Monolithic Refractories for Iron and Steel Industry - Castable Refractory for Cement Kiln and Boiler
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Benefits:
1) Good performance to thermal stability, slag and abrasion resistance.
2) Good fluidity and convenient to install and maintain
3) Less installation and drying/sintering time
4) Efficiently reduced the production stoppages & downtimes
5) Labor and cost saving by prolonging campaign length.
| Refractory Castable for cement kiln | | | | |
| Items | HGJ-1 | HAJ-3 | HAM-2 | HAL-2 |
| Main Contents | Al2O3 | Al2O3 | MgO-Al2O3 | Al2O3-SiO2 |
| Characteristics | High strength anti-abrasion steel fiber castables | Chemical-bonding refractory castables | Low cement magnesium-aluminum castables | high purity bauxite low cement |
| Refractoriness | 1950℃ | 2150℃ | 2150℃ | 1700℃ |
| Density | 2.95g/cm3 | 2.89g/cm3 | 2.92g/cm3 | 2.55g/cm3 |
| Compressive Strength | 110℃×2h68.5MPa; | 110℃×2h59.2MPa; | 110℃×2h40.8MPa; | 110℃×2h52MPa |
| | 1500℃×3h 96.8 MPa | 1500℃×3h106.1MPa | 1500℃×3h102.5MPa | 1500 ℃×3h 75 MPa |
| Permanent Linear Changing Rate | 1500℃×3h+0.21% | 1500℃×3h+0.29% | 1500℃×3h+0.32% | 1500℃×3h±0.5% |
| Installation mode | casting | casting | casting | casting |
| Additive required | 5-10%water | 5-10%water | 5-10%water | 5-10%water |
| Application | Rotary kiln or industry furnace | Industry kiln | Ladle | differentpartsforcementkiln |
characteristics:
1. The dosage of cement is low, the content of calcium only accounts for 1/4-1/3 of common Refractory Castable
2. Wter consumption rate during the construction is almost 1/2 or 1/3 of the common Refractory Castable, so the Low Cement Refractory Castable has high density and low porosity.
3. High normal temperature cure property, intensity will be increased after medium temperature and high temperature. Three or five times more than common Refractory Castable.
4. Good volume stability under high temperature.
Application:
Material for metallurgy, petroleum, chemical and other industries kilns
Part of refining installation, like ladle cover
Insert for roof of the kiln
- Q: How do monolithic refractories contribute to the overall efficiency of iron and steel production?
- Monolithic refractories play a crucial role in enhancing the overall efficiency of iron and steel production. These refractories, which are made from a single material, provide exceptional thermal insulation, resistance to high temperatures, and excellent mechanical strength. By lining the furnaces, ladles, and other equipment used in the production process, monolithic refractories help in maintaining and regulating the required high temperatures for melting, refining, and shaping iron and steel. This insulation reduces heat loss, minimizes energy consumption, and ensures a more efficient and cost-effective production process. Additionally, the mechanical strength of monolithic refractories allows for better protection against wear and tear, resulting in increased equipment lifespan and reduced downtime for repairs and maintenance. Overall, the use of monolithic refractories significantly contributes to the efficiency, productivity, and sustainability of the iron and steel production industry.
- Q: How do monolithic refractories contribute to energy efficiency in iron and steel production?
- Monolithic refractories play a crucial role in enhancing energy efficiency in iron and steel production processes. These refractories are unshaped materials that are used to line the various components of furnaces, kilns, and other high-temperature equipment involved in the production of iron and steel. One way monolithic refractories contribute to energy efficiency is by providing excellent insulation. These materials have low thermal conductivity, which means they effectively reduce heat transfer from the furnace or kiln to the surrounding environment. By minimizing heat loss, monolithic refractories help maintain high temperatures within the production units, which in turn reduces the energy required to sustain the desired operating conditions. Furthermore, monolithic refractories offer superior resistance to thermal shock and wear, ensuring the longevity of the lining materials. This durability reduces the need for frequent repairs and replacements, leading to less downtime and increased operational efficiency. As a result, energy is conserved since the production units can continuously operate at optimal temperatures without interruptions. In addition, monolithic refractories have excellent resistance to chemical reactions, corrosion, and erosion caused by molten metals and slag. This resistance reduces the formation of cracks and defects in the lining, which can compromise the insulation and increase heat loss. By maintaining a robust and intact lining, monolithic refractories contribute to energy efficiency by minimizing heat escape and ensuring the efficient utilization of energy for the iron and steel production processes. Moreover, the use of monolithic refractories allows for design flexibility in the construction of furnaces and kilns. Their ability to be shaped and applied in various configurations enables the creation of optimized lining structures that enhance heat transfer and combustion efficiency. This flexibility empowers engineers and operators to design and modify the production units to maximize energy efficiency and minimize energy wastage. Overall, monolithic refractories contribute significantly to energy efficiency in iron and steel production by providing excellent insulation, durability, resistance to thermal and chemical degradation, and design flexibility. By reducing heat loss, minimizing repairs and replacements, and optimizing heat transfer, these refractories play a vital role in conserving energy and improving the overall sustainability of the iron and steel industry.
- Q: In iron and steel industry, the main raw materials for blast furnace ironmaking are iron ore, coke and limestone. What's the use of limestone here?
- Calcium oxide absorbs sulfur dioxide and prevents it from polluting the air.
- Q: What are the typical operating temperatures for monolithic refractories?
- The typical operating temperatures for monolithic refractories vary depending on the specific composition and type of refractory material. However, in general, monolithic refractories are designed to withstand high temperatures ranging from 1500°C (2732°F) to 1800°C (3272°F) and even higher in some cases. These refractories are commonly used in industries such as steelmaking, cement production, glass manufacturing, and petrochemical processing, where they are subjected to extreme thermal conditions. Different types of monolithic refractories have different temperature limits. For instance, basic refractories made of magnesia or dolomite can withstand temperatures up to 1800°C (3272°F). On the other hand, alumina-based refractories can typically handle temperatures up to 1700°C (3092°F). Silicon carbide-based refractories have even higher temperature resistance, with the ability to withstand temperatures above 2000°C (3632°F). It is crucial to select the appropriate monolithic refractory material based on the specific operating temperature requirements of the application. Using refractories beyond their recommended temperature limits can cause thermal shock, spalling, or reduced performance, leading to potential equipment failure or safety hazards. Therefore, consulting with refractory manufacturers or experts in the field is essential to ensure the correct selection and optimal performance of monolithic refractories in high-temperature applications.
- Q: How do monolithic refractories perform in reheating furnace applications?
- Monolithic refractories perform exceptionally well in reheating furnace applications due to their excellent thermal shock resistance, high temperature stability, and superior insulation properties. They are able to withstand the extreme temperatures and rapid temperature changes that occur during the reheating process, ensuring consistent and efficient heat distribution. Additionally, their flexible and easy-to-install nature makes them an ideal choice for lining the complex geometries of reheating furnaces, resulting in improved performance and extended service life.
- Q: How long is the lifespan of monolithic refractories in iron and steel applications?
- Several factors can influence the lifespan of monolithic refractories in iron and steel applications. These factors encompass the type of refractory material utilized, the specific application, the operational conditions, and the implemented maintenance practices. Monolithic refractories employed in iron and steel applications are generally engineered to endure high temperatures, thermal shock, chemical attack, and mechanical stress. When compared to other refractory materials, they are expected to possess a relatively extended lifespan. Under normal operating conditions and with appropriate maintenance, monolithic refractories can typically endure anywhere from several months to several years in iron and steel applications. Nevertheless, it is important to acknowledge that certain areas of the application may be subjected to more severe conditions, necessitating more frequent repairs or replacements. Regular inspections and monitoring of the refractories' condition are vital in order to detect any signs of deterioration or damage. Any necessary repairs or replacements should be promptly executed to prevent further damage and reduce downtime. It is also noteworthy to mention that advancements in refractory technology and materials have resulted in the development of more resilient and durable monolithic refractories. These advancements have extended the lifespan of refractories in iron and steel applications, ultimately enhancing the overall efficiency and productivity of the operations.
- Q: What are the key considerations when selecting monolithic refractories for tundish applications?
- When selecting monolithic refractories for tundish applications, the key considerations include thermal stability, erosion and corrosion resistance, thermal shock resistance, ease of installation and maintenance, and cost-effectiveness.
- Q: How do monolithic refractories perform in high-temperature environments?
- Due to their unique characteristics, monolithic refractories are highly effective in high-temperature environments. Unlike traditional refractories made of multiple bricks or tiles, these refractories are composed of a single, continuous composition. This monolithic structure offers several advantages when it comes to performance in high-temperature conditions. First and foremost, monolithic refractories exhibit excellent thermal shock resistance. They can endure rapid temperature changes without cracking or spalling. While high temperatures can impose significant stress on materials, the monolithic structure allows for better expansion and contraction, minimizing the risk of damage. Furthermore, monolithic refractories possess high resistance to chemical attack. In high-temperature environments, aggressive chemical agents are often present, which can corrode and erode traditional refractory materials. However, the monolithic composition is typically designed to be chemically inert, creating a protective barrier against these corrosive elements. Moreover, monolithic refractories offer superior strength and durability at high temperatures. Their single composition ensures a dense and compact structure, reducing the likelihood of cracking or breaking under extreme thermal conditions. This strength enables them to maintain their integrity and performance even in the most demanding environments. Additionally, monolithic refractories can be easily installed and repaired. Unlike traditional refractories that demand precise brick or tile placement, monolithic materials can be poured or sprayed into place, adapting to any shape or size. This flexibility expedites installation, making it more cost-effective and reducing downtime and maintenance costs. Overall, monolithic refractories excel in high-temperature environments due to their thermal shock resistance, chemical inertness, durability, and ease of installation. Their capacity to withstand extreme heat and harsh conditions makes them the preferred choice for industries such as steel, cement, glass, and petrochemicals, where high temperatures are prevalent.
- Q: Can monolithic refractories be used for the lining of ladle refining furnaces and VOD converters?
- Indeed, ladle refining furnaces and VOD converters can benefit from the utilization of monolithic refractories. These refractories, which consist of a single, uniform material, can be molded and installed in various settings, particularly those involving extreme temperatures such as ladle refining furnaces and VOD converters. The advantage of monolithic refractories lies in their simplicity of application and repair. They can be either cast or gunned in place, offering flexibility in terms of lining design and installation. The lining of ladle refining furnaces and VOD converters requires materials capable of withstanding high temperatures, chemical reactions, and mechanical stresses. Monolithic refractories are well-suited for these demanding applications due to their exceptional resistance to thermal shock and chemical attack. In the case of ladle refining furnaces, monolithic refractories are used to line the vessel in which molten metal is contained and processed. By doing so, these refractories help to maintain the desired temperature and safeguard the ladle from the corrosive effects of both molten metal and slag. Additionally, they serve as insulation to minimize heat loss and enhance energy efficiency. VOD converters, on the other hand, are employed in the steelmaking process to reduce the carbon content of molten steel. Monolithic refractories play a crucial role in lining the converter's vessel and ensuring the maintenance of the required temperature for the decarburization reaction. Furthermore, they provide protection against the corrosive impact of molten metal and slag, thereby guaranteeing the converter's durability and performance. To summarize, monolithic refractories possess outstanding characteristics that make them an excellent choice for lining ladle refining furnaces and VOD converters. Their versatility, ease of installation, and ability to withstand high temperatures and chemical attack render them perfectly suited for these critical applications within the steel industry.
- Q: How do monolithic refractories improve the performance of ladles and tundishes?
- The performance of ladles and tundishes is significantly improved by monolithic refractories in various ways. Firstly, these vessels are thermally insulated by monolithic refractories, which act as a barrier against heat loss and help maintain the desired temperature. This insulation reduces energy consumption and minimizes heat loss. Secondly, monolithic refractories offer excellent resistance to chemical corrosion and erosion. When ladles and tundishes come into contact with molten metal and fluxes, they can be severely corroded and eroded. However, the use of monolithic refractories protects against chemical attacks and extends the lifespan of these vessels. This saves costs associated with frequent repairs or replacements and ensures their integrity and safety. Furthermore, monolithic refractories provide superior mechanical strength and structural stability. Ladles and tundishes must withstand the weight of molten metal and the stresses caused during pouring and handling. With high mechanical strength, monolithic refractories can withstand these loads, maintaining their shape and integrity. This reduces downtime and increases productivity in the steelmaking process. Moreover, monolithic refractories offer flexibility in design and installation. They can be shaped and applied in various configurations, allowing customization to meet the specific requirements of ladles and tundishes. This flexibility ensures a better fit and improves the overall efficiency of the refractories, ultimately enhancing the performance of the vessels. In conclusion, monolithic refractories enhance the performance of ladles and tundishes by providing improved thermal insulation, resistance to chemical corrosion and erosion, increased mechanical strength, and flexibility in design and installation. These benefits contribute to the longevity, efficiency, and cost-effectiveness of ladles and tundishes in steelmaking operations.
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Monolithic Refractories for Iron and Steel Industry - Castable Refractory for Cement Kiln and Boiler
- Ref Price:
-
- Loading Port:
- China Main Port
- Payment Terms:
- TT OR LC
- Min Order Qty:
- -
- Supply Capability:
- -
OKorder Service Pledge
Quality Product, Order Online Tracking, Timely Delivery
OKorder Financial Service
Credit Rating, Credit Services, Credit Purchasing
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