can withstand temperatures up to 1800°C without any significant deterioration, making them an ideal material for use in high-temperature processes such as furnace linings, kiln linings, and catalyst support materials.

Another advantage of high alumina ceramic balls is their wear resistance. They are able to withstand repeated impacts and abrasion without any significant degradation, which makes them useful in a variety of wear applications such as grinding media, wear-resistant linings, and ball bearings.

In addition, high alumina ceramic balls exhibit excellent chemical resistance. They are able to withstand exposure to harsh chemicals, acids, and alkalis without any significant degradation, making them useful in a variety of chemical processing applications.

Overall, high alumina ceramic balls are versatile and high-performance advanced ceramic materials that offer excellent thermal, mechanical, and chemical properties. They are widely used in a variety of industrial applications that require high-temperature resistance, wear resistance, and chemical resistance.

High alumina refractory balls vs. high alumina ceramic balls

High alumina refractory balls and high alumina ceramic balls are both made from high-purity alumina materials, but they have different properties and are used for different applications.

High alumina refractory balls are typically used as a type of refractory material in high-temperature industrial applications such as furnaces and kilns. They are designed to withstand high temperatures up to 1800°C without any significant deterioration and have excellent thermal insulation properties due to their low thermal conductivity. High alumina refractory balls are also highly durable and have excellent chemical resistance, making them ideal for use in harsh chemical environments.

On the other hand, high alumina ceramic balls are used for a variety of industrial applications such as grinding media, wear-resistant linings, and ball bearings. They have excellent wear resistance and can withstand repeated impacts and abrasion without any significant degradation. High alumina ceramic balls also have high hardness and high strength, making them suitable for use in high-stress applications.

While both high alumina refractory balls and high alumina ceramic balls are made from high-purity alumina materials and offer excellent properties, they are designed for different applications. High alumina refractory balls are used for high-temperature industrial applications where thermal insulation and chemical resistance are important, while high alumina ceramic balls are used for wear-resistant and high-stress applications such as grinding media and ball bearings.

In summary, high alumina refractory balls and high alumina ceramic balls are both useful advanced ceramic materials that offer unique properties for different applications. It’s important to choose the right material for the specific application to ensure optimal performance and durability.

How Many Bricks in a Pallet of Refractory Bricks？

2023-03-07 by globalrefractory

Refractory bricks are a special type of brick that is designed to withstand high temperatures and harsh environments. They are commonly used in industrial settings such as furnaces, kilns, and incinerators. If you’re working with refractory bricks, you may be wondering how many bricks are in a pallet. The number of bricks required to complete a construction project depends on the size and scope of the project, as well as the size of the bricks themselves. In this essay, we will explore the answer to this question in detail.

How Many Bricks in a Pallet of Refractory Bricks？

A pallet of bricks is a standard unit of measurement used by manufacturers and suppliers to package and transport bricks. It is a rectangular wooden or plastic platform that is used to hold a certain number of bricks. The number of bricks in a pallet can vary depending on the size of the bricks and the dimensions of the pallet.

The number of refractory bricks in a pallet can vary depending on the size and thickness of the bricks. A standard pallet of refractory bricks typically contains between 300 and 500 bricks. However, it is important to note that this number can vary depending on the manufacturer’s specifications.

Refractory bricks are typically denser and heavier than standard bricks, which means that fewer bricks can fit on a pallet. The size and thickness of the bricks can also play a role in determining the number of bricks that can fit on a pallet. Thicker and larger bricks take up more space, which can result in fewer bricks being able to fit on a pallet.

The weight of the pallet can also vary depending on the number of bricks on the pallet. A pallet of 300 refractory bricks will be lighter than a pallet of 500 refractory bricks, for example. This is an important consideration for those who need to transport bricks from one location to another.

When working with refractory bricks, it is important to know how many bricks are in a pallet. This information can help you plan your project and determine how many pallets of bricks you will need. It can also help you estimate the weight of the pallets, which is an important consideration when transporting the bricks.

In conclusion, the number of refractory bricks in a pallet can vary depending on the size and thickness of the bricks, as well as the manufacturer’s specifications. A standard pallet of refractory bricks typically contains between 300 and 500 bricks. Knowing how many bricks are in a pallet is an important consideration when working with refractory bricks, as it can help you plan your project and estimate the weight of the pallets. If you are unsure about the number of bricks in a pallet, be sure to check with the manufacturer or supplier for more information.

What is Refractory Cement?

2023-02-10 by globalrefractory

Refractory cement is a type of cement that is used in high-temperature applications. It is made from a combination of high-alumina cement, silica sand, and other materials that are resistant to extreme temperatures. Refractory cement is used in a variety of industries, including steel production, glass manufacturing, and ceramic production. Refractory cement is used to form a protective layer between the heat source and the equipment. It is designed to resist thermal shock, abrasion, and corrosion. Refractory cement is also used to fill cracks and gaps in the walls of furnaces and other equipment. It is also used to repair damage caused by thermal shock or abrasion.

Refractory Cement for Refractory Materials — Refractory Cement from Rongsheng Refractory Factory

High alumina cement is the main component of refractory cement. It is made from a combination of alumina and calcium oxide and is highly resistant to extreme temperatures. This type of cement is also known for its high strength and durability. It is used in applications where temperatures can reach up to 3,000°F. Refractory cement is an important component of any high-temperature equipment. It is designed to withstand extreme temperatures and protect the equipment from damage. It is also used to repair damage caused by thermal shock or abrasion. Refractory cement is a reliable and durable material that can be used to ensure the safety and efficiency of any high-temperature equipment.

Castable refractory cement is a type of refractory cement that is used in applications where temperatures can reach up to 3,000°F. It is made from a combination of high-alumina cement, silica sand, and other materials that are resistant to extreme temperatures. This type of cement is used in applications where the cement needs to be poured or cast into a specific shape. Castable refractory cement is a type of cement that is used to line the walls of furnaces, kilns, and other high-temperature equipment. It is designed to withstand temperatures up to 3,000°F and is composed of high-alumina cement, which is a combination of alumina and calcium aluminate. Refractory cement is also known as castable refractory cement and cement refractory. And so is Cement refractory.

Refractory cement is an important material in many industries. It is used in applications where temperatures can reach up to 3,000°F, and is made from a combination of high-alumina cement, silica sand, and other materials that are resistant to extreme temperatures. It is used in steel production, glass manufacturing, and ceramic production.

Refractory cement can be used in a variety of ways. It can be used to make castable refractory cement, which is used to line furnaces, kilns, and other high-temperature equipment. It can also be used to make cement refractory, which is used to line fireplaces and other areas where heat is present.

Refractory cement is an important material in many industries. It is strong, heat-resistant, and can withstand high temperatures. It is used in a variety of applications, from steel and aluminum manufacturing to fireplaces and furnaces. It is made from a combination of high-alumina cement, silica sand, and other materials. Contact Rongsheng Refractory Manufacturers for free price information and samples.

How to Use Low Cement Refractory Castable?

2023-01-14 by globalrefractory

Low-cement castables are mainly used in various heat treatment furnaces such as furnace walls, furnace roofs, furnace bottoms, aluminum ladles, chutes, smelting equipment, high-temperature kiln linings, heating furnaces, and soaking furnaces of aluminum melting furnaces. Low-cement castables have high refractoriness, good high-temperature performance, high medium-temperature, and high-temperature strength, and good anti-stripping and anti-erosion properties. So, how to use low cement refractory castable? What are the precautions in the use of low cement castables? Rongsheng refractory manufacturers, based on years of experience in production, sales, and construction, will answer your questions.

How to Use Low-Cement Castables?

Stir

Must be mixed with a forced mixer. Use clean water, the water temperature should be 10-25 ℃. Strictly follow the mixing ratio given in the material instruction manual for ingredients and water. In order to overcome the uneven particle size distribution of the dry aggregate during transportation, it should be dry mixed for 1 minute and then mixed with water for 4 to 5 minutes.

Pouring

The mixed castable is quickly transported to the pouring site, and the castable is poured into the mold with a small shovel and a special hopper. When pouring, the material should be cut from one side of the formwork to prevent the lower part from creating a void. When cutting the material, prevent the wrapped ceramic fiber felt from breaking and falling off. After the material is full, start the vibrator, and the material surface will sink during the vibration. Add materials in time. When the castable surface no longer sinks or the surface is flooded and no bubbles escape, the vibration can be stopped, and the vibration time is generally 2 minutes.

Demolition and repair

When the temperature in the furnace is between 10 and 25°C, the formwork can be removed 8 hours after pouring, and the castable can be cured naturally after the formwork is removed. The pouring quality should be checked in time, and general defects will not be dealt with. However, important parts and larger problems need to be repaired to make the lining meet the requirements of the production process.

Precautions for the Use of Low-Cement Castables

Adjust the castable according to the proportion

When using low-cement castables, attention should be paid to the deployment method, and the proportion must follow the corresponding regulations. Do not add water arbitrarily or blindly add castables. Once the ratio is wrong, the pouring effect will be greatly reduced. Therefore, castable operators must have rich experience and be able to complete the deployment of castables in a reasonable proportion to ensure smooth follow-up work.

The evenly stirred castable should be used as soon as possible

In the actual application of low-cement castables, many customers mixed the castables evenly and left them aside, and did not use them in time. The disadvantage of this is that the low-cement castable exposed to the air will evaporate more water, which will reduce the moisture content of the castable, which is not conducive to the use of the castable.

The storage of castables should be mainly dry

If the amount of low-cement castables purchased is large, it needs to be stored in a relatively dry environment in time, and the corresponding protection work should be put in place to ensure that the castables are not affected by the external air and avoid quality damage. Take the appropriate amount before use, and do not put all the castables on the construction site, this behavior will interfere with the preservation of castables.

Formulate a reasonable oven curve

The outstanding feature of low-cement castables is dense and high strength, which brings benefits to use, but improper baking will easily cause peeling or bursting. Therefore, it is very important to formulate a reasonable oven curve. If necessary, an excellent explosion-proof admixture can be used, so that the moisture of the low-weight cement castable can be removed smoothly without causing any side effects.

According to the use method of low cement castable, the ideal use effect can be achieved. It should be noted that the air permeability of low-cement castables is poor, and it is easy to cause peeling or bursting during the baking process. The baking system should be formulated reasonably according to its material, construction thickness, and construction site. At the same time, metal aluminum powder, organic fiber, etc. can also be added to the castable. Make it easier to remove moisture and increase the service life of low cement refractory castables. Rongsheng Refractories Co., Ltd. produces and sells various castable products such as low-cement castables, which are easy to use, excellent in performance, and wide in application. Contact us for free samples and price information.

Comparison of the Performance of Corundum Bricks and Chrome Corundum Bricks in Applications

2022-12-06 by globalrefractory

Corundum bricks are refractory bricks with an alumina content greater than 90%. Corundum bricks are divided into sintered corundum bricks and fused corundum bricks. The chrome corundum brick is a refractory brick with Cr2O3 added to the corundum. Chrome corundum bricks are divided into two types: fused cast chrome corundum bricks and sintered chrome corundum bricks.

Corundum bricks are used in industrial furnaces under high temperatures, high pressure, and other environments. Corundum bricks and chrome corundum bricks have similarities and differences.

Fire resistance

Adding Cr2O3 to the corundum material will not only reduce the fire resistance of the material but will improve the fire resistance of the material. The refractoriness of chrome corundum bricks is greater than 1790°C and the softening temperature under load is greater than 1700°C, both of which are better than corundum bricks.

Compressive strength

The normal temperature compressive strength of corundum bricks is 70~100MPa. The room temperature compressive strength of high-performance chrome corundum bricks is generally greater than 150MPa, which is significantly higher than that of corundum bricks. During the firing process of corundum bricks and chrome corundum bricks, Al2O3-Cr2O3 solid solutions are formed between the particles, between the particles and the fine powder, and between the fine powder and the fine powder. The solid solution connects the particles and fine powder together like a bridge so that the strength of the material is greatly improved.

Thermal shock stability

Adding Cr2O3 to corundum, when the Cr2O3 content is 10%-66%, the thermal shock stability of the material decreases with the increase of the Cr2O3 content. That is, chromium corundum bricks with low Cr2O3 content have better thermal shock stability than chrome corundum bricks with high Cr2O3 content. The Cr2O3 content of high-performance chromium corundum bricks is between 12% and 20%, and its thermal shock stability is improved compared with corundum bricks. Especially the AKZ chrome corundum brick produced by adding a small number of additives that cause phase change has better thermal shock stability.

Resistance to slag erosion

Corundum bricks are severely eroded by slag, and the slag will completely penetrate into the brick and penetrate to the surface along the pores inside the brick, and the brick will turn brown with almost no slag remaining. Chrome corundum bricks are hardly corroded by molten slag, there is no obvious chemical reaction between the slag and the brick surface, the boundary between the inner hole edge and the slag is clear, and the slag rarely penetrates into the brick. Only a 5-10 mm thick metamorphic layer is formed around the brick hole, and a large amount of slag remains in the crucible hole. Chromium corundum bricks have better resistance to chemical erosion and permeability of gasifier slag than corundum bricks, and their resistance to structural spalling is also superior to corundum bricks.

Application

Chrome corundum bricks are used as glass kiln lining, brushed glass flow hole cover, and plate brick, and are used for molten iron pretreatment devices, garbage incinerators, gasifier backing, etc. Corundum bricks are used in various high-temperature kiln linings and kiln furniture such as cracking and reforming furnaces in the petrochemical and chemical fertilizer industries, steelmaking furnaces in the metallurgical industry, and blast furnaces. Among them, chrome corundum bricks are more resistant to high temperatures and corrosion than corundum bricks, which can meet the common needs of industrial kilns.

The Use Nature of Refractory Cement in Refractory Materials

2022-10-11 by globalrefractory

What is refractory cement? What are the precautions in the use of refractory cement? Rongsheng REFRACTORY CEMENT FACTORY will provide you with high-quality refractory inorganic binders, including refractory cement, aluminum dihydrogen phosphate, etc. Next, we will introduce the use nature of refractory cement in refractory materials.

What is refractory cement?

Cement with refractoriness not less than 1580℃. The different compositions can be divided into aluminate refractory cement, low calcium aluminate refractory cement, calcium magnesium aluminate cement, and dolomite refractory cement.

Historical data show that with the discovery and understanding of the heat resistance of calcium aluminate, the yield of calcium aluminate in Europe in 1913 had a rapid increase. In the 1920s, indestructible refractory casting materials began to take their own steps of development. In the late 1980s and 1990s, new pouring techniques gradually emerged. The pump and flow gating technology with low cement castables is introduced. Then came wet spray or jet technology. In these technological changes, refractory cement was produced.

Refractory cement is also called aluminate cement. Aluminate cement is made of bauxite and limestone as raw materials, calcined with calcium aluminate as the main component, the alumina content of about 50% of clinker, and then grinding into hydraulic cementitious materials. Aluminate cement is often yellow or brown, but also gray. The main mineral composition of aluminate cement is calcium aluminate and another aluminate, and a small amount of dicalcium silicate.

The use nature of refractory cement in refractories

Aluminate cement is a kind of binder (permanent binder) that can be combined at room temperature and high temperature. The refractoriness of amorphous refractories is very important. In general, the higher the Fe2O3 in cement, the lower its fire resistance. The type and content of calcium aluminate affect the fire resistance of cement. Practice shows that ordinary high aluminum cement is used at less than 1300℃, high aluminum cement (bauxite cement) is used at less than 1500℃, and low calcium high aluminum cement (high aluminum cement) is used at higher than 1600℃ temperature.

Aluminate cement often refers to calcium aluminate as the main component of cement. Calcium aluminate cement is the basic binder of amorphous refractories, especially cast refractories. The properties of aluminate cement mainly depend on its mineral composition. The main mineral composition of aluminate cement, calcium aluminate (CA), has a high hydrohard activity, the setting is not fast but hardening is very rapid, and the hardening time is not more than one day. It is the main source of the strength of high aluminum cement, especially the early strength. Calcium dialuminate (CA2) has a slow hydration hardening, low strength in the early stage, and high strength in the later stage. Dodecalcium heptaaluminate (C12A7) has the characteristics of quick hydration and rapid condensation, but the strength is not high. In ordinary high alumina cement containing inclusions, impurities affect the hardening effect of the cement and its strength.

Calcium aluminate cement contains these 5 kinds of calcium aluminate minerals, which will be along with the hydration reaction and show an intense heating phenomenon. The temperature of common high-alumina cement (53~55% A12O3) reaches the peak after 5~8h, reaching 80~90℃. The temperature of advanced high alumina cement containing 70% A12O3 reaches the peak value after 10~12h and that of 80% A12O3 after 8~10h. The temperature is 80C and 70C respectively.

The heating temperature and the time to reach the highest temperature of single castable of different kinds of high aluminum cement are determined by the heating characteristics and content of calcium aluminate. Therefore, the calorific value of high aluminum cement will also change due to the different calcium aluminate contents. If too much high aluminum cement containing C12A or CAF as the main component is added to the cast refractory, it will cause cracks and surface spalling due to intense evaporation of water in the castable hardening body due to concentrated heat. Therefore, the choice of cement dosage and quality is very important.

Precautions for the use of refractory cement

At a room temperature of 350 degrees, it is most likely to cause local bursting, and special attention should be paid to slow baking. If there is still a lot of steam bubbling up after 350 degrees of insulation, the heating rate should still be slowed down.
in the condition of poor ventilation, water is not easy to discharge, to appropriately extend the holding time.
When baking with heavy oil, it is necessary to strictly prevent heavy oil from spraying on the surface of the furnace lining to prevent local bursts.
When using wood to bake, direct contact with the flame often causes local heating to be too rapid, which should be protected.
the newly poured refractory cement, at least after 3d can be baked.
the cooling of refractory cement furnace lining should also be slow to avoid forced ventilation.

What is Alumina Silicate Refractory Brick?

2022-09-26 by globalrefractory

Alumina Silicate Refractory Bricks, for those who do not understand the refractory industry, maybe this is a kind of refractory bricks containing aluminum and silicon. But for people in the refractory industry, there is no such name, only aluminum-silicon-based refractory bricks. So, what are Alumina Silicate Refractory Bricks? What is Alumina-Silicate Refractory Brick? First of all, let’s take a look at the definition, what does aluminum-silicon refractory brick mean?

Silicon Bricks - Rongsheng Refractory Bricks — Silicon Bricks

Alumina Silicate Refractory Bricks, also known as aluminum-silicon refractory bricks, are refractory products containing Al2O3 and SiO2 and are a series of aluminum-silicon refractory bricks. Aluminum-silicon-based refractory bricks have a wide range of applications and occupy a very important position in the refractory application industry. Its usage accounts for more than 40% of the entire refractory products.

By definition, Alumina Silicate Refractory Bricks are a series that includes multiple types of refractory bricks. Below we categorize them to give you a deeper understanding.

High Alumina Refractory Bricks - Rongsheng Company — High Alumina Refractory Bricks

Aluminum-silicon-based refractory bricks are classified in the order of increasing composition from SiO2 content to Al2O3 content.

(1) Silica brick: SiO2 content ≥93%;
(2) Semi-silica brick: Al2O3 content is 15%-30%;
(3) Clay brick: Al2O3 content is 30%-48%;
(4) High alumina brick: Al2O3 content ≥48%;
(5) Mullite brick: Al2O3 content ≥72%, SiO2 content ≥28%;
(6) Corundum brick: Al2O3 content ≥90%.

It can be seen from the classification that silica bricks, clay bricks, and high alumina bricks are all commonly used refractory bricks for kilns. Often used for masonry kiln working layer, permanent layer, etc. Below we introduce the application of aluminum-silicon-based refractory bricks.

Alumina Silicate Refractory Bricks and Their Application Range

Silica brick. Partition wall and lining of coke oven carbonization chamber and combustion chamber, the lining of hot blast stove roof and regenerator, small electric furnace roof masonry, glass kiln roof, acid steel furnace, and firing kiln dome.
Semi-silica brick. Mainly used in coke ovens, acidified iron furnaces, metallurgical furnace flues, ladle linings, molten iron tanks, glass kilns, heating furnaces, hot blast stove tops, boiler combustion chambers, etc. Semi-silica bricks are not only used in these parts but can also be used as raw materials to make refractory materials with better quality, such as flow steel bricks.
Clay bricks. Clay bricks are used to build heating and heat treatment furnaces, flues, open hearth regenerator checker bricks, and the bottom of regenerator walls. The lining of air ducts and gas ducts, dust collectors of iron furnaces, and linings of flues. The drying zone and preheating zone of the rotary kiln are lined. It is also a commonly used refractory material in furnaces such as boilers, lime kilns, glass kilns, and ceramic kilns.
High alumina brick. Masonry blast furnace, hot blast stove, ladle, rotary kiln lining, and other metallurgical kilns. High-alumina bricks can also be used as lattice bricks on hot blast stoves to stack regenerators.
Mullite bricks. Mullite bricks are commonly used in hot blast furnaces for ironmaking at high temperatures above 1200°C, parts of torpedo tankers impacted by molten iron, and slag lines. Furnace roof of steelmaking electric arc furnace, ceramic industrial furnace, regenerator arch, the superstructure of glass melting furnace, cement, rotary kiln lining, etc.
Corundum brick. Used in blast furnaces, hot blast furnaces, and refining furnaces in the metallurgical industry. Second-stage furnaces, gasification furnaces, gas-making furnaces, cracking furnaces, and various high-temperature heating furnaces in ceramics, building materials, and other industries in the petrochemical industry.

It can be seen from the above list that aluminum-silicon-based refractory bricks are widely used in various kilns. One kind of refractory brick can be used for the refractory lining of many kinds of thermal furnace equipment, and one kind of kiln needs many kinds of refractory bricks. Therefore, when users communicate with refractory manufacturers about aluminum-silicon-based refractory bricks, they should determine the location of use and the use environment, so as to choose the correct Alumina Silicate Refractory Bricks.

Good quality refractory bricks are the basic conditions for increasing the service life of the kiln lining. Choosing a strong refractory manufacturer not only saves procurement costs, but also ensures the quality of refractory materials, reduces the number of furnace shutdowns and repairs, and briefly increases production costs. Contact Rongsheng refractory manufacturers to get the most competitive price of Alumina Silicate Refractory Bricks.

Corundum Mullite Wear-Resistant Refractory Castable

2022-09-08 by globalrefractory

Corundum (mullite) wear-resistant refractory castable is made of corundum and mullite as the main material, plus a special matrix and binder. The product has high strength wear resistance, erosion resistance, erosion resistance, good high-temperature volume stability, and thermal shock resistance. Mainly used for the wear-resistant lining of large CFB boilers with special requirements and lining of other high-temperature furnaces.

Lightweight Mullite Insulating Refractory Castable

Mullite castable is made of porous mullite aggregate as raw material, plus fine powder and additives. The critical particle size of mullite aggregate is 12mm, and the long-term use temperature is 1350 degrees.

Product features of mullite castables

The mullite castable has a high temperature and can be used as a working lining in direct contact with the flame to achieve high temperature and energy saving. The unit density is light, the structural weight is reduced by 40-60%, and the hidden danger of broken bricks is eliminated. Low thermal conductivity, porous mullite aggregate ingredients, low thermal conductivity, and good thermal insulation performance. The oven can be quickly baked, shortening the oven construction period, and the economic benefit is high.

Product application of mullite-corundum castables

Mullite castables are used in the petrochemical industry in tubular heating furnaces, light diesel oil, ethane cracking furnace linings, atmospheric and vacuum furnaces, and sulfur recovery devices. Steam boilers, tortoiseshell mesh insulation layer, two-piece cylinder and pipeline insulation single layer, other industrial furnace doors, fire holes, observation hole door linings, etc.

The aggregate of the mullite-corundum castable is high-purity fused mullite produced by our castable manufacturer, and the fused white corundum fine powder produced by our factory is used as the main matrix material. And introduced a small amount of active silica fume (SiO2 micro powder recovered from the ferroalloy factory), kyanite powder, and additions such as sodium tripolyphosphate or sodium hexametaphosphate. Based on initial success in use in steel company pellet furnaces. We also prepared mullite-corundum low-cement castable precast blocks for a large-scale pellet furnace of a steel company. It was built in the hot spot of the combustion chamber of the pellet furnace and the corresponding combustion chamber built with high alumina bricks was used for a comparative use test. After three months of ignition operation, the masonry of the combustion chamber built with high-alumina bricks peeled off seriously, and local fires occurred. The mullite-corundum prefabricated block masonry of the corresponding combustion chamber is intact, and there is no peeling phenomenon. The combustion chamber built with high alumina bricks was re-ignited and operated for 6 months after cold repair and was observed after being forced to shut down for maintenance due to mechanical failure. The high-alumina brick masonry has been peeled off in a large area and is seriously damaged. The corresponding mullite-corundum castable precast block masonry has not found obvious signs of spalling.

Rongsheng Unshaped Refractory Castable Manufacturer

Compared with pure corundum castables and high alumina bricks, mullite-corundum castables and prefabricated blocks have better thermal shock resistance and spalling resistance. It is a new type of refractory castable and prefabricated block worthy of promotion when used at high temperatures with severe thermal shock, and it can be expected to obtain better results. Rongsheng refractory manufacturer provides high-quality monolithic refractory lining solutions for industrial furnace linings. Our environmentally friendly advanced monolithic refractory castable production line has an annual output of 6W tons. Contact us for free refractory castable configurations, quotes, and samples. The quality of our products never disappoints customers.

Refractory Castable for Waste Heat Boiler Lining

2022-08-15 by globalrefractory

Working principle of waste heat boiler. Fuel, gas, and coal are burned to generate high-temperature flue gas to release heat. The high-temperature flue gas first enters the furnace, then enters the waste heat recovery device of the front smoke box, and then enters the pyrotechnic tube. Finally, it enters the waste heat recovery device in the flue of the rear smoke box, and the high-temperature flue gas becomes low-temperature flue gas and is discharged into the atmosphere through the chimney. Because the waste heat boiler greatly improves the utilization rate of the heat released by fuel combustion, this kind of boiler is very energy-saving. The refractory castable for waste heat boiler lining is a mixed powdery granule composed of various aggregates or aggregates and one or more binders. When used, it needs to be mixed with one or more liquids and stirred evenly, and has strong fluidity and plasticity. Refractory castables for waste heat boiler lining usually use unshaped refractories such as high-strength wear-resistant castable, self-flowing corundum castable products, lightweight thermal insulation castable, and thermal shock-resistant refractory products.

Corundum Self-Flowing Refractory Castable

Corundum self-flowing castable

Rongsheng self-flowing refractory castable products have good fluidity, reasonable setting time, labor-saving, fast and convenient. High strength and long life. It has good thermal insulation performance, high temperature resistance, good thermal shock stability, corrosion resistance and erosion resistance. And it can pump mechanized construction, shorten the time of building the furnace, and can bake quickly and shorten the time of the furnace. It is a substitute for low-cement, ultra-low-cement, and no-cement castables. Especially used for heating furnace roof, furnace wall, water-cooled pipe wrapping system and other thin-walled linings and thermal repair of various kilns.

Lightweight thermal insulation castable

Lightweight thermal insulation castables are light in volume, high in compressive strength, and resistant to acid and acid gas corrosion. Heat insulation, heat preservation, low water absorption and other characteristics. The construction is simple, and it is an ideal product for the construction of parts with alkali corrosion resistance at high temperatures. Lightweight thermal insulation castables have the characteristics of low bulk density, low thermal conductivity, lightweight, high compressive strength, acid resistance, and acid gas corrosion resistance. Thereby, the thermal energy consumption of the industrial kiln can be reduced, and the weight of the furnace lining can also be reduced.

High-strength wear-resistant castable

Rongsheng high-strength wear-resistant castable, refractory products can be used by adding water and stirring on site. It has high bonding strength with basic concrete (steel silo), strong impact resistance, compressive strength and good workability. A certain thickness of anti-wear layer is formed on the surface of the silo or mine by manual plastering. It can meet the technical requirements after normal maintenance, and has the characteristics of high wear resistance, good durability and long service life.

Selection of refractory materials for lining of waste heat boiler cooling chamber

When refractory materials are required for the lining of the cooling chamber, these requirements must be followed. In the cooling room without water wall, when the temperature of the inner wall of the furnace wall is below 1300 ℃, the vault and the firewall directly scoured by the flue gas can be made of clay refractory materials for boilers with an Al2O3 content of not less than 40%. For the inner wall of the furnace wall with a wide tube water wall, because of the cooling effect of the water wall tube on the flue gas, a general clay refractory material with an Al2O3 content of less than 40% can be selected. When there is a water wall composed of finned tubes, because the finned tubes have a good shielding effect on the flue gas radiation, the lining of the furnace wall directly laid with refractory materials can be sintered clay water glass refractory concrete or sintered Portland cement refractory concrete. When there is a membrane-type water-cooling wall, because the membrane-type water-cooling wall can completely block the flue gas radiation, it is only necessary to directly lay the thermal insulation material and the thermal-insulation material on the membrane-type water-cooling wall.

RS Global Refractory Manufacturer

Rongsheng refractory material manufacturers provide high-quality refractory lining materials for various industrial furnaces. Our unshaped refractory castable workshop has an annual output of tons. Our products have been sold to more than 70 countries around the world. If you need to buy high-quality refractory castable products and refractory castables for waste heat boiler lining, or other refractory materials, please contact us.

Checker Bricks for Heat Storage – Checker Bricks Reheating Furnace

2022-06-27 by globalrefractory

Checkered bricks for heat storage of hot blast stoves. Clay checker bricks for hot blast stoves refer to the refractory materials for building the regenerators of hot blast stoves, which are mainly used for the lower part of the regenerators. Checker bricks for heat storage – checker bricks reheating furnace. According to different furnace types and different heat storage areas, it is usually divided into 7 holes, 19 holes, and 37 holes. Clay checker brick is a heat transfer medium used in the regenerator of blast furnace hot blast stove.

Checker Brick - Rongsheng Refractory Bricks — Checker Brick

Comparison of the heat storage area of checkered bricks:

(1) Traditional 7-hole lattice bricks: the diameter of the lattice holes is 43Mm, and the heat storage area is 38.1m2/m3;
(2) High-efficiency 7-hole lattice brick: the diameter of the lattice hole is 30mm, and the heat storage area is 47.08m2/m3;
(3) High-efficiency 19-hole lattice brick: the diameter of the lattice hole is 30mm, and the heat storage area is 48.6m2/m3;
(4) High-efficiency 37-hole lattice bricks: the diameter of the lattice holes is 20mm, and the heat storage area is 68.7m2/m3.

Checker Bricks Product Category

Checker bricks for heat storage – checker bricks reheating furnace. Because clay bricks are widely used, in addition to conventional sizes, most of them are designed and customized according to furnace type requirements. The hole bricks have 7 holes, 19 holes, 37 holes, 65 holes, etc., and support customization.

Clay grate bricks for coke ovens use bauxite clinker, mullite, and coke gemstone as the main raw materials and soft bonded clay. Formed by high pressure and sintered at high temperature. Commonly used checker bricks have three rows of nine holes, three rows of fifteen holes, three rows of twelve holes, and two rows of fourteen holes (7.63 meters of coke oven).

Advantages and disadvantages of silica lattice bricks and high alumina lattice bricks

The checkered bricks in the middle and upper part of the regenerator are still in a higher temperature area, and at the same time, the checkered bricks in this area also bear the load of the upper checkered bricks, so the collapse of the checkered bricks occurs. That is to say, the damage to the checkered bricks in the quasi-high temperature zone is mainly caused by the uneven subsidence of the checkered bricks caused by creep. Especially when the high-temperature airflow on the cross-section of the checkered brick is unevenly distributed, the situation is particularly serious. For the checker bricks in the middle and lower parts of the regenerator, high alumina and clay refractory materials are usually used. With the increase in the height of the regenerator of the large-scale hot blast stove, the pressure of the upper lattice bricks on the lower refractory materials is also increasing. In addition, according to the damage investigation of large-scale high-temperature hot blast stove lattice bricks abroad, it was found that the cracking and breaking of lattice bricks caused by the influence of periodic temperature fluctuations on the lower lattice bricks is increasing. Therefore, in addition to continuing to control the creep characteristics of the lower clay bricks, higher requirements must be put forward for the normal temperature compressive strength and thermal shock stability of the products.

Silicon refractory is an acidic refractory material, which has good resistance to oxides such as CaO, FeO, and Fe2O3, and has the advantages of high softening temperature under load, stable volume at high temperature, and high thermal conductivity. However, the low temperature (below 800°C) has poor thermal stability. The specific realization is: that the softening temperature under load can be as high as (1640-1680°C), which is close to the melting point of tridymite (1670°C), and the thermal stability above 800°C is very good. Adapt to large changes in temperature. Silica bricks for hot blast stoves use tridymite as the main crystal phase, which has stable volume and low creep rate under high-temperature load, and its anti-adhesion performance is also better than other refractory materials. Proper use can make the structure of hot blast stoves more stable. However, at 200-300°C and 573°C, due to the crystal form transformation, the volume expands suddenly, which is easy to cause structural damage. Therefore, severe temperature changes should be avoided below 600°C.

Compared with silica bricks, high-alumina refractories have lower softening temperature under load and poor volume stability at high temperatures, but high-alumina refractories have the advantages of large capacity and good thermal shock stability.

Checker bricks for heat storage – checker bricks reheating furnace. Purchase high-quality regenerator checker bricks. Please contact Rongsheng Global refractory manufacturers.