MULLITE HEAT INSULATING CASTABLE
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characteristic:
construction convenient
using for furnace lining
wear-resistant,flame-proof
Item | | insulating castable | ||||||
JNL-45 | JBN-40 | JGL-85 | JGL-70 | JDL-80 | JLL-75 | JLL-60 | ||
Al2O3 % | 45 | 40 | 80 | 70 | 80 | 75 | 60 | |
CaO % | — | — | — | — | 2.5 | — | — | |
Refractoriness °C | 1700 | 1670 | 1790 | 1750 | 1790 | 1790 | 1750 | |
Linear change affter sintered ≤±1% | 1350°C ×3h | 1000°C ×3h | 1500°C ×3h | 1450°C ×3h | 1500 °C ×3h | 1500°C ×3h | 1450°C× 3h | |
110°C±5 After drying | Crushing strength Mpa | 8 | 20 | 35 | 30 | 40 | 30 | 25 |
Modulus rupture Mpa | 1 | — | 5 | 5 | 6 | 5 | 4 | |
Bonder | clay | water glass | cement | cement | lower cement | phosphate | phosphate |
High-strength lightweight Insulating refractory castable
1. low bulk density, low thermal conductivity, high intension.
2. good integrity and excellent air impermeability.
3. be used as cover of warm or low- temperature heat engineering equipments
4. It can also be thensulating material in hot temperature furnace.
5. way of usagre: daubing or casting.
The index is as follows:
- Q:
- There are several types of monolithic refractories used in the iron and steel industry, including castables, ramming mixes, gunning mixes, and plastic refractories. Castables are a mixture of refractory aggregates, binders, and additives that can be poured and shaped into various forms. Ramming mixes are granular refractories that can be packed and tamped into place using a ramming tool. Gunning mixes are similar to ramming mixes but are applied using a gunning machine. Plastic refractories are moldable materials that can be shaped and installed by hand. These different types of monolithic refractories offer flexibility and ease of installation in various applications within the iron and steel industry.
- Q:
- The use of monolithic refractories is essential for enhancing the quality and consistency of iron and steel products. These refractories, which are not shaped and can be easily molded and installed, offer several advantages over traditional brick refractories. To begin with, monolithic refractories provide superior thermal insulation properties, which effectively manage heat during the production process. By maintaining consistent and controlled temperatures, these refractories prevent thermal shocks and minimize thermal gradients, resulting in reduced cracking and distortion in the final products. As a result, the dimensional stability and overall quality of the products are improved. Additionally, monolithic refractories exhibit excellent resistance to thermal spalling and erosion. They can withstand high temperatures, chemical attacks, and mechanical stress, protecting the lining of furnaces and vessels used in iron and steel production. This resistance enhances the durability and reliability of refractory linings, preventing premature failure and extending the lifespan of the equipment. Another advantage of monolithic refractories is their ability to create a seamless lining. Unlike brick refractories, which have joints and gaps that can cause heat loss and uneven distribution, monolithic refractories form a continuous lining with no weak points. This ensures uniform heat distribution and minimizes the risk of hotspots or cold spots, resulting in consistent and reliable iron and steel products. Moreover, monolithic refractories offer flexibility in design and installation. They can be customized to fit various shapes and sizes, allowing for better furnace design optimization. This flexibility enables efficient use of space, improved heat transfer, and reduced energy consumption, all of which contribute to the overall quality and consistency of the final iron and steel products. In conclusion, monolithic refractories enhance the quality and consistency of iron and steel products by providing superior thermal insulation, resistance to thermal spalling and erosion, seamless linings, and flexibility in design and installation. These refractories improve the efficiency and reliability of the production process, resulting in higher-quality final products that meet the industry's stringent standards.
- Q:
- Monolithic refractories improve the performance and efficiency of iron and steel production by providing superior thermal insulation and resistance to high temperatures. They help to minimize heat loss, enhance heat transfer, and reduce energy consumption during the production process. Additionally, monolithic refractories offer excellent resistance to chemical reactions and erosion caused by molten metal and slag, thus extending the lifespan of refractory linings and reducing maintenance requirements. Overall, their use in iron and steel production improves productivity, reduces downtime, and contributes to cost savings.
- Q:
- Monolithic refractories contribute to the overall efficiency of ladle slagging operations by providing excellent thermal insulation, high resistance to thermal shock, and superior corrosion resistance. These properties allow for better heat retention, reduced heat loss, and extended refractory lifespan. As a result, ladle slagging operations can be carried out at higher temperatures with minimal refractory wear and tear, leading to increased productivity and cost savings. Additionally, monolithic refractories offer ease of installation and maintenance, ensuring quick turnaround times and minimizing downtime during ladle slagging operations.
- Q:
- Monolithic refractories enhance the performance of ladle and tundish purging systems by providing high thermal insulation, excellent erosion resistance, and increased durability. These refractories help maintain the desired temperature in the ladle and tundish, ensuring optimal conditions for purging operations. Additionally, their erosion resistance properties prevent excessive wear and tear, extending the lifespan of the purging systems. Overall, monolithic refractories play a crucial role in enhancing the efficiency and effectiveness of ladle and tundish purging systems.
- Q:
- There are several differences between monolithic refractories and traditional brick refractories. Firstly, monolithic refractories are composed of a single, homogeneous material, whereas traditional brick refractories are made up of individual bricks that are pieced together. This variance in construction allows monolithic refractories to possess a more uniform and consistent structure, which can enhance their performance and durability. Secondly, installing monolithic refractories is typically easier compared to traditional brick refractories. Due to their composition, they can be poured or sprayed into place, eliminating the need for precise bricklaying and mortar application. This simplified installation process saves time and labor during construction or repair projects. Furthermore, monolithic refractories often exhibit superior resistance to thermal shock when compared to traditional brick refractories. The homogeneous structure of monolithic refractories enables them to expand and contract more uniformly under thermal stress, reducing the risk of cracking and failure. This characteristic makes monolithic refractories more suitable for applications with rapid temperature changes, such as in furnaces or kilns. Additionally, monolithic refractories offer better resistance to chemical attacks and erosion. Traditional brick refractories may have joints and gaps between bricks, which can become vulnerable to chemical reactions or erosion over time. Conversely, monolithic refractories possess a seamless structure that minimizes the risk of chemical penetration and erosion, enhancing their longevity and performance. In conclusion, monolithic refractories provide advantages in terms of uniformity, ease of installation, thermal shock resistance, and chemical resistance compared to traditional brick refractories. These disparities make monolithic refractories the preferred choice for numerous industrial applications that involve high temperatures and harsh environments.
- Q:
- Yes, monolithic refractories can be used in both electric arc furnaces and induction furnaces. Monolithic refractories are versatile and can be shaped and installed easily, making them suitable for various types of furnaces, including electric arc furnaces and induction furnaces. These refractories are composed of a single material, such as castables, gunning mixes, ramming mixes, and plastic refractories, which can withstand high temperatures and thermal shock. They are commonly used to line the walls, roofs, and bottoms of furnaces to provide insulation and protection against the extreme heat generated during the melting and refining processes. Monolithic refractories offer excellent resistance to chemical attack, erosion, and mechanical stress, making them ideal for use in electric arc furnaces and induction furnaces, where intense heat and harsh operating conditions are encountered.
- Q:
- There are several ways in which monolithic refractories differ from conventional refractories. To begin with, conventional refractories are typically constructed using pre-formed shapes like bricks or tiles, whereas monolithic refractories are shapeless and can be installed through casting, gunning, or ramming. This allows for greater design and installation flexibility since monolithic refractories can be molded to fit any complex shape or size requirement. Additionally, monolithic refractories possess a higher level of thermal shock resistance compared to conventional refractories. This means that they can withstand rapid temperature changes without cracking or spalling. This characteristic is especially significant in applications where the refractory is exposed to extreme temperature fluctuations, such as in furnaces or kilns. Moreover, monolithic refractories exhibit superior corrosion resistance, making them more suitable for environments with acidic or alkaline conditions. They are also renowned for their exceptional mechanical strength and resistance to abrasion, making them ideal for situations where the refractory experiences high mechanical stress or wear. Lastly, monolithic refractories offer enhanced energy efficiency due to their lower thermal conductivity. Consequently, they can retain heat more effectively, resulting in reduced energy consumption and cost savings. In summary, the key distinctions between monolithic refractories and conventional refractories lie in their installation methods, thermal shock resistance, corrosion resistance, mechanical strength, and energy efficiency. These factors establish monolithic refractories as the preferred choice in numerous industrial applications where flexibility, durability, and performance are of utmost importance.
- Q:
- Yes, monolithic refractories can be used for the lining of reheating furnaces and walking beam furnaces. Monolithic refractories are a type of refractory material that is characterized by its ability to be cast or gunned into place, rather than being made up of individual bricks or precast shapes. This makes them highly versatile and adaptable for various furnace applications, including reheating furnaces and walking beam furnaces. Reheating furnaces are used to heat metal products to a specific temperature before further processing, such as rolling or forging. The lining of these furnaces is subjected to high temperatures, thermal cycling, and mechanical stress. Monolithic refractories are well-suited for these conditions, as they have excellent thermal shock resistance and can withstand rapid temperature changes without cracking or spalling. Walking beam furnaces are used in the steel industry for the continuous heating and transport of steel slabs or billets. These furnaces require a lining material that can withstand the abrasion and mechanical stress caused by the movement of the material. Monolithic refractories with high abrasion resistance and good mechanical strength are ideal for the lining of walking beam furnaces. Additionally, monolithic refractories offer other advantages such as easy installation, reduced downtime for repairs, and improved energy efficiency. They can be tailored to specific furnace designs and can be easily repaired or replaced when necessary. In conclusion, monolithic refractories are a suitable choice for the lining of reheating furnaces and walking beam furnaces due to their ability to withstand high temperatures, thermal cycling, mechanical stress, and abrasion. Their versatility, ease of installation, and repair make them a preferred option for these furnace applications.
- Q:
- Monolithic refractories are installed in iron and steel production processes using various methods depending on the specific application and requirements. The installation process typically involves the following steps: 1. Surface Preparation: Before installing monolithic refractories, the surface where they will be applied must be properly prepared. This involves cleaning and removing any loose materials, dust, or contaminants from the substrate. 2. Mixing: Monolithic refractories consist of different materials such as aggregates, binders, and additives. These components are mixed in specific proportions to achieve the desired properties and consistency. The mixing process can be done manually or using mechanical mixers. 3. Application: There are different techniques for applying monolithic refractories, including gunning, casting, ramming, and troweling. The chosen method depends on factors such as the shape of the structure, accessibility, and required thickness. - Gunning: This method involves using a gunning machine to spray the refractory material onto the surface. It is commonly used to repair or patch existing linings or for rapid installation in areas that are difficult to access. - Casting: In casting, the refractory material is poured into molds or forms and left to set and harden. This method is suitable for creating complex shapes and large-sized components. - Ramming: Ramming involves manually or mechanically compacting the refractory material into a mold or form using a ramming tool. This technique is commonly used for lining induction furnaces, ladles, and other equipment. - Troweling: Troweling is a manual method where the refractory material is applied and smoothed using a trowel. It is often used for smaller repairs or touch-ups. 4. Curing: After the refractory material is applied, it needs to be cured to achieve its optimum strength and performance. Curing involves allowing the material to dry and harden at a controlled temperature and humidity for a specified period. This step is crucial to ensure the long-term durability and resistance of the monolithic refractory lining. Overall, the installation of monolithic refractories in iron and steel production processes requires careful preparation, proper mixing, and the appropriate application technique. It is essential to follow manufacturer guidelines and industry best practices to ensure a successful installation that meets the specific needs of the production process.
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