Phosphoric Acid bonded High Aluminum Castable with Good Wear Resistance and Air Tightness

What are the advantages of phosphate-bound high-aluminum castables? Phosphoric acid combined with high aluminum castable is one of the castables. Compared with other castables, its advantage is that high-aluminum phosphate castables have the advantages of high medium-temperature strength, good thermal shock resistance, wear resistance, and good air tightness.

Phosphoric Acid Bonded High Aluminum Castable

Phosphoric acid-bonded high-aluminum castables are not only resistant to high temperatures and corrosion but also have excellent thermal shock resistance and wear resistance. It is widely used in metallurgical heating furnaces water-cooled tube wrapping, heating furnace top prefabricated blocks, high-temperature flame furnace burner bricks, and kiln car table prefabricated blocks. The overall lining of induction furnaces in the precision casting industry, as well as the abrasive parts of power plant boilers and other thermal kilns.

High-Strength Aluminum Phosphate Bonded Refractory Plastics
High-Strength Aluminum Phosphate Bonded Refractory Plastics

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    Phosphoric acid combined with high alumina castables generally uses high alumina cement as a setting accelerator. When the amount of high alumina cement is increased, the castable hardens and sets too quickly, making construction difficult. When the amount of high alumina cement is increased, the castable does not solidify, and there is no way to demould it later, and the castable needs to be baked after demoulding to develop strength.

    Although phosphoric acid combined with high-aluminum castables has many advantages, the amount of high-aluminum cement added is difficult to control and the construction is too difficult, which affects the progress of castable construction. These problems also hinder the widespread application of high-aluminum phosphate castables. In a large number of practical applications by castable manufacturers, continuous exploration and research have found that fused spinel fine powder has an accelerating effect on phosphoric acid. This procoagulant effect is relatively mild and easy to control. At the same time, the phosphoric acid-bound castable can produce high strength without baking after demolding.

    Phosphoric acid combined spinel high alumina castable, after adjusting the formula of the castable manufacturer and adding fused spinel powder. In various industrial kilns and in various temperature ranges, it has higher strength than ordinary phosphate-bonded high-aluminum castables. The high-temperature resistance is more than 200 ℃ higher than that of ordinary phosphoric acid combined with high aluminum castables. At the same time, it can produce strength without baking, overcoming the disadvantages of the difficult construction of ordinary phosphate-bonded high-aluminum castables. The adjusted phosphoric acid combined with high aluminum castable material does not absorb moisture after natural curing and is not afraid of water, which brings great convenience to on-site construction and storage and transportation of prefabricated parts. Its good thermal shock resistance greatly extends the service life of furnace linings or objects working under alternating hot and cold conditions.

    High-Quality High Alumina Castable of Rongsheng
    High-Quality High-Alumina Castable of Rongsheng

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      High Alumina Cement Combined Refractory Castable

      High alumina cement refractory castables are made by using high alumina cement as a cementing agent, mixing refractory aggregates and powders in proportion, adding water, mixing, shaping, and curing. Refractory aggregates and powders are generally made of clay, high alumina, corundum, etc. Commonly known as clay castables, high alumina castables, corundum castables, etc.

      The main mineral of high alumina cement is calcium aluminate (CA), which hydrates quickly and does not precipitate calcium hydroxide. Therefore, refractory castables formulated with high alumina cement have the characteristics of rapid hardening and high strength.

      Factors Affecting the Performance of Aluminate Cement Bonded Castables

      The general ratio of aluminate cement combined with refractory castables is. Refractory aggregate 62%-76%, refractory powder 17%-28%, cement 10%-24%, water 7%-14%, and appropriate amount of admixtures. This is also the general ratio of refractory castables. On the premise of meeting construction and use requirements, the amount of cement and water should be minimized. This type of castable is divided into many categories based on aggregate types, and many factors affect performance.

      1. Cement dosage.

      Cement is one of the important components of refractory castables. It is an important material that determines the strength of the material and also affects other properties. Different types of cement and their dosages have different effects on performance. As the amount of cement increases, the normal temperature compressive strength increases, and later the compressive strength and high-temperature compressive strength decrease, and the linear change after burning changes from expansion to contraction. Therefore, while ensuring that the normal temperature strength meets the requirements, the amount of high-alumina cement should be reduced as much as possible to improve the high-temperature performance of refractory castables. However, while reducing the amount of cement, it is necessary to appropriately increase the refractory powder so that the mixture of powder and cement can fully wrap the refractory aggregate.

      1. Water consumption.

      When configuring aluminate cement combined with refractory castables, the amount of water used is very important. When too much water is used, the water will overflow after heating, resulting in increased pores and loose structure, resulting in a decline in overall performance. Therefore, under the conditions of ensuring construction, the amount of water added should be reduced as much as possible. Without adding a water-reducing agent, the suitable water content of aluminate cement castable is 10%-13%.

      1. Refractory powder dosage.

      The type, fineness, and dosage of refractory powder are important factors affecting the performance of castables. The fineness of the powder directly affects the strength, volume density, and apparent porosity of the castable. The finer the refractory powder, the better the performance of the castable. When the amount of powder is small, the mixture with cement cannot completely wrap the aggregate, resulting in a loose structure. When the amount of powder is too much, there will be a significant surplus of aggregate wrapped in the mixture with cement, resulting in an increase in the amount of water used and a large shrinkage during high-temperature sintering.

      1. Amount of refractory aggregate.

      The variety, grade, and particle matching of aggregates are the main properties that affect the performance of castables. It plays a skeleton role in the castable. The aggregates are divided into coarse aggregates and fine aggregates. It is very important to match the particles of the aggregates. The most ideal particle gradation is that the gaps caused by coarse aggregate are filled by the fine aggregate, and the gaps between the two are filled by powder, with no shortage or surplus.

      In addition, high alumina cement refractory castables can also be added with admixtures (such as water-reducing agents, etc.) to improve construction performance and fire resistance.

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        Iron Ditch Anti-Scouring Silicon Carbide Refractory Castable

        The blast furnace tap trough system consists of a main tap trough, branch troughs, and slag troughs. It is an important system to realize the separation of molten iron and slag in the blast furnace. With the enlargement of iron-making blast furnaces and the development of high-temperature and high-pressure technology, higher requirements have been placed on the service life and iron flux of the blast furnace tap trough. The trough material is the main factor affecting the performance of the blast furnace tap trough. Its high-temperature resistance, thermal shock resistance, erosion resistance, erosion resistance, and other properties directly affect the iron flux and service life of the blast furnace tap channel. This in turn affects the production cost and labor intensity of the entire production process.

        Aluminum Silicon Carbide Castables
        Aluminum Silicon Carbide Castables

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          Refractory Material Al2O3-SiC-C Castable for Tap Trough

          At present, the refractory materials used in the blast furnace tap trough are mainly Al2O3-Si C-C castables. Although it has the advantages of good high-temperature mechanical strength, good resistance to slag erosion and permeability, good thermal shock resistance, and small changes in reburning. However, in the face of technological advancements such as increased molten iron temperature, increased iron tapping volume, prolonged iron tapping time, and faster-molten iron flow rate caused by modern large-scale blast furnace smelting. The original iron trench materials cannot meet production needs. Therefore, improving Al2O3-SiC-C castables or developing new refractory materials for blast furnace tap troughs are the research directions of many scholars.

          Aluminum silicon carbide carbonaceous castables, which are unshaped refractory materials, are often used in blast furnace tap troughs, so they are also called trough castables. The blast furnace tap trough castable is made of fused corundum (or sintered corundum, special high-aluminum clinker) and silicon carbide. It is a high-performance refractory castable containing 90%-95% fixed carbon (or flake graphite), binder, and various admixtures.

          Aluminum silicon carbide carbonaceous castable. The aggregate part can be made of one or two types of fused or sintered corundum, brown corundum, spinel, and bauxite clinker. Carbonaceous raw materials can be asphalt, coke, graphite, or electrode powder. The binding agent can be bonded clay, oxide micro powder or ultrafine powder, and pure calcium aluminate cement with good dispersion properties.

          Silicon Carbide Refractory Castable
          Silicon Carbide Refractory Castable

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            The blast furnace tap trough is a channel through which high-temperature molten iron or molten slag flows. Its refractory lining should have the following characteristics. These features are complementary to each other and should be compatible with each other.

            • ① Strong resistance to erosion and erosion from molten iron and slag.
            • ② Good thermal shock resistance and small change in volume after reheating.
            • ③ Strong antioxidant capacity.
            • ④ Easy to construct, can be baked quickly without bursting, and is easy to repair and dismantle.
            • ⑤ When used, it does not produce harmful gases, does not stick to slag iron, and has a long service life.

            Iron trench castable is a high-tech refractory castable with exquisite preparation technology and excellent performance, which can significantly increase the service life of the trench lining. The key issue is that the amount of construction water must be strictly controlled, operated carefully, and maintained carefully to achieve the expected purpose.

            At the same time, the specific selection of tap trough castables also depends on the size of the blast furnace. Generally speaking, high-aluminum silicon carbide carbonaceous castables can be used for the main ditch, slag ditch, and slag line of small blast furnaces. Corundum silicon carbide carbonaceous castables can be selected for medium and large blast furnaces.

            Wear-Resistant Corundum Silicon Carbide Castable
            Wear-Resistant Corundum Silicon Carbide Castable

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              Erosion-resistant Molten Iron-Clad Aluminum Silicon Carbide Castable

              Spheroidized ladle castable is an unshaped refractory material with high aluminum and silicon carbide materials as the main raw materials and refractory cement as the binder. It is widely used in molten running ladles, launders, and working linings of kilns. It has high strength and refractory resistance and has good impact resistance, corrosion resistance, wear resistance, and other properties. It has a long service life, convenient construction, and easy maintenance. It is suitable for the overall lining of ladles and is the refractory material of choice for spheroidized ladles.

              Molten iron and slag react with the castable, resulting in chemical slag sticking. According to ASTM C01-91 Al2O3-SiO2 series castables, those with CaO content >2.5 are traditional cement-bound castables. The CaO content between 1.0% and 2.5% is low cement castable. The CaO content <1.0% is cement-castable. The lower the CaO content, the higher the temperature at which the liquid phase appears, and therefore the higher the fire resistance. The CaO content of the existing castable is 3.78%, which is a traditional high cement content castable. Aluminum silicon carbide castables are erosion-resistant, heat-exchange-resistant, refractory castables, and ladle castables.

              The liquid phase of this material appears at a low temperature, about 1300°C. The temperatures of molten iron and slag are generally >1300°C, and the interface is prone to reaction at this time. For example, the components in the refractory material, especially the liquid phase in the matrix, easily react with CaO, SiO2, Fe2O3, etc. in the slag to form Al2O3-SiO2-CaO-Fe2O3 series low-melting materials. The molten iron, molten slag, and refractory materials are melted together to form sticky slag. The sticky residue that occurs in this form is strong and difficult to clean.

              Low Cement Silicon Carbide Castable in RS Factory
              Low Cement Silicon Carbide Castable in RS Factory

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                Development of Aluminum Silicon Carbide Refractory Castables for Tap Trench

                Al2O3-SiC-C castable is the most widely used iron trench refractory material in my country. Improving the quality of Al2O3-Si C-C castables is an important factor in reducing the cost of molten iron and achieving efficient production. RS Unshaped Refractory Castable Manufacturer puts forward several suggestions based on the current development situation.

                (1) Different companies have different compositions of molten iron and slag. The reasons why molten slag and molten iron corrode the iron trench materials should be analyzed based on the actual situation to achieve “prescribing the right medicine”.

                (2) Using slag or other industrial waste residues as raw materials to prepare Al2O3-Si C-C castables has extremely high added value. At the same time, it can also solve problems such as waste residue accumulation and environmental pollution.

                (3) Improve the production of Al2O3-Si C-C castables in the direction of green and environmental protection, and remove or replace toxic and harmful components in the raw materials. It not only achieves green production but also protects the health of workers.

                (4) Many new Al2O3-Si C-C castables have been applied in enterprise blast furnace production, achieving mutual benefit and win-win results between scientific research and enterprises.

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                  How to Choose Refractory Materials for Circulating Fluidized Bed Boilers?

                  Circulating fluidized bed boiler refractory lining. Material circulation path in circulating fluidized bed furnace. Pulverized coal (generally with a particle size of 0~10mm) and limestone powder are fed into the fluidized bed combustion chamber (dense phase area) through a feeder, and the fuel boils and burns in this area. The flue gas rises, passes through the dilute phase zone to the separator inlet and enters the cyclone separator. The coarse particles sink and return to the combustion chamber through the return valve for combustion again. The flue gas carries the fly ash and rises through the convection flue into the external heat exchanger. Refractory materials are mainly lined in the combustion chamber, ceiling, separator inlet, high-temperature cyclone separator, and return valve.

                  Taking a 220t circulating fluidized bed boiler in a certain factory as an example, the working conditions of the refractory materials in each part are as follows.

                  • (1) Dense phase area. The depth of this area is 220~1530mm. A 2100mm long sandy medium (pulverized coal and limestone powder) is boiled here. The pressure in this area is 13818~20580pa, the flue gas flow rate is about 1.2~1.8 m/s, and the normal operating temperature is 820~900°C.
                  • (2) Dilute phase area. The area above the secondary air outlet is where the fine particles of fuel combustion are concentrated. The solid material concentration here is about 12~16kg/m3, the flue gas flow rate is 1.2~3 m/s, and the normal operating temperature is 930~980℃.
                  • (3) Stovetop area. The normal operating temperature is 850~1100℃, and the flue gas flow rate increases by 18m/s at the separator inlet.
                  • (4) Cyclone separator. The normal operating temperature is 850~930℃, and the flue gas flow rate at the cyclone outlet can reach 29m/s.
                  • (5) Cyclone separator air outlet main pipe. The dust content of the flue gas here is 70~530g·m-3, the normal operating temperature is 850-930°C, and the maximum flue gas flow rate is 18m/s.
                  Monolithic Refractory Castables for CFB Boilers Refractory Linings
                  Monolithic Refractory Castables for CFB Boilers Refractory Linings

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                    According to the design requirements, the average working time of the boiler is 8600 hours, and the boiler starts and stops 2 to 10 times a year. Each ignition takes 12 to 24 hours. After ignition, the temperature is raised to 800°C at a rate of 65°C/h and kept warm for 8 hours. The service life of the furnace lining is required to be at least 2 years.

                    Circulating Fluidized Bed Boiler Refractory Materials

                    (1) Medium temperature, the working temperature of each part of the circulating fluidized bed boiler lining is 800~1000℃. From the perspective of refractory materials, this belongs to the medium-temperature range. When selecting refractory materials, first consider the medium-temperature physical and chemical properties of the material. For fired products, the sintering temperature is generally higher than this temperature range, so its physical and chemical properties at high temperatures can be directly used as a basis for selecting refractory materials. For unshaped refractory materials and unfired products, the physical and chemical properties at mid-temperature must be examined. Organically bonded materials or hydration-bonded hydraulic materials tend to have the worst strength at medium temperatures. These materials create a ceramic bond at high temperatures, which greatly increases their strength. Therefore, its physical and chemical indicators at high temperatures cannot be used as a basis for selecting refractory materials.

                    (2) Thermal shock. Under normal operating conditions, circulating fluidized bed boilers start and stop 2 to 10 times a year. In the early stages of operation, due to improper operation, the refractory lining was subjected to a strong thermal shock every year when starting and stopping. If the refractory material has poor thermal shock resistance, the spalling of the refractory material caused by thermal shock will become a fatal factor in its damage.

                    (3) Sand blasting wear, flue gas flow rate in circulating fluidized bed boilers is high (up to more than 29m·S-1), and solid material concentration is high. At medium temperatures, high-speed flue gas entrains a large number of solid particles, causing strong erosion and wear on the refractory lining. Especially in the impact zone of the cyclone, the erosion is most serious. For circulating fluidized bed boilers and cyclones with single-side return, the cyclic flow of materials causes wear areas on the refractory lining walls.

                    Monolithic Refractory Construction for CFB Boiler
                    Monolithic Refractory Construction for CFB Boiler

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                      Causes of Wear of Refractory Materials in Circulating Fluidized Bed Boilers

                      (1) Wear caused by thermal stress and thermal shock. Wear caused by thermal stress and thermal shock mainly manifests as cracks and spalling of refractory materials caused by temperature cycle fluctuations, thermal shock, and mechanical stress.

                      (2) Wear caused by erosion of solid materials. The wear caused by the erosion of solid materials is mainly the damage caused by the strong erosion of refractory materials by materials. The wear areas of refractory materials in circulating fluidized bed boilers include corner areas, cyclone separators, and solid material return paths. In general, refractory material wear increases with the increase of impact angle.

                      (3) Wear caused by changes in the properties of refractory materials. Wear caused by changes in the properties of refractory materials is mainly manifested as damage caused by the deterioration of refractory materials and the reduction of physical and chemical properties. The main manifestation is that the penetration of alkali metal causes the deterioration of refractory materials. Some refractories and bonds have lost strength, and some ovens have not met requirements, causing linings to delaminate and collapse.

                      The above technical guidance on refractory materials for circulating fluidized bed boilers mostly summarizes the requirements for the use of wear-resistant refractory materials from the combustion temperature of the fuel, wear values, theoretical data, etc. Start from the overall performance.

                      High-Strength Aluminum Phosphate Bonded Refractory Plastics
                      High-Strength Aluminum Phosphate Bonded Refractory Plastics

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                        Refractory plastic for circulating fluidized bed boiler repair

                        Refractory plastics are suitable for the construction of thin parts such as furnace water-cooled walls. It is mainly used in the dense phase area of the furnace and steam-cooled and water-cooled cyclone separators.

                        The wear-resistant refractory material in this area is designed as a single-layer ramming structure and is fixed with wear-resistant pins. Its design thickness is thin and can be laid directly on the construction surface.

                        In the application of repairing circulating fluidized bed cyclone separators, it’s super strong bonding performance can repair any irregular wear parts at will. There is no need to use steel formwork or moulds, and it can be ignited immediately after construction is completed without special maintenance. Thereby shortening the construction period and saving costs.

                        Refractory materials for circulating fluidized beds, refractory plastics for circulating fluidized beds, wear-resistant refractory castables, etc. RS refractory material manufacturer can provide high-quality refractory materials products and comprehensive customer service. Product quality is guaranteed and the delivery cycle is short. Effectively ensures the long life and safe operation of high-temperature industrial furnace linings.

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                          Why Should High-Strength Wear-Resistant Castables be Used in Cement Kilns?

                          During the production and operation of cement rotary kilns, highly worn parts such as tertiary air duct bends and grate coolers need to withstand high-temperature alkali corrosion of about 1200°C, as well as continuous erosion by high-speed tertiary air flows, and are very easy to be damaged. The traditional refractory lining mainly adopts a combined construction structure of wear-resistant bricks and mullite corundum castables. However, it often only lasts about half a year. Therefore, Rongsheng Refractory Materials Manufacturer recommends the use of high-strength wear-resistant refractory castables in this part of the cement kiln.

                          High-Strength Wear-Resistant Corundum Refractory Material
                          High-strength Wear-Resistant Corundum Refractory Castable Material

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                            Performance of high-strength wear-resistant refractory castables used in cement kilns

                            High-strength and wear-resistant refractory castables incorporate high-quality refractory raw materials with very high strength, such as corundum and silicon carbide. The castable has the characteristics of high density, low porosity, high strength, high refractoriness, high wear resistance, erosion resistance, and strong integrity. Therefore, it is recommended to use high-strength wear-resistant castables in areas prone to wear in cement kilns.

                            Application of high-strength wear-resistant refractory castables

                            High-strength wear-resistant refractory castables can be used in high-wear parts such as the tertiary air duct elbows of cement kilns, the throat of grate coolers, and the air intake of waste heat power generation. As we all know, corundum and silicon carbide have very strong wear resistance and high strength. High-strength wear-resistant castables configured with micro powder, mud, and chemical agents have excellent wear resistance. The lining constructed with this castable will produce a strong and reliable combination after high temperatures, which can effectively prevent the intrusion of kiln materials and the strong erosion of high-temperature gas and dust.

                            Wear resistant castable for sale
                            Rongsheng Wear-resistant Castable for Sale

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                              How to Efficiently Select High-Strength and Wear-Resistant Castables?

                              High wear-resistant castables are generally used in furnace areas where dust erosion is severe. Some manufacturers of refractory castables regard high medium-temperature strength, extreme corrosiveness, and erosion resistance as the key points to overcome in production technology.

                              High wear-resistant castable is a good wear-resistant amorphous material currently used in boilers. The wear-resistant castable is sintered the high temperatures during the use of the furnace, completing the necessary physical and chemical processes and automatically adapting to the requirements during its own use. The current circulating fluidized bed boilers have high thermal efficiency and low pollution emissions and are mostly used in thermal power plants and heating projects. The furnace lining temperature ranges from 800°C to 1100°C and has been severely eroded by dust for a long time, thus placing higher requirements on the wear resistance of the castables in the location. Manufacturers of wear-resistant castables are also constantly adjusting the process to correspondingly reduce the amount of fine particles added to continuously improve the wear resistance.

                              However, during the user’s use, it depends on the situation that occurs during use. Rongsheng refractory castable manufacturer also adopts different furnace types and different temperatures. To develop some production processes to meet the needs of users for various furnace types and actual situations.

                              However, there are also many customers who only pay attention to the price of refractory castables and do not pay attention to the actual operating temperature of their own furnaces. However, it is understandable that people often do not buy genuine products without comparing the price and usage. Good products have a long service life and do not delay production time, as well as maintenance costs. Don’t just look at the low price to decide the base of the product you want to buy.

                              As mentioned above, different castable manufacturers provide different high-strength, good wear-resistant, wear-resistant aggregates, and advanced dense matrices, and their costs are also different. Therefore, the price of refractory castables will vary.

                              Generally, high-strength and wear-resistant castables are used in hot water boilers, chain furnaces, waste incinerators, CFB boilers, cement plant grate coolers, kiln mouths, etc. However, users must also consider the size and temperature of the furnace to determine the level of high wear-resistant castables that are the best choice.

                              In terms of the construction of high-strength wear-resistant refractory castables, high-strength wear-resistant castables can be cast in formwork or constructed in the form of more advanced prefabricated parts. Rongsheng refractory castable manufacturers’ high-strength and wear-resistant castables have achieved good results in the large-scale cement production lines of many customers. Its use effect far exceeds that of castables made of other materials, and its service life can reach more than 3 years. Contact us to get free samples and quotes.

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                                What Kind of Ramming Material Should be Used for the Working Layer at the Electric Furnace Bottom?

                                The working layer at the bottom of the electric furnace is in direct contact with molten steel and slag, and is subject to high-temperature heat loads and erosion by molten slag. The erosion of molten steel, mechanical impact of scrap steel, and oxidation and reduction operations at high temperatures in the furnace will all lead to erosion and thinning of the furnace bottom. Therefore, the choice of ramming material for the working layer of the furnace bottom will have a great impact on the service life of the refractory lining of the furnace bottom working layer.

                                When the furnace bottom is operating, the dicalcium silicate in the slag absorbs moisture in the atmosphere and collapses. The durability of eroded ramming material is reduced and its service life is shortened. Therefore, the refractory material selected for the furnace bottom must be sufficient to resist the mechanical impact of the charge. At the same time, it must have suitable expansion performance. Its expansion and contraction will not produce excessive cracks to reduce the intrusion of molten steel and steel slag.

                                Excessive shrinkage will cause local floating. The natural bulk density and post-fired density of the ramming material can avoid uneven density caused by construction and sintering. It also has high resistance to penetration of molten steel and steel slag.

                                Magnesia Refractory Ramming Mass Material from Rongsheng
                                Magnesia Refractory Ramming Mass Material from Rongsheng

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                                  It is a ramming material with strong resistance to erosion by molten steel and steel slag, low erosion rate, uniform erosion, and long service life. The furnace bottom hot surface and the furnace bottom ramming material must have a strong affinity to ensure the repair effect. The working layer of high-power and ultra-high-power electric furnaces is generally constructed with magnesia dry ramming material. It is made of synthetic magnesia and fused magnesia as a fine powder, with a critical particle size of 5mm, without adding any binder and using multi-stage ingredients.

                                  Through strong ramming construction, the density and thickness after construction are guaranteed. It can be sintered into a solid whole at the appropriate temperature, and its lifespan will be improved several times by knotting and bricklaying methods. If hot repair is used in time during use, the service life can be extended to 800-1400 heats. Not only the number of furnace shutdowns is reduced, but the consumption of ramming materials per ton of steel is significantly reduced.

                                  Technical Characteristics That Electric Furnace Bottom Refractory Ramming Materials Should Have

                                  The bottom of the electric furnace is built with ramming materials, mainly magnesia-calcium dry ramming materials. It has ceramic bonding, low silicon, high calcium, a moderate amount of iron, and many fine powders. It has a thin sintering layer, dense sintering, high density, and high thermal strength. Good resistance to molten steel penetration and volume stability. For different furnace masonry, the thickness of the furnace slope ramming material and the thickness of the furnace bottom ramming material are different. During construction, materials should be laid in layers, each layer being 150mm. Tread it firmly with your feet, poke it with a steel drill to facilitate exhaust, and finally vibrate it with a special vibrator.

                                  Magnesia Ramming Material
                                  High-Strength Magnesia Ramming Material

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                                    The ideal electric furnace bottom refractory ramming material should generally have the following technical characteristics:

                                    • (1) Rapid sintering to form a solid working layer.
                                    • (2) Use medium and low melt cementing phase to transform into high melting point phase.
                                    • (3) Prevent molten penetration to the greatest extent and maintain appropriate looseness of deep-seated materials.

                                    There are also electric furnace manufacturers that convert steel parts and iron parts for use. If the electric furnace burns iron parts, then acidic ramming material should be used at the bottom of the furnace. It uses fused quartz and some other auxiliary materials as raw materials. The price is much different from that of magnesia or neutral furnace bottom ramming materials, but it is suitable for use when sintering iron parts. The choice of neutral ramming material, magnesia ramming material, or acidic ramming material for the furnace bottom is selected according to the different sintering conditions of the furnace lining. If it is burned iron parts, neither neutral nor magnesia ramming materials are suitable. If it is burned steel parts, acidic ramming materials will basically not be used.

                                    Rongsheng Refractory Castable Material Manufacturer

                                    Rongsheng unshaped refractory material manufacturer is a powerful refractory material manufacturer. Our environmentally friendly monolithic refractory production line has an annual capacity of tons and provides refractory services to the world. In addition, our new factory mainly produces various refractory precast shapes. In order to better serve high-temperature industrial furnaces, Rongsheng Refractory Materials Manufacturer is constantly improving our service content and service quality. To operate high-temperature industrial furnaces efficiently, contact us for free refractory solutions.

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                                      Acid Resistant Castables – Furnace Linings Resistant to Acid Attack

                                      Acid-resistant castables are divided into dense, semi-light, and light, and their main function is to be used for furnace linings resistant to acid corrosion. Acid-proof castables are generally combined with acid-resistant cement and are applicable to acid-resistant chimneys and liquid sulfur tank linings in the petrochemical industry.

                                      Rongsheng Acid Resistance Castable
                                      Rongsheng Acid Resistance Castable

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                                        Acid-Resistant Refractory Castable Used in Acid-Resistant Atmosphere Furnace Lining

                                        Other refractory castables of this kind of castable are also different, and they belong to an acidic medium. During production, it is also raw material processing granules and fine powder in an acidic medium, adding a certain proportion of ultra-fine powder and additives. However, this castable cannot be used in an atmosphere with a large temperature difference, and it cannot be used for construction in a place that is too humid. If the temperature is not suitable, it will reduce the later use strength and acid resistance of the acid-resistant castable, and it will peel off.

                                        For example, acid-resistant castables for chimneys are generally semi-light, which can not only keep warm but also resist erosion and acid gas erosion. Because the semi-lightweight acid-resistant castable can save energy. Improve the operating rate and service life of the chimney, and at the same time, the weight of the chimney body will not be too heavy.

                                        The acid-resistant refractory castables are all used in the lining of the acid-resistant atmosphere, and cannot be used in the neutral or alkaline lining atmosphere. Because the high-temperature resistance of this castable is not as good as the high-alumina series castables used in neutral atmospheres. The use of Castables that are not as good as the magnesium series in alkaline atmospheres are mainly used in chimneys, flues, and nitric acid pus tower linings in acidic atmospheres, as well as container linings for acidic gases. The high-temperature resistance of acidic materials is not as good as that of the high aluminum series and magnesium series.

                                        However, acid-resistant castables can be used as a separate lining material. Used in a furnace with a consistent atmosphere will play the role of acid resistance of the castable itself, and cannot be used as a furnace lining for other atmospheres. The first is high-temperature resistance, and then there is a gap in the effect of corrosion resistance in other atmospheres.

                                        That is to say, acid-resistant castables, whether heavy, semi-light, or light, can only be used as a lining for acid gas.

                                        Acid Resistance Castable Directly from Factory
                                        Acid Resistance Castable Directly from Factory

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                                          Characteristics and Configuration Methods of Acid-Resistant Castables

                                          Acid-resistant castable is a castable refractory material prepared with water glass as a binder, acid-resistant refractory aggregate, powder, and admixture. Acid-resistant castables have higher binder and moisture content and better fluidity, so monolithic refractory materials have a wider range of applications. Specifically, the materials and binders used can be selected according to the conditions of use. It can be directly poured into a lining body, and can also be used as a prefabricated block by pouring or shaking.

                                          The products of acid-resistant castables are inseparable from the environment and pigments, so you must pay attention to these when using acid-resistant castables. Many customers know what castables are, but in terms of subdivision, they don’t know much about acid-resistant castables, nor do they know what the composition ratio of acid-resistant castables is.

                                          The composition ratio of the acid-resistant castable is acid-resistant refractory aggregate 60%-75%, powder 25%-30%, and water glass 13%-16%. The general classification standard of acid-resistant castables is to classify according to the actual use situation, use temperature, and functional characteristics. The main varieties of acid-resistant castables produced by Rongsheng manufacturers include ordinary calcium aluminate cement, pure calcium aluminate cement, and Portland cement. The basic technical characteristics of acid-resistant castables are similar to those of general water glass refractory castables. The products of acid-resistant castables are inseparable from the use environment, which is directly related to the quality of acid-resistant castables. Acid-resistant castables are very picky about the construction environment. When we use acid-resistant castables, the construction temperature must be properly controlled. Too high or too low temperature will be harmful to the castable, and the use environment will also affect the corrosion resistance of the castable.

                                          Because acid-resistant castables have excellent anti-corrosion properties, acid-resistant castables can not only meet the anti-corrosion requirements in corrosive environments but also meet the performance fatigue requirements of alternating performance. Acid-resistant castables can survive in extremely harsh environments for a long time. The shrinkage rate, hardness, toughness, wear resistance, and high-temperature resistance of the acid-resistant castable itself have laid a solid foundation for its long-life use in harsh environments. In terms of acid resistance, the acid resistance of aggregate and powder is mainly considered. Factors such as the acid resistance after being formulated into an acid-resistant castable and the change in the strength of the castable after pickling. Acid-resistant castables are easy to harden and can be hardened by hydration at room temperature. For example, soaking in different concentrations of the sulfuric acid solution, as the concentration of the acid solution increases, the strength of the castable also increases. It has good strength stability when soaked in concentrated acid. The strength not only does not decrease after soaking but increases slightly with the extension of soaking time.

                                          Lightweight Acid-Resistant Castable For Chimney
                                          Lightweight Acid-Resistant Castable For Chimney

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                                            Advantages and Construction Precautions of Lightweight Heat-Insulating and Acid-Resistant Castables

                                            Lightweight heat-insulating and acid-resistant castables have the advantages of light volume, strong compression resistance, high acid corrosion resistance, and low water absorption. Fully play the role of heat preservation. It can ensure the compactness of the masonry especially when it is used in the parts with serious acid corrosion. It is an ideal refractory material for a high chimney, high-temperature flue, and pipelining.

                                            Lightweight heat-insulating and acid-resistant castables are easy to construct and have strong cohesive force. The initial setting time and construction operation time are long, and the strength increases rapidly, the impermeability is strong, no acid treatment is required, and it is easy to ensure the denseness and fullness of the masonry mortar joints. It can significantly improve the airtightness and integrity of the chimney lining wall and the acid corrosion resistance of the lining.

                                            When the lightweight heat-insulating and acid-resistant castable is used, it can be dry-mixed and then wet-mixed with water. The amount of water added to acid-resistant castables also needs to be strictly controlled. The amount of water added is directly related to the performance and strength of the castable. Therefore, attention must be paid during construction, and the mixed water must be added according to the amount of water added in the construction instructions.

                                            Lightweight heat-insulating and acid-resistant castables can be used as acid-resistant castables and refractory castables without heat insulation. The main component of the lightweight acid-resistant castable binder is water glass. However, some require different parts to be used, and they are also combined with phosphoric acid, and the acid-resistant castables combined with phosphoric acid have low calcium content.

                                            Due to the large porosity of the lightweight aggregate structure, rough surface, and particle size of about 5mm, the water absorption and hygroscopicity of the aggregate and powder are large. Therefore, according to the mixing ratio, the fluidity is poor after stirring, the thermal conductivity is small, and the linear expansion coefficient is small. It can also be used as filling material in the lining of a blast furnace.

                                            Lightweight acid-resistant castables must be protected from moisture. Rongsheng monolithic refractory manufacturers will mix the aggregate and powder into a mixture before leaving the factory, and pack it in a woven bag before transportation. For temporary storage, it should be stored in a dry warehouse with good drainage and moisture-proof.

                                            Rongsheng Refractory Castable Manufacturer
                                            Rongsheng Refractory Castable Manufacturer

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                                              High-Quality Monolithic Refractory Manufacturers

                                              Rongsheng Refractory Material Manufacturer is a refractory material manufacturer with rich production and sales experience. Our environmentally friendly fully automatic monolithic refractory production line has an annual output of tons. Specially provide solutions for refractory lining materials for various high-temperature industrial furnaces. We can not only provide various monolithic refractory castable products but also provide turnkey projects of refractory lining. Various refractory precast shapes. Contact us for free samples and quotes.

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                                                Application of Monolithic Refractory Materials – Conventional Castable

                                                In the process of iron and steel smelting, in addition to some commonly used refractory brick products with regular shapes, some refractory mortar is also used to fill the gaps between bricks and bricks. Or directly use Monolithic Refractory Materials for construction, which is faster and more convenient. Or use Monolithic Refractory Materials to produce irregular Precast shapes. To learn more about the Application of Monolithic Refractory Materials – Conventional Castable, please read on, or contact us.

                                                Slag Retaining Wall/Weir, Breathable Curtain Wall

                                                It is mainly used to block steel slag, change the trajectory of molten steel, prolong the residence time of molten steel, and promote the collision and floating of inclusions in molten steel to purify molten steel. Change the flow distribution of molten steel in the tundish, make the flow field of molten steel reach the best state, reduce the stagnation area, and expand the steady flow area. The product has the characteristics of high strength, corrosion resistance, erosion resistance, and strong slag-retaining ability.

                                                All Kinds of Covering Materials

                                                It is mainly used for sealing steel containers to prevent heat loss and secondary oxidation of molten steel. The product has the characteristics of excellent thermal shock resistance, low thermal conductivity, and good thermal insulation performance.

                                                Current Stabilizer, Impact Plate

                                                It is mainly used to accept the molten steel injected from the ladle, absorb the kinetic energy of the impact of molten steel injection, reduces the splash of molten steel, and promote the orderly flow of molten steel. To ensure that the inclusions are fully removed by collision and floating, and reduce the erosion of refractory materials in the injection area. The product has the characteristics of high-temperature strength, impact resistance, and excellent volume stability.

                                                Well Block Bricks, Separation rings

                                                It is mainly used with nozzle products to play the role of fixing the nozzle. The product has the characteristics of good volume stability and thermal shock resistance.

                                                Ceramic Wear-Resistant Coating
                                                Ceramic Wear-Resistant Coating

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                                                  Dry Materials, Spray Coatings, Coating Materials

                                                  It is mainly used in the working layer of the tundish to protect the permanent layer, contains high-temperature molten steel, and absorbs inclusions in molten steel. The product has a simple construction, safety, and environmental protection. It has the characteristics of high service life, good disintegration, and a remarkable effect of purifying molten steel.

                                                  Permanent Layer Castable

                                                  It is mainly used in the permanent layer of each steel container to support the working layer and reduce the heat loss of molten steel. The product has the characteristics of good fluidity, no baking, excellent thermal insulation performance, and thermal shock resistance.

                                                  Blast Furnace Gunning Materials

                                                  Blast furnace gunning material, which is characterized by automatic remote control mechanical gunning construction, high strength, and good wear resistance. It is mainly used for gunning lining and lining maintenance of large, medium, and small blast furnaces, which can prolong the service life of blast furnaces.

                                                  Lightweight High-Strength Castable for Steel Ladle
                                                  Lightweight High-Strength Castable for Steel Ladle

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                                                    Iron Ditch Castables

                                                    The tap trough is the main channel for transporting molten iron and iron slag. The iron channel material is divided into main channel material, branch channel material, and slag channel material according to the use-part, which are respectively used for the main channel, branch channel, and slag channel of the iron channel. It is characterized by excellent slag iron erosion resistance and erosion resistance, and good thermal shock resistance.

                                                    Heating Furnace Castables

                                                    Heating furnace series castables are characterized by good thermal shock resistance, high strength, and good thermal insulation. It is mainly used in the working layer and heat insulation layer of the furnace top, furnace wall, furnace bottom, and other parts of various heating furnaces.

                                                    Nickel-Iron Rotary Kiln Castables

                                                    Nickel-iron rotary kiln castable is characterized by excellent acid and alkali resistance, high strength and high wear resistance, good thermal insulation, and thermal shock stability. Mainly used for lining and other auxiliary parts of the nickel-iron rotary kiln;

                                                    Desulfurization Guns

                                                    The desulfurization spray gun is mainly used in the molten iron pre-desulfurization system. It is characterized by good integrity, good thermal shock stability, and long service life. It is the main refractory product for molten iron injection desulfurization. It plays an important role in reducing the sulfur content in molten iron to produce high-quality steel.

                                                    KR Mixer

                                                    KR mixer is mainly used in molten iron pre-desulfurization systems. It is characterized by good integrity, good thermal shock stability, long service life, good slag resistance, and hot metal erosion resistance, and is the main product for hot metal desulfurization by stirring method. It plays an important role in reducing the sulfur content in the iron removal water to produce high-quality steel.

                                                    Furnace Covers

                                                    The furnace cover products are mainly used for the furnace roof of electric arc furnace smelting and the furnace roofs of LF refining furnaces. It is characterized by good thermal shock stability, high-temperature resistance to acid and alkali gas, good corrosion resistance, and long service life.

                                                    Ladle Working Layer Refractory Castables

                                                    It is mainly used for the ladle working layer cladding wall and ladle bottom working layer to undertake molten steel. The product has the characteristics of high strength, erosion resistance, good slag erosion resistance, and good thermal stability.

                                                    Rongsheng Refractory Mortar for Sale
                                                    Rongsheng Refractory Mortar for Sale

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                                                      Refractory Mortars

                                                      It is mainly used for the masonry of working linings’ refractory bricks and permanent linings’ bricks. It has the characteristics of convenient construction, firm bonding of lining refractory bricks, and excellent erosion resistance.

                                                      PreCasting Ladle Bricks

                                                      It is mainly used for ladle working layer wrapping wall and bottom working layer, for smelting low carbon steel and ultra-low carbon steel. The product has the characteristics of high strength, the ability to withstand high-temperature erosion of molten steel, high-pressure argon flow stirring and impacting, good resistance to slag erosion, and good thermal stability.

                                                      Refractory Castable Precast Shapes Block for Electric Furnace Top
                                                      Refractory Castable Precast Shapes Blocks

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                                                        Rongsheng Refractory Castable Precast Shapes Parts

                                                        The refractory castable Precast Shapes part is a mold designed according to the shape required by the industrial furnace. The refractory castable is selected for casting, and it is put into use after curing, de-moulding, and drying. Conventional Castable Precast Shapes parts are made of high alumina, alumina silicon carbide carbon, corundum, magnesia, and other raw materials. The material of the castable Precast Shapes part is determined according to the actually poured lining. Refractory castable Precast Shapes part is a kind of precasting refractory product, and it is also a refractory material product commonly used in industrial kilns. Because of the convenient construction, it can improve the furnace building efficiency and is widely used in various industrial kiln linings and parts where it is not convenient to build refractory bricks. Specifically as follows.

                                                        1. Heating furnace roof and taphole precast shapes parts
                                                        2. Precast Shapes parts of the electric furnace roof
                                                        3. Iron ditch Precast Shapes parts
                                                        4. Ladle furnace bottom Precast Shapes parts
                                                        5. Precast Shapes parts of intermediate frequency furnace sleeve
                                                        6. Tundish covers precast shapes parts

                                                        In industrial kilns and thermal equipment, refractory castable Precast Shapes parts are used to build furnaces. It can realize mechanized installation, save labor and labor, shorten the construction period, and improve the efficiency of furnace construction. Monolithic Castable Precast Shapes parts are widely used in blast furnaces, hot blast stoves, heating furnaces, electric furnace roofs, iron ore powder roasting shaft furnaces and pellet roasting furnaces, and other industrial kiln masonry. The lining speed is fast, it can be used without baking, and the service life is long. The castable Precast Shapes parts can be poured into precasting parts of various materials and shapes according to the construction needs and drawing design.

                                                        The above is the description of the common refractory castable Precast Shapes parts by the Rongsheng Refractory Castable Manufacturer, Zhengzhou Rongsheng Refractory Material Manufacturer. Rongsheng Refractory Material Manufacturer Co., Ltd. is located in Xinmi, Henan. Specializing in the production of non-stick aluminum castables, low cement castables, high aluminum castables, lightweight castables, dense refractory castables, wear-resistant castables, etc. Rongsheng Refractories Factory has successively developed shaped products such as alumina-silicate series, silica series, alkaline series, lightweight heat insulation brick series, and castables of different raw materials, self-flowing refractory castable materials, ramming mass refractory materials, etc. Indeterminate materials such as refractory plastics. Contact us for free prices and samples.

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                                                          Refractory Castable Precast Shapes for Heating Furnace Roofs

                                                          Refractory castable for heating furnace roofs is a kind of refractory material specially designed for heating furnace roofs. It is used to protect the structure inside the furnace body, reduce heat loss and increase the service life of the furnace. Refractory castables have the advantages of high compressive strength, wear resistance, corrosion resistance, and good thermal stability, so they are widely used in the manufacture and maintenance of heating furnace roofs. Rongsheng refractory castable manufacturer can customize Refractory Castable Precast Shapes for Heating Furnace Roofs for customers. The mold size is accurate, and the quality of the refractory castable precast shape is reliable and guaranteed.

                                                          Electric Arc Furnace Roof Precast Shape
                                                          Electric Arc Furnace Roof Precast Shape

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                                                            Refractory Castable Precast Shapes for Heating Furnace Roofs

                                                            In industrial kilns and thermal equipment, using castable refractory precast shapes to build furnaces can realize mechanized installation, save labor and labor, shorten the construction period, and improve furnace building efficiency. Castable refractory precast shapes are widely used in blast furnaces, hot blast stoves, heating furnaces, electric furnace roofs, iron ore powder roasting shaft furnaces and pellet roasting furnaces, and other industrial kilns masonry. The lining speed is fast, it can be used without baking, and the service life is long. Castable refractory precast shapes can be poured into precast shapes of various materials and shapes can according to construction needs and drawing design.

                                                            Rongsheng Refractory Castable Precast Shapes
                                                            Rongsheng Refractory Castable Precast Shapes

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                                                              Main components and characteristics of refractory castables for heating furnace top precast shapes

                                                              main ingredient

                                                              The main components of precast shapes refractory castables include refractory aggregates, refractory binders, refractory fillers, and some additives. Among them, the refractory aggregate generally adopts materials with high refractoriness such as blast furnace ore, brown corundum, and corundum. The refractory binder can choose aluminum silicate cement, phosphate cement, and so on. Refractory fillers are mainly refractory fibers, lightweight refractory castables, etc. Additives mainly include waterproofing agents, precipitation agents, etc. to improve the performance of castables.

                                                              Compressive strength

                                                              The precast shapes refractory castables have high compressive strength and can withstand large mechanical loads. This enables the furnace roof to maintain good stability and service life under long-term high-temperature conditions.

                                                              wear and corrosion resistant

                                                              The precast shapes refractory castables have good wear resistance and corrosion resistance. It can resist the erosion of materials and gases in the furnace under high temperatures, and protect the internal structure of the furnace body.

                                                              thermal stability

                                                              Precast shapes refractory castables have good thermal stability. It can withstand high temperature and temperature fluctuations, prevent the roof from cracking due to thermal expansion and contraction, and prolong the service life of the furnace roof.

                                                              construction performance

                                                              The precast shapes refractory castables have good construction performance. The construction can be carried out by pouring, spraying, or wet spreading, which makes the production and maintenance of the furnace roof more convenient and quick.

                                                              Refractory Castable Precast Shapes Block for Electric Furnace Top
                                                              Refractory Castable Precast Shapes Block for Electric Furnace Top

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                                                                Requirements for the use of precast shapes refractory castables for heating furnace roof

                                                                Refractory castables for heating furnace roofs have strict requirements in terms of material selection, design, and construction to ensure that their performance and service life can meet the expected goals. The following are the requirements for the use of precast shapes refractory castables for heating furnace roofs.

                                                                1. Material selection

                                                                When selecting refractory castables, appropriate refractory aggregates, binders, and fillers should be selected according to the working environment and requirements of the heating furnace. In addition, factors such as thermal conductivity and thermal expansion coefficient of the castable should also be considered to ensure good performance under high-temperature conditions.

                                                                1. Design

                                                                When designing the furnace roof, factors such as temperature distribution, heat loss, and thermal stress in the furnace should be fully considered in order to reasonably select the type and thickness of the refractory castable. At the same time, the structural design of the furnace roof should also be considered to improve the overall stability and service life of the furnace roof.

                                                                1. Construction

                                                                During the construction process, the operation should be carried out in strict accordance with the technical requirements provided by the refractory castable manufacturer to ensure that the castable is fully stirred evenly and the pouring compaction is good. Air bubbles and slag inclusions should be avoided during pouring to ensure the compactness and refractory performance of the furnace roof.

                                                                1. Maintenance

                                                                After the pouring is completed, the furnace roof should be properly maintained to ensure the strength and stability of the refractory castable. Conservation methods include wet cultivation, natural conservation, etc. During the maintenance process, the furnace roof should be prevented from being damaged by external force to ensure the integrity of the furnace roof.

                                                                1. Repair and maintenance

                                                                During the operation of the heating furnace, the condition of the furnace roof should be checked regularly, and problems should be dealt with in time. If the furnace top is found to be partially damaged, it can be repaired by partial repair. If the overall damage to the furnace roof is serious, it should be considered to replace the furnace roof.

                                                                In a word, refractory castables for heating furnace roofs play a key role in protecting the internal structure of the furnace body, reducing heat loss, and prolonging the service life of the furnace. Choosing the right refractory castable and strictly following the construction and maintenance requirements can ensure the performance and service life of the heating furnace roof to the expected level. Rongsheng refractory material manufacturer has rich experience in production and sales. The quality of precast shapes refractory castables for heating furnace roofs is reliable. At the same time, Rongsheng manufacturers can provide customization of refractory castable materials to meet the needs of heating furnace lining materials. Customized refractory lining material solutions, free design of refractory materials for high-temperature kiln insulation layer. Contact us to enjoy free benefits.

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                                                                  What is the Proper Bulk Density of Refractory Castable?

                                                                  What is the bulk density of the refractory castable? Generally, this technical index will be given before the refractory castable leaves the factory. The unit of castable bulk density is usually g/cm3. The bulk density of the castable can range from 0.8g/cm3 (or even lower) to 3.2g/cm3 (or even higher). Which castable to choose depends on the production conditions of the high-temperature industrial furnace.

                                                                  What is the Proper Bulk Density of Refractory Castable?
                                                                  Kinds of Refractory Castables in Rongsheng

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                                                                    The bulk density of refractory castables refers to the mass per unit volume after adding a specified amount of water or liquid binder to the castables, stirring, pouring, curing, and hardening, and then drying at 110°C. It is one of the commonly used physical and chemical indicators of refractory castables. The difference between the unit volume dosage and bulk density of refractory castables. A test method for testing the dosage per unit volume of refractory castables is introduced. The test results intuitively reveal the difference between the unit volume dosage of refractory castables and their bulk density, and the differences between different types of castables. Taking the hydraulic refractory castable as an example, the reasons for this difference are analyzed.

                                                                    What is the Proper Bulk Density of Refractory Castable?

                                                                    The density of the castable affects the wear resistance, strength, service life and thermal insulation, and energy-saving effect. So, what is the appropriate density of the castable? Is the higher the density of the castable, the better? The density of the castable we use has a great influence on its performance, and some people think that the denser the castable, the better, which is wrong. It should be determined according to the occasion you use and the type of castable.

                                                                    Rongsheng Refractory Castables
                                                                    Rongsheng Refractory Castables

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                                                                      Now refractory castables are used in many industries, and different industries have different standards for the use of castables. The density of the castable is one of the most critical factors. The density of the castable has a great influence on its performance, so the requirements for the density of the castable are different in different situations.

                                                                      The different industries used have different requirements for the wear resistance of castables. For example, tunnel kilns, such as mechanical equipment, have different requirements for wear resistance. Therefore, the density requirements for refractory castables are also different. In addition, different types of refractory castables also have great differences in construction density.

                                                                      What is the appropriate density of castable? For parts that need to be exposed to flames and require high wear resistance, it is recommended to use corundum series products or corundum plastics with high density and good wear resistance. For those who require good heat preservation and heat insulation effect and have requirements on weight, light castables with low density and light weight are used.

                                                                      Bulk Density and Apparent Porosity of Refractory Castables

                                                                      In addition to the solid body, the prepared refractory castable sample also has many pores of different sizes and shapes, that is, the sample is a porous body. There are three types of pores: open pores that are closed on one side and open to the outside world, closed pores that are closed in the sample and not connected to the outside world, and penetrating pores that penetrate through several sides of the sample. The total porosity, that is, the true porosity, refers to the percentage of the total volume of the pores in the sample to the total volume of the sample; in general, the through pores are combined with the open pores, and the closed pores are less and difficult to measure directly. Therefore, the porosity is expressed by the open porosity, that is, the apparent porosity. Apparent porosity refers to the percentage of the total volume of open pores in the sample to the total volume of the sample.

                                                                      Bulk density refers to the ratio of the amount of castable to the total volume of the sample after drying, that is, the ratio of the amount of castable to the total volume of the porous body, expressed in Kg/m3 or g/cm3.

                                                                      Apparent porosity and bulk density are one of the basis for controlling the amount of castable in the construction of refractory castable. The two performance indicators can be measured with the same sample. The followings are the bulk density and apparent porosity of commonly used refractory castables.

                                                                      • CA-50 cement high alumina castable bulk density 2.3–2.6g/cm3, apparent porosity 17-20%
                                                                      • CA-50 cement clay castable bulk density 2.2-2.35g/cm3, apparent porosity 18-22%
                                                                      • Clay combined with high alumina castable bulk density 2.25–2.45g/cm3, apparent porosity 16-21%
                                                                      • Low cement high aluminum castable bulk density 2.4–2.7g/cm3, apparent porosity 10-16%
                                                                      • Ultra-low cement high aluminum castable bulk density 2.3–2.6g/cm3, apparent porosity 10-16%
                                                                      • CA-70 cement corundum castable bulk density 2.7–3.0g/cm3, apparent porosity 12-16%
                                                                      • Water glass clay castable bulk density 2.10–2.35g/cm3, apparent porosity 15-19%
                                                                      • High aluminum phosphate castable bulk density 2.3–2.7g/cm3, apparent porosity 17-20%
                                                                      • Aluminum phosphate high alumina castable bulk density 2.3–2.6g/cm3, apparent porosity 16-20%
                                                                      Rongsheng Low Cement Castable Materials
                                                                      Rongsheng Low Cement Castable Materials

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                                                                        What is the Density of Low Cement Refractory Castables?

                                                                        Before understanding the density of low cement refractory castables, it is necessary to understand the composition of low cement refractory castables. Low-cement castables use calcium aluminate cement as the binder, and castables with a CaO content of less than 2.5% are collectively referred to as low-cement castables. Different from traditional castables, low-cement castables are used to replace most or all of the high-alumina cement with coagulated ultrafine powder (particle size less than 10 microns) with the same or similar chemical composition as the main material. Optimize particle gradation, fine powder, particle shape, and other factors. At the same time, it is formulated by adding a small amount of dispersant (water-reducing agent) and an appropriate amount of retarder and other compound admixtures.

                                                                        • The density of clay low cement refractory castable is about 2.26g/cm³.
                                                                        • The density of high alumina low cement refractory castables is around 2.3~2.6g/cm³.
                                                                        • The density of corundum low cement refractory castable is about 2.65~2.9g/cm³.

                                                                        The density of low-cement castables is that if the content of alumina is 51%, its density is 1.3g/m3; if it is 60%, its density is 1.52g. The alumina content is 63%, its density is 1.51g; 65%, its density is 1.78g. The smaller its volume density, the lower its thermal conductivity and absorption, and the better its thermal insulation performance. Its scope of use plays a role in heat preservation and heat insulation in industrial kilns and thermal equipment, and its withstand temperature is 600 °C. It can be divided into low-temperature lightweight low-cement castables that can withstand below 900 °C. Medium-temperature lightweight low-cement castables can withstand temperatures between 900-1200°C. High-temperature lightweight low-cement castables can withstand temperatures above 1200°C.

                                                                        This product is formulated by adding a small amount of dispersant (water reducer) and a certain amount of slow-acting retarder. Because the cement content of this product is low, the eutectic phase is reduced, thereby improving refractoriness, high-temperature strength, and slag resistance. And when heated, the strength can also increase with the increase of heat treatment temperature. The small amount of cement also allows low-cement castables to achieve the corresponding effect without pouring too much water. The service temperature of low cement castables and ultra-low cement castables is higher than that of ordinary refractory castables of the same material. In the glass kiln tin tank bottom, cement kiln front and rear kiln door cover cooler front and other high-temperature resistant parts, front and rear kiln mouth, coal injection pipe, etc. Heating furnaces, soaking furnaces, and other heat treatment furnaces. The lining of the intermediate frequency induction furnace, the high-temperature wear-resistant lining of the petrochemical catalytic cracking reactor, and the lining of other industrial kilns have been fully applied.

                                                                        Regarding the appropriate density of castables, Rongsheng monolithic refractory castable manufacturers provide refractory castables with various volume densities(lightweight refractory castables 0.5g/cm3、0.6g/cm3、0.8g/cm3、1.0g/cm3、1.2g/cm3、1.5g/cm3; dense refractory castables 2.0g/cm3、2.2g/cm3、2.3g/cm3、2.4g/cm3、2.5g/cm3、2.6g/cm3、2.7g/cm3、2.8g/cm3, etc. ), which can be selected for high-temperature industrial kilns. Purchase kiln lining refractory bricks and monolithic refractory castables find suitable refractory manufacturers, high-quality construction teams for refractory lining materials, and perfect customer service from Rongsheng manufacturers. Help you solve all-around services from refractory production and construction after-sales. Let your high-temperature kiln run smoothly on the road of high efficiency and long life. Look forward to working with you.

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                                                                          Acid-Resistant Castables for Chemical Plant Chimneys and Pipes

                                                                          Castable refractory castable light acid-resistant castable, lightweight castable manufacturer, light acid-resistant castable, acid-resistant castable for chemical plant chimneys, acid-resistant castable for pipelines, Rongsheng refractory castable manufacturers. Acid-resistant castables are easy to construct and have good acid corrosion resistance, and are widely used in chimneys and other parts of the power industry. Because acid-resistant refractory is suitable for acidic environments, they can be used for a long time at 800 ° C ~ 1200 ° C, and are a monolithic refractory material that can resist acid corrosion.

                                                                          Acid proof castables
                                                                          Acid proof castables

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                                                                            Acid-resistant castable is a kind of monolithic refractory material, which has excellent fire resistance and acid resistance, so acid-resistant castables for chemical plant chimneys and acid-resistant refractory for pipes are widely used. Acid-resistant castables use water glass as a binder, and acid-resistant refractory materials as aggregates and powders, which can have a good coagulation effect with the assistance of a coagulant. There are two kinds of acid-resistant castable products: heavy and light. The light heat preservation effect is good, and the compressive strength of the heavy is higher than that of the light.

                                                                            Acid-Resistant Castables for Chemical Plant Chimneys and Pipes

                                                                            1. Acid-resistant castables are stable in various concentrations of organic acids and inorganic acids. Especially in dilute acid, industrial water, and neutral aqueous solution, no crystalline salt is produced, and it has high impermeability.
                                                                            2. Good heat resistance, the lining of titanium dioxide rotary kiln, the service temperature is as high as 800°C-1000°C.
                                                                            3. The curing agent used in acid-resistant castables is harmful to operators and construction personnel. Appraised by the health department, it can be used in various equipment anti-corrosion projects.
                                                                            4. Compared with organic acid-resistant refractory materials, acid-resistant castables are cheaper. In addition to having the same performance as an organic acid and corrosion resistance, it also has the characteristics of corrosion resistance to strong oxidizing media.
                                                                            5. Curing at room temperature, simple construction, and convenient use. Easy to transport, moisture-proof storage.
                                                                            Acid Resistance Castable Manufacturing
                                                                            Acid Resistance Castable Manufacturing

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                                                                              Acid-resistant castables have a wide range of raw materials and low prices. Commonly used aggregates are silica, diabase, andesite, and wax stone. These kinds of stones have relatively strong acid resistance, especially silica, and cast stone are the most commonly used. Of course, it is not possible to use it in any situation if it is acid-resistant, and it should be selected according to the requirements of the construction site.

                                                                              In addition, it should be noted that silica will change to polycrystalline when quartz is heated, and its volume will shrink and become larger during this process, in order to avoid this phenomenon. Therefore, we usually use discarded silica brick materials to replace part of the silica raw materials. The powder used in acid-resistant refractory castables is mostly silicon powder, high-silica clay powder, porcelain powder, etc. Due to the polycrystalline shrinkage characteristics of silica, it is used on a smaller scale than cast stone, which is also a common acid-resistant castable aggregate.

                                                                              The commonly used components of acid-resistant castables can be divided into three types, namely aggregate, powder, and binder. According to the specific requirements and the situation of the construction site to formulate the appropriate preparation ratio. The acid-resistant refractory aggregate is between 60% and 70%, the powder is between 30% and 40%, and the water glass solution with a density of 1.4g/cubic centimeter is used as a binder.

                                                                              Precautions for the Use of Acid-Resistant Castables

                                                                              1. The acid-resistant castable itself has excellent fire-resistant and acid-resistant functions. However, its impermeability is average. Therefore, try not to use acid-resistant castables in wet and liquid conditions. If it is necessary to construct under such circumstances, preparations must be made before construction, and waterproof and moisture-proof materials should be laid in the wet place.
                                                                              2. Try not to use light acid-resistant castables as refractory materials. Since the castable will add a certain amount of binder during the distribution process, direct contact with the flame may destroy the adhesive additive in the acid-resistant castable.
                                                                              3. The characteristics of acid-resistant castables are somewhat similar to those of cement, and both require a certain setting time. If the temperature difference of the refractory lining is too large, it will affect the condensation process of the acid-resistant castable. There may even be cracks, which should be paid special attention to.
                                                                              4. Requirements for the construction environment temperature of acid-resistant castables. Acid-resistant castables are actually very picky about the construction environment. When using acid-proof castables, the construction temperature should be between 5 degrees Celsius and 30 degrees Celsius. If the temperature is too low during construction, then we should store the dry material in a room with a suitable temperature. During construction and stirring, the temperature of the acid-resistant castable can be kept at more than ten degrees Celsius by heating the water or adding an appropriate amount of coagulant. If the construction of acid-resistant castables is carried out in areas with high temperatures, and the temperature exceeds 30 degrees Celsius, then some methods are required to cool down. Containers and pipes can be placed in a cool place to prevent the material from being exposed to sunlight, perhaps mixed with ice water, or a cooling fan can be used to cool the surrounding environment, so as to prevent the acid-resistant castable from being affected by high temperature.
                                                                              Lightweight Acid-Resistant Castable For Chimney Wall Lining
                                                                              Lightweight Acid-Resistant Castable For Chimney Wall Lining

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                                                                                Application of Acid-Resistant Castables for Chimneys and Pipes

                                                                                Acid-resistant castables are mainly used as anti-corrosion flue and chimney linings, acid storage tanks, pickling tank linings, and nitric acid shrinkage tower linings. Acid recovery furnace lining and other container linings corroded by acidic high-temperature gas, etc. The acid-resistant castable is flexible in use and can be poured and constructed. It can also be used by Rongsheng refractory castable manufacturers to make acid-resistant refractory prefabricated parts (precast blocks). The use of prefabricated refractory castables greatly improves construction efficiency and saves construction time. Rongsheng refractory castable manufacturer is located in Xinmi, Henan. The refractory castables produced include steel fiber castables, lightweight castables, iron trench castables, high-aluminum castables, lightweight thermal insulation castables, wear-resistant castables, refractory ramming materials, refractory plastics, unshaped prefabricated blocks, etc. Contact us for free samples and quotes.

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