rsrefractorycastable, Author at Rongsheng Refractory Castable Cement for Sale Manufacturer and Supplier

How Much Water Should be Added During the Construction of Refractory Castables?

January 3, 2023 by rsrefractorycastable

The amount of water added to the refractory castable is very important, and directly affects the service performance and service life of the castable. How much water should be added during the construction of refractory castables? Different binders are used in castables, and the prepared refractory castables are also different. Even the same kind of refractory cement can be used as a binder to prepare various refractory castables. The amount of water added to the castable is also different during construction. The strength and service life of castables are inseparable from water consumption.

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During the construction of castables, the increase in water consumption will generally lead to a large decline in various properties. When the amount of water is large, the water will escape after heating, and the pores will increase accordingly, forming a loose structure, resulting in an overall decline in the performance of the castable and affecting the service life of the castable. Therefore, during the construction of castables, it is necessary to minimize the amount of water used during mixing.

According to the current use of castables, basically, the amount of cement is increasing, and the amount of cement added is basically canceled. Because the amount of low-cement castable high-alumina cement added is small, the amount of water added during construction is also small, and the situation of low medium-temperature strength is also overcome. If the amount of water added to the castable is too large, it is not only a coagulation problem, but the biggest reason is to affect the later use strength.

When the ratio of refractory castables and the production process are basically the same, water consumption has the best value. Generally, after the castable is produced, the manufacturer will make a sample block and do certain chemical and physical tests. Then, according to different situations, determine the optimal value of water consumption for each pouring material. Sometimes it is necessary to do certain tests or equip some binders according to the temperature on the spot during construction so that the water consumption of different castables during construction can be used at different temperatures.

Therefore, when making cement-bonded refractory castables, they should be mixed to the best fluidity. Then, according to the size of the normal temperature strength, determine the optimal amount of water.

The main points of adding water during the construction of refractory castables

Refractory castables are divided into neutral, alkaline, and acidic. The materials are divided into high aluminum, magnesium, acid, light series, and so on. Regardless of the series, the amount of water added is different for different models and materials.

Mixing of Refractory Castables Water Addition

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During the construction of refractory castables, drinking water with pH = 6-7.5 must be used. In general, the water content of the high aluminum series is 10-15%, the water content of the low cement series is 6-8%, and the water content of the wear-resistant series is controlled at 5.5-6.5%. The amount of water added to the spray paint is 10-15%, and the amount of water added to the corundum series is 5-6%. If it is the refractory mud for brick matching, the water addition is 20-25%, and the water added for the light series is 20-25%. Be sure not to add too much water. Adding too much water will prolong the setting time of the castable and affect the strength of use.

The amount of water added to the refractory castable also has a great influence on the internal structure. If you add too much water, the internal performance will gradually decline. As the amount of water added increases, the strength decreases, the porosity increases, and the anti-scouring ability also decrease, which seriously affects the service life.

During the construction of refractory castables, the amount of water added is determined according to the particle gradation and the ratio of the binder. The castable does not have a large amount of water and good performance. If too much water is added, the aggregate will be separated from the base material, which will affect its performance and reduce its density and corrosion resistance.

However, the amount of water added is insufficient, the fluidity cannot be achieved, the air bubbles cannot be discharged, and the internal structure cannot form density accumulation, which will still affect various performances.

Therefore, in the construction, it is necessary to follow the instructions provided by the manufacturer, add water and stir the construction reasonably, so that the performance of the refractory castable can be fully utilized.

How to judge the appropriate amount of water added to monolithic refractory castables?

Why do castables that add water in strict accordance with the construction instructions still have problems? This problem is often encountered in actual use. Most people will say that I added water strictly according to the construction instructions, why is it still too wet (too dry)? In fact, the amount of water added in the construction instructions is only a theoretical reference, and the specific amount of water added should be determined according to actual construction needs.

After determining the raw materials of castables, qualified refractory castables are produced after a series of processes. Users can use it by adding water and stirring it, but it is precisely the step of adding water that stumps many construction workers. Either the mixing is too dry, or it is too wet. I have summed up a method in many times of practices, which can well control the amount of water added so that the performance of the castable can be better exerted.

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the appropriate amount of water added to monolithic refractory castables

The reference water content of general refractory castables is 8%-10%. When actually adding water, you can add water according to the principle of “small amount and many times”. Control the time well, and the mixing time of the pouring material should not be too long. After the mixing is finished, grab a handful of castables with your hands and hold them into balls (balls). If the dough disperses immediately after holding the ball, it means that the amount of water added is too small. If the spherical castable flows down from the fingers after holding the ball, it means that the amount of water added is too large. The amount of water added is appropriate only if the spherical castable does not disperse or flow out.

The amount of water to be added to the castable during construction is not only related to the raw materials, but also factors such as the construction site environment, dryness and humidity, and seasons. Only by controlling the amount of water added can the performance of the castable be maximized.

Alkaline Castables and Magnesia Refractory Castables for Rotary Kilns

December 28, 2022 by rsrefractorycastable

As a component part of the kiln body, the cement kiln mouth is the most vulnerable part of the cement kiln and the weakest link in the whole kiln lining. The kiln mouth has the shortest service life of the refractories used in cement kilns. When the refractory material in this part is corroded, it will often cause serious deformation of the kiln mouth shell, or even crack. Finally, the cylinder has to be replaced, which seriously affects normal production and brings great economic losses to the enterprise. Alkaline castable magnesia refractory castables for rotary kilns and new alkali-resistant castables, compared with traditional refractory materials, can increase the service life of the kiln mouth by more than double (up to 180 days or more). It has broad promotion prospects and obvious economic benefits.

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Alkaline castable magnesia refractory castable for rotary kiln

Magnesia refractory castable is made of fused magnesia or sintered magnesia aggregate and fine powder. The binder uses periclase cement, magnesium chloride, magnesium sulfate, water glass, polyphosphate, etc.

(1) The magnesia castable with periclase cement as the binder has the characteristics of high purity, small line change after burning, and high load softening temperature.
(2) Magnesium castables using water glass as a binder have the advantages of high strength, and strong corrosion resistance to alkali and sodium salt melts.
(3) The magnesium castable combined with polyphosphate has the characteristics of high load softening temperature, high strength, and excellent thermal shock resistance.

What is the composition of magnesia refractory castable?

Magnesia refractory castable is prepared from fused magnesia or sintered magnesia aggregate and its fine powder. The binder uses periclase cement, magnesium chloride, magnesium sulfate, water glass, polyphosphate, etc. The magnesia refractory casting material combined with periclase cement has the advantages of high purity, a small change of line after burning, and high softening point under load. However, as the heat treatment temperature increases, especially between 400 and 1200 °C, the cementation will be lost due to the dehydration of the magnesium hydroxide generated by the hydration of magnesia. The combination of refractory aggregate and powder is very loose, and the solid phase reaction is very weak, resulting in a sharp drop in the strength of the refractory castable. It is prone to loosening and peeling.

Magnesia refractory castables using water glass as a binder have the advantages of high strength, corrosion resistance to alkali and sodium salt melts, etc. However, due to the use of water glass as a binder, a large amount of Na2O (or K2O) and SiO2 are brought in. Therefore, the refractoriness and load softening point of magnesia refractory castables are greatly reduced, thereby limiting the maximum use temperature of water glass bonded castables.

The magnesia refractory castable combined with polyphosphate has the advantages of high strength after firing, a small decrease in strength with the increase of heat treatment temperature, high softening point under load, and good thermal shock stability. However, at high temperatures (above 1400°C), the strength of magnesium castables decreases due to the large amount of volatilization of P2O5. In general, sodium polyphosphate is often used as a binder in magnesium castables, such as sodium tripolyphosphate, sodium hexametaphosphate or sodium polyphosphate. The degree of polymerization of polyphosphate and the content of P2O5 has a great influence on the strength of castables. When the average degree of polymerization of polyphosphate is 24, the castable has the highest strength.

In addition, in order to improve the high-temperature strength of magnesia refractory castables, an appropriate amount of calcium-containing materials (such as calcium carbonate, etc.) is added to the components to form Na2O2CaOP2O5 phases with high bonding strength and stable existence at high temperatures. However, no matter what kind of binder is used, it is difficult to overcome the problem of easy hydration of magnesium refractory castables and the phenomenon of cracks in the drying process. For this reason, the method of adding an appropriate amount of silicon oxide ultrafine powder can overcome the problem of hydration.

Magnesia Refractory Castable for Rotary Kiln

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Mixing ratio and properties of magnesia refractory castable

Magnesia refractory castables usually use sintered and fused magnesia as refractory aggregate and powder. Its particle gradation is 5~2.5mm, 33%; 2.5~1.2mm, 1.2~0.6mm, 25%; 0.6~0.15mm; magnesia powder fineness <0.09mm is greater than 85%. Sodium hexametaphosphate solution with a concentration of 30% or an equivalent concentration of 4N is used as a binder, and aluminate cement is used as a coagulant. Some are mixed with a sintering machine, such as iron phosphorus or clay powder. The preparation process is to mix the refractory aggregate with two-thirds of the sodium hexametaphosphate solution, and then add the refractory powder after the surface of the aggregate is completely wet, and stir evenly. Finally, add the remaining sodium hexametaphosphate solution and continue to stir for 1-2 minutes; after vibration molding, it should be cured naturally for 3 days without water. The ambient temperature should not be lower than 10°C, the higher the better.

The refractoriness of magnesia refractory castables is >1830°C, and the load softening temperature of 4% deformation is greater than 1400°C. The temperature of fused magnesia aggregate can reach 1520°C; the drying bulk density is larger and the apparent porosity is smaller. The use of aluminate cement coagulant does not reduce the refractoriness but increases the load-softening temperature. At the same time, the compressive strength after firing at 1000°C increased from 19.1MPa to 26.5~34.8MPa, which was caused by the formation of Na2O·2CaO·P2O5 minerals. From the perspective of strength change characteristics, the medium temperature strength has a large decrease, but the absolute value is still greater than 25MPa. Therefore, it does not affect the use of magnesia refractory castables. The reason for the decrease in strength can be seen from the petrographic analysis, which is caused by the change in the structure of sodium hexametaphosphate during the heating process and the lack of sintering of the base material.

The relationship between concentration and strength of sodium hexametaphosphate solution. With the increase of its concentration, the compressive strength after burning at 1000°C is peak-shaped, that is, when the concentration of sodium hexametaphosphate solution is 23%~30%, the strength is the best, which can reach more than 30MPa. When preparing sodium hexametaphosphate refractory castable, its concentration should be selected as 25%~30%.

In alkaline refractory castables, under the premise of ensuring the workability of the mixture, the amount of sodium hexametaphosphate solution should be used as little as possible to ensure its high-temperature performance. In addition, the type of refractory aggregate, particle gradation, amount of bone powder, type and amount of aluminate cement, etc. also affect the performance of refractory castables and should be selected reasonably.

Rongsheng Refractory Castable Manufacturer

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Rotary kiln refractory castable manufacturer

Rotary kiln refractory castable manufacturer is a powerful manufacturer and seller of refractory castables. Rongsheng’s monolithic refractory castable production line has an annual output of 80,000 tons. Moreover, it is equipped with an advanced and environmentally friendly fully automatic production environment and production equipment. Our production line has served the supply of monolithic refractories for many turnkey projects. And received praise from customers. If you are looking for a manufacturer of monolithic refractory materials and buy rotary kiln refractory castables, please try to contact us. We will provide you with the most suitable refractory castable products according to your specific production needs.

Solutions for Aluminum-Magnesium Castables in Use

December 5, 2022 by rsrefractorycastable

Alumina Magnesite Refractory Castable is a refractory castable with corundum as the aggregate, spinel and corundum powder as the matrix and pure calcium aluminate cement as the binder. Its chemical composition is Al2O3 89%~93%, MgO 5%~8%. It has good corrosion resistance and slag penetration resistance and can be used as a large ladle lining for continuous casting.

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Application of aluminum-magnesium refractory castable

Aluminum-magnesium refractory castables have been widely used in ladles for medium and small die-casting. The average package age is 60 to 80 times. Compared with clay ladle bricks, the refractory material consumption per ton of steel is reduced by about 70%.

The raw materials of aluminum-magnesium castables for ladles are basically the same as that of aluminum-magnesium refractory ramming materials. In order to obtain normal temperature strength, sodium fluorosilicate should be added as coagulant. The load softening temperature of the ladle aluminum-magnesium castable is low, which is due to the combination of some low-baking substances formed by adding magnesia powder and the joint action of water glass and sodium fluorosilicate.

The solution to cracks in aluminum-magnesium castables during use

Aluminum-magnesium castables crack during use, which reduces the service life. The specific manifestation is: when the ladle is used for 5 heats, cracks begin to appear on the inner wall of the ladle, covering the entire ladle wall. As the number of uses increases, the cracks become deeper and wider. When more than 20 furnaces were used, they had to be forced to stop using them. In order to solve the problem of castable cracks, the following methods have been tried.

(1) Replace the bauxite clinker calcined by the shaft kiln with the bauxite calcined by the downdraft kiln, so that the sinterability and bulk density of the bauxite are increased. The theory was that this might reduce volume shrinkage caused by incomplete calcination of alumina and re-sintering during use, but without success.
(2) It is believed that the cracks are related to the total amount of fine powder in the castable. Try to reduce the fine powder in the castable to less than 30% (mass fraction), the lowest to 25%. Didn’t solve the problem either.
(3) Start to solve the crack from the chemical reaction. Because Al2O3 and MgO can generate aluminum-magnesium spinel under high temperature, accompanied by large volume expansion. After a series of experiments, adjusting the ratio of Al2O3/MgO did not achieve satisfactory results. Even when the MgO content is too high, peeling occurs instead.

Solution: Finally, the following method was adopted to basically solve this problem.

(1) The upper limit of the aggregate particle size was raised from 15 mm to 5 mm, of which 20-25 mm accounted for 7.2% (mass fraction) of the total. This is due to the existence of super-large particles, which not only act as a skeleton, but also can change the direction of long cracks, helping to prevent the expansion of internal cracks.
(2) Add zircon powder into the matrix. This zircon powder is produced in Australia, and the ZrO2 content is about 66%. Since ZrO2 itself has a high melting point, it can absorb CaO in slag during use to generate CaZrO3 with high melting point and high corrosion resistance, which can close pores and cracks and strengthen the matrix. At the same time, due to the existence of zircon, micro-crack structures can also be formed in the castable, improving the high-temperature performance of the castable.
(3) Reduce the amount of active silica fume powder as much as possible. Since the quality of silica fume powder is unstable, if the amount added is large, there will be many impurities brought in, which is unfavorable for use. It is better to control the amount of silica fume in the castable below 1.5% (mass fraction).
(4) When pouring, it is also critical to strictly control the amount of water added and ensure uniform vibration.

Rongsheng Refractory Castable Manufacturer

Rongsheng refractory castable manufacturer is a powerful monolithic refractory manufacturer. Rongsheng Environmental Protection’s advanced fully automatic monolithic refractory production line has an annual output of 80,000 tons. Provide high-quality monolithic refractory products for thermal equipment of various furnace structures such as circulating fluidized bed boilers, gasification furnaces, fluidized furnaces, and waste incinerators. Our refractory products have been sold to more than 70 countries all over the world, such as South Africa, the Philippines, Chile, Malaysia, Indonesia, Vietnam, Kuwait, Turkey, Zambia, Peru, Mexico, Qatar, Egypt, Russia, Kazakhstan, etc. To purchase high-quality aluminum-magnesium refractory castables and get free refractory castable lining configuration solutions, please contact us. We will provide you with the configuration of refractory lining material that best suits your production needs.

Low Cement Refractory Castable for Cement Kiln Lining

September 30, 2022 by rsrefractorycastable

With the continuous progress of the production and use technology of monolithic refractories, especially the development of low-cement refractory castables, self-flowing castables, and wet injection technology. The refractory lining used in the new dry-process cement kiln system has gradually developed into a castable-based lining structure.

Multifunctional refractory castables have many functions such as high early strength, high thermal strength, alkali resistance, wear resistance, and heat insulation. For the vulnerable parts in the new dry process cement kiln system. Such as the kiln mouth, the top of the kiln door cover and the blanking slope, the low wall of the grate cooler, and the high-temperature area on the top of the grate cooler. Coal injection pipe, tertiary air pipe elbow, and other parts. Various refractory castables have different damage mechanisms under different conditions of use parts. Because the vulnerable parts in the new dry-process cement kiln system are in harsh environments such as high temperature, cement clinker erosion, abrasion, rapid cooling, rapid heating, etc. And it is located in special parts of the port, and the service cycle of these parts seriously restricts the life of the kiln lining of the whole kiln. According to the specific use characteristics of each part of the kiln, the development trend of refractory castables for the cement industry is as follows.

Improve the wear resistance of wear-resistant castables.
Improve the thermal shock resistance of wear-resistant castables.
Reduce Fe2O3 content.
Reduce the bulk density of the castable. Reducing the load on the equipment Reduce the bulk density of the castable on the premise of ensuring wear resistance and thermal shock resistance.

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Low Cement Refractory Castable for Cement Kiln Lining

Low cement refractory castables for cement kilns mainly include high alumina, mullite, and corundum refractory castables. This series of products has the characteristics of high strength, erosion resistance, wear resistance, and excellent performance. At the same time, the material can be made into a quick-baking explosion-proof castable according to the user’s baking time requirements.

Rongsheng monolithic refractory castables are the first to produce low-cement products with reliable quality and stable performance. It is widely used in blast furnace tap ditch, cast iron furnace tap trough, integral powder spray gun for molten iron pretreatment, high-temperature burner lining, heating furnace water cooling tube wrapping lining, etc.

Corundum and chromium-containing corundum low-cement castables are used for the lining of some parts of the refining device outside the molten steel furnace. It is also used in the lining of power frequency induction furnaces, the high-temperature wear-resistant lining of the petrochemical catalytic cracking reactor, etc. The low-cement refractory castable has the properties of high strength, alkali resistance, and wear resistance, which is obvious to all who have used it.

Corundum Self-flowing Wear-resistant Castable

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Index of low cement refractory castable for cement kiln

There are three common low-cement refractory castables, where low refers to less cement content in the product. The cement content of castables is as high as 10-30%, and the cement content of low-cement castables is between 3%-8%, so there are also 1% of ultra-low cement castables.

How to cure and bake low cement castable in the rotary kiln?

Low cement castables are widely used in new dry process cement rotary kilns. It is mainly used in the rear kiln mouth, kiln door, decomposition furnace, cooler and other parts. As we all know, the construction of refractory castable is mainly composed of three links, namely mixing, pouring, and curing. So how to maintain and bake it?

Maintenance

The tools that low-cement castables need to use in the curing process are polyethylene plastic film, straw bags, etc.

Ambient temperature requirements and controls. The curing temperature of the casting body is preferably between 15-35 ℃. Outside this temperature range, corresponding heating or cooling measures should be taken. Otherwise, the performance of the product will be degraded.

conservation. After the castable is hardened, the surface of the construction body must be covered with polyethylene plastic film immediately. A wet straw bag is added on top to prevent water evaporation and promote cement activation. After hardening, it is forbidden to beat and vibrate within one day. According to the hardening situation, the mold can be removed after 24-30 hours of hardening, or it can be removed in 3 days. After de-molding, continue curing for 2 days. Continue to cover with polyethylene film and wet straw bags during maintenance. After 3 days of curing, remove the polyethylene plastic film and a wet straw bag. Let the cast body dry naturally in the air for 1 day before baking.

Baking

One of the most critical aspects when using castables during baking. Because the casting body is relatively thick and dense, the water is not easy to discharge. Therefore, it is absolutely forbidden to heat up too fast during baking, otherwise, it will cause the casting body to crack.

Process of Lightweight High Strength Castable for Ladle Insulation Layer

September 21, 2022September 19, 2022 by rsrefractorycastable

The process of using lightweight and high-strength castables for ladle insulation. The choice of insulation layer material, the traditional insulation layer is built with clay bricks, which is cumbersome in process, frequent maintenance, easy to penetrate the brick seam, low life, and high cost. The technology of unshaped refractories is becoming more and more mature, and the lightweight and high-strength castables have the characteristics of low bulk density, low thermal conductivity, and high compressive strength, and are widely used.

Lightweight High-Strength Castable for Steel Ladle

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Preparation and Characteristics of Lightweight and High Strength Castables for Ladle Insulation Layer

The aggregate of the castable is made of floating beads, high alumina porous clinker, and alumina hollow sphere composite aggregate. The castable has the properties of low bulk density, low thermal conductivity, good thermal insulation performance, high refractoriness, and high compressive strength. Clay clinker powder and industrial alumina powder are used as powders so that the mass fraction of Al2O3 in the castable reaches 45% to 50%. Pure calcium aluminate cement is used as a binder to ensure high strength after casting without reducing the mass fraction of Al2O3. Adding an appropriate amount of fused magnesia to maintain the volume stability of the product, reduce the cracking and peeling phenomenon in use, enhance the resistance to rapid cooling and rapid heating, and improve the service life of the insulation layer.

Table 1 Performance indexes of the light-weight and high-strength castables for ladle

Operating Temperature / ℃	Bulk Density g/cm3	Thermal Conductivity / w·(m·K)^-1	Compressive Strength / MPa	Line Change Rate After Heating / % (1400 ℃)	W(Al2O3)
1200 ~ 1400	1.5 ~ 1.7	0.41 ~ 0.52	7 ~ 15	+0.3 ~ (-1.0)	45 ~ 50

Thickness Design of Ladle Insulation Layer

The refractory lining of the ladle requires a working layer thickness of 180mm, a minimum use thickness of 60mm, and service life of not less than 25 times. Considering the thermal insulation performance of the ladle and the service life of the working layer, the thickness of the thermal insulation layer of the clad wall is determined to be 80mm. The thickness of the bottom insulation layer is 140mm.

Production of tire molds

Design the insulation layer mold according to the designed insulation layer size and the size of the cladding. In order to facilitate the vibrating and ramming of the castable, so that the castable fills the entire insulation layer and facilitates de-moulding, the tire mold is made into a split structure of upper and lower layers. The taper is the same as that of the cladding, the outer diameter of the lower mold is 190mm smaller than the inner diameter of the cladding (10mm to 20mm for the thermal insulation layer), and the outer diameter of the upper mold is 180mm smaller than the diameter of the inner wall of the cladding (10mm to 20mm for the thermal insulation layer). The welding of the tire mold steel plate should be smooth and flat, with a support plate inside to prevent deformation of the tire mold, and hooks are welded on the support plate to facilitate lifting.

Pouring Construction of Castables for Ladle Insulation Layer

The overall knotting process of lightweight and high-strength castables is adopted. The process is carried out in stages, and each batch of castables should be fully stirred in the mixer. The amount of water added is controlled at 10% to 15%.

① Knot the bag wall and evenly coat the outer wall of the lower mold with a layer of release agent put it in the bag, and fix it, and the gap between the mold and the insulating layer is uniform. Then pour the stirred castable into the gap between the mold and the heat insulating layer, taking care not to peel off the heat insulating castable material or roll it into the castable. Then use a vibrating rod to vibrate the castable evenly and densely. After the lower layer is knotted, put the upper layer of the mold in and tie the knots in turn.
②Dry naturally for 24h-48h, and the mold will come out. Install the seat brick and the breathable brick mold, and then use the evenly stirred castable to tie the bottom insulation layer.
③ Natural drying for 12h ~ 24h, the mold comes out. Then natural curing for more than 72h, and finally baking.

Baking of ladle insulation

The water content of the poured insulation layer is relatively large, and the water in the castable needs to be discharged by baking to increase the strength of the insulation layer. In order to prevent the thermal insulation layer from bursting due to the excessive heating speed, the baking is carried out in strict accordance with the heating speed and holding time specified by the process. The total baking time shall not be less than 15h.

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Rongsheng Unshaped Refractory Castable Manufacturer

Rongsheng Unshaped Refractory Castable Manufacturer is an unshaped refractory manufacturer with rich experience in production and sales. Our environmentally friendly fully automatic monolithic refractory castable production line has an annual output of 60,000 tons. Our refractory materials have been sold to more than 80 countries all over the world, eg, South Africa, Philippines, Chile, Malaysia, Indonesia, Vietnam, Kuwait, Turkey, Zambia, Peru, Mexico, Qatar, Egypt, Russia, Kazakhstan, etc. Moreover, our technical team is also keeping pace with the times, providing high-quality materials for the refractory lining of high-temperature industrial furnaces. Including light and high-strength castables for ladle insulation, ladle wear-resistant refractory castables, etc. Contact us for free quotes and samples.

Differences between Dense Castable Refractory and Lightweight Refractory Castable

September 5, 2022 by rsrefractorycastable

What are the commonly used refractory castables? What is the difference between dense castables refractory and lightweight refractory castables? Castable refractory, also known as refractory castable, is an unshaped refractory material, also called monolithic refractory castable. The refractory castable is easy to construct and has good integrity. It can be used for the lining of various industrial kilns and can also be used to manufacture prefabricated parts.

High-Alumina Refractory Castables Manufacturer — High-Alumina Refractory Castables – Dense Refractory Castable

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Classification of Commonly Used Refractory Castables

There are many types of refractory castables, which can be distinguished according to different dimensions.

1) According to the characteristics of refractory castables, they can be divided into high-strength wear-resistant castables, high-temperature-resistant castables, low-cement castables, steel fiber castables, acid-resistant, and heat-resistant castables, etc.
2) According to refractory raw materials, it is divided into clay castable, high alumina castable, silicon castable, mullite castable, corundum castable, silicon carbide castable, etc.
3). According to the applicable industrial kiln environment, including aluminum-silicon carbide castables for ladle ditch, aluminum-magnesium spinel castables for ladle, etc.
4) According to the density, it is divided into lightweight castables and dense castables refractory.
5) According to the composition of the binder, organically bonded castables and inorganic bonded castables, such as resin bonded castables and cement bonded castables;
6). According to chemical properties, refractory castables can be divided into acid-resistant castables, neutral castables, and alkali-resistant castables.

High-Quality High Alumina Castable of Rongsheng

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What is the difference between dense castables refractory and lightweight insulation castables?

Analyze the difference between dense castables refractory and lightweight insulation castables. The main difference between dense refractory castables and lightweight castables is the difference in bulk density. Lightweight castables with a density lower than 1.6 and dense castables with a density higher than 1.8.
The characteristics of dense castables differ from lightweight insulating castables. Dense castables have high-temperature resistance, erosion resistance, erosion resistance, thermal shock resistance, spalling resistance, etc. Lightweight castables have low thermal conductivity and a good thermal insulation effect.
Dense refractory castables and lightweight insulating castables are also used differently, that is, they are used in different environments. The dense refractory castables are wear-resistant, high-temperature-resistant, and corrosion-resistant, and are used in kilns with harsh environments. Lightweight castables are generally used for heat insulation layers to avoid heat loss from the kiln and have the effect of heat insulation. And because the kiln skin temperature is low, fuel can be saved.
The raw materials used for dense castables and lightweight castables are also different. Bauxite particles and powders with high density are generally used for heavy castables, and materials with low specific gravity such as floating beads and alumina hollow spheres are used as raw materials for lightweight castables.
The amount of water added to heavy castables and light castables is different, and the amount of water added to lightweight castables is larger than that of dense castables. Because lightweight castables have higher water absorption than dense castables.
The addition of binders for heavy castables and light castables is different. Lightweight castables are added more than heavyweight castable binders, the purpose of which is to increase the initial strength of lightweight castables.

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How to choose refractory castable?

Heavy castables and light castables are selected according to the characteristics of the castables. Dense refractory castables can exert the maximum performance of castables at different positions, different temperatures, and different degrees of erosion in the kiln, and different castables are used. Lightweight castables are made of materials with different bulk densities according to different kilns and different temperature requirements to play the role of heat insulation.

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Rongsheng refractory castable manufacturer

Castable is a kind of amorphous refractory material that does not need to be formed and has fluidity. It is composed of aggregates, powders, and binders according to technological proportions. Under certain conditions, it can replace the refractory brick products with complex shapes and a high degree of irregularity. It has the advantages of convenient construction, a short construction period, and light labor intensity. For more product information about refractory castables, please contact Rongsheng refractory castable manufacturer. Based on your specific needs, we will provide you with the product that best suits your thermal kiln production needs. Contact us for free samples and quotes.

Thermal Insulation Acid Resistant Refractory Castable for High Temperature Chimney

July 2, 2022 by rsrefractorycastable

Lightweight Thermal Insulation acid-resistant refractory castables are usually used for the lining of the chimney wall of the circulating fluidized bed boiler. On the lining of the chimney wall of the circulating fluidized bed boiler, the castable is used not only as an acid-resistant lining, but also as a refractory and heat-insulating layer, and no insulation layer is added.

The light acid-resistant castable is composed of light aggregate, powder, binder, and additives, and the main component of the binder is water glass. The lightweight aggregate structure has a large porosity, a rough surface, and a particle size of about 5mm, and the aggregate and powder have high water absorption and hygroscopicity.

Lightweight Acid-Resistant Castable For Chimney Wall Lining

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Lightweight acid-resistant castables have the characteristics of low bulk density, fast solidification, high service temperature, increased compressive strength with the increase of temperature and acidity, small thermal conductivity, and a small coefficient of linear expansion. However, lightweight Thermal Insulation acid-resistant castables have relatively high requirements for transportation and storage. This is because the manufacturer has prepared the aggregate and powder into a mixture when leaving the factory, and then packed it in a woven bag. When transported to the site, it needs to be temporarily stored in a warehouse with good drainage measures, rain-proof, moisture-proof, and dry.

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Features of Lightweight Thermal Insulation Acid-Resistant Castables

Lightweight Thermal Insulation acid-resistant castables are unshaped refractories that can be directly cast into linings as needed, and can also be made into prefabricated bricks.

Lightweight heat-insulating acid-resistant castables have the characteristics of high compressive strength, acid and acid gas corrosion resistance, light volume, and low water absorption. Thermal Insulation acid-resistant refractory castables fully play a role in thermal insulation in tall chimneys, high-temperature flues, and pipe linings. The light acid-resistant castable can ensure the compactness of the masonry when it is used in places with severe acid corrosion. It can also be used in acid-resistant projects such as acid-resistant pools and tanks in petroleum, chemical, non-ferrous metallurgy, and other industries.

Lightweight Thermal Insulation acid-resistant castables are easy to construct, have strong cohesion, and have a long initial setting time and construction operation time. The strength of the castable increases rapidly, the impermeability is strong, and no acid treatment is required. It is convenient to ensure the dense and full masonry ash joints, and can significantly improve the air tightness and integrity of the chimney lining wall and the anti-corrosion ability of the lining.

Lightweight Thermal Insulationacid-resistant castables need to be poured in layers, and the layered vibrating time should be shorter than the vibrating time of the castable. The amount of water added to the castable also needs to be strictly controlled, and the amount of water determines the performance and strength of the castable. Therefore, attention must be paid to the construction of the castable, and the mixed water should be added according to the construction standards of the castable.

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Matters needing attention in the construction of light acid-resistant castables

In the construction of castables, it is necessary to choose a more suitable construction environment, and a suitable temperature is a key to the construction of refractory materials. How much should the construction temperature of acid-resistant castables be controlled? Let’s find out together.

In the preparation of lightweight thermal insulation and acid-resistant castables, the main raw materials used are aluminate cement and light aggregates. Raw materials such as perlite aggregates are made by adding various additives such as high alumina fine powder and silicon powder. The product has the characteristics of light volume, high compressive strength, alkali resistance, acid gas resistance, heat insulation, heat preservation, and low water absorption. The lightweight Thermal Insulation acid-resistant refractory castable has the characteristics of convenient construction and convenient construction in the preparation process and is an ideal product for the construction of high-temperature acid-resistant components.

After talking about the characteristics of so many lightweight Thermal Insulation acid-resistant refractory castables, according to the structural characteristics of acid-resistant castables, what temperature should the construction temperature be controlled at? In the construction of castables, the construction temperature can be flexibly selected according to seasonal changes. In the summer construction environment, the construction temperature is about 20 to 30 ℃. When the temperature is too high in summer, the setting speed of the acid-resistant castable will be accelerated, but the strength of the castable will be affected. When the castable is prepared, a small amount of retarder can be added to slow down the setting process of the castable. In the winter construction environment, the construction temperature should be between 5°C and 10°C at room temperature, and the construction temperature should not be lower than 0°C. When the temperature is too low, an accelerator needs to be added to accelerate the setting of the castable.

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Thermal Insulation Acid Resistant Refractory Castable for High-Temperature Chimney Wall Lining. High-quality lightweight heat-insulating acid-resistant refractory castables, free samples, and quotations, please contact us.

Industrial Kiln Insulation Refractory Castable for Sale

June 10, 2022 by rsrefractorycastable

With the development trend of the integration of the global economy, resources, and environment, industrial kiln technology and equipment level are facing great challenges, and it is imperative to save energy and reduce emissions. Therefore, the development of industrial kilns must take a sustainable development path with high technological content, good economic benefits, low resource consumption, and less environmental pollution. Therefore, more and more industrial kilns now put forward higher requirements on the thermal insulation layer of the kiln body. This is also a great challenge for refractory manufacturers. Rongsheng refractory castable material manufacturer, through years of accumulated experience in the use of industrial kiln lining refractory materials, is more careful and perfect in the configuration and design of materials for the thermal insulation layer of industrial kilns. Rongsheng has made greater breakthroughs in the production of unshaped monolithic refractory castables for industrial kilns. Industrial Kiln Insulation Refractory Castable for Sale, contact Rongsheng for free samples and prices.

High-Quality Lightweight Insulation Castables for Industrial Kilns

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Industrial Kiln Insulation Refractory Castable for Sale

The design of the thermal insulation layer of the industrial kiln slows down the loss of temperature in the kiln, reduces thermal energy consumption, and saves fuel costs. On the one hand, it ensures the safety of production, and on the other hand, it is of great help to save production costs and prolonging the operating life of kiln furnace equipment. So, how is the thermal insulation layer of industrial kilns generally designed?

In the design of the thermal insulation layer of industrial kilns, the materials generally used are ceramic fiber products, thermal insulation bricks, and thermal insulation refractory castables. These materials, according to the different working conditions of different industrial kilns, choose different materials of thermal insulation bricks and thermal insulation refractory castables for industrial kilns and configure different indicators.

Insulation refractory castable is also called lightweight refractory castable, thermal insulation refractory castable. The Industrial Kiln Insulation Refractory Castable is mainly composed of light thermal insulation aggregate, added with refractory powder, together with bonding material and admixture. A hydraulic unshaped thermal insulation material is prepared by dry mixing according to the optimum ratio. It has the characteristics of low bulk density, low thermal conductivity, and high thermal insulation performance, and can be constructed and poured on-site. Lightweight refractory castables, also known as lightweight insulating castables, are widely used in the thermal insulation layer of boilers, industrial kilns, and other equipment bodies. It is mainly used for heat preservation of kiln and to prevent the loss of heat energy.

Industrial Kiln Insulation Refractory Castables for Sale in Rongsheng — Industrial Kiln Insulation Refractory Castables for Sale

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Classification of Industrial Kiln Insulation Refractory Castables

Insulation castables are used for boiler linings and are generally used as insulation linings. The use temperature is generally under 1000 ℃. Thermal insulation refractory castables are classified into the following three categories according to the operating temperature.

Low-temperature lightweight castable, the operating temperature is 600℃-900℃.
Medium temperature light castable, the operating temperature is 900℃-1200℃.
High-temperature lightweight castable, the operating temperature is >1200℃.

Lightweight castables with bulk densities of 0.8 and 1.0 are common for thermal insulation castables. Lightweight castables with a bulk density of 0.8 or 1.0 can also be used for thermal insulation refractory castables for industrial kilns. In the refractory industry, thermal insulation castables can also be divided into 3 categories according to their bulk density.

Semi-light castable (1.0-1.8 g/cm3)
Lightweight castable (0.4-1.0 g/cm3)
Ultra-light castable (less than 0.4g/cm3)

Industrial Kiln Insulation Refractory Castables Construction

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Properties of thermal insulation castables for industrial kilns

The selection of the thermal insulation layer lining of the industrial kiln generally refers to the operating temperature and thermal conductivity. In the end, it is necessary to select an insulating castable with a suitable bulk density. The smaller the bulk density of the Industrial Kiln Insulation Refractory Castables, the smaller the thermal conductivity, and the better the thermal insulation performance. During the production of thermal insulation castables, high-index thermal insulation castables can also be customized according to requirements. Insulation castables of different materials are used in thermal insulation layers of boilers and high-temperature kilns at different temperatures.

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Rongsheng refractory castable factory can provide unshaped monolithic refractory castables for thermal insulation layers for various industrial kilns. Moreover, Rongsheng Environmental’s advanced monolithic refractory castable production line provides a production guarantee for refractory castables of various raw materials used in industrial kilns. Please use it in strict accordance with the construction and storage instructions of the unshaped refractory materials when you use the unshaped refractory castable. The quality of our monolithic refractory castables products is guaranteed, and our perfect after-sales service system can also provide reliable solutions for your refractory lining problems. To purchase high-quality Insulation Castables for Industrial Kilns, please contact us.

The Differences Between the Three Different Monolithic Refractories

April 19, 2022 by rsrefractorycastable

Refractory mortar, refractory cement, and refractory castables are all monolithic refractories, and they are commonly used in the refractory industry. So, what are the differences between these three different monolithic refractories? Simply put, refractory mortar is used for masonry refractory bricks. Therefore, refractory mortar is also known as refractory mortar or joint compound. Refractory cement is one of the materials for making refractory concrete and is generally used as a binder. Refractory castables are sometimes referred to as refractory concrete. It is made of refractory aggregates, powders, and binders, and is also called refractory castables because of its pouring construction.

The Difference Between Three Different Amorphous Refractories

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Refractory Mortar

Refractory mortar can be divided into fireclay, high alumina, silica, and magnesia refractory mortar according to the material. It is composed of refractory powder, binder, and admixture. The general refractory mortar is made of refractory clinker powder and an appropriate amount of plastic clay as a binder and plasticizer. Its normal temperature strength is low, and it has high strength only when it constitutes a ceramic bond at a high temperature. The particle size of refractory mortar varies according to the application requirements, and its limit particle size is generally less than 1mm, and some are less than 0.5mm or finer.

The material of refractory mortar should be considered together with the material of masonry refractory products. In addition to being used as a joint material, refractory mortar can also be used as a maintenance coating for the lining body by the modification method or the spray method.

refractory castable cement — High-Temperature Refractory Cement

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Refractory Cement

Refractory cement is also called aluminate cement. Aluminate cement is a hydraulic cementitious material obtained by calcining bauxite and limestone as raw materials, clinker with calcium aluminate as the main component and alumina content of about 50%, and then grinding. Aluminate cement is often yellow or brown, but also gray. For the lining of industrial kilns.

Refractory Castables (Refractory Concrete)

What is refractory concrete? What is refractory concrete composed of? Refractory concrete is composed of refractory aggregate, refractory powder, and cement or admixture in a certain proportion. After stirring (the cement should be mixed with appropriate water), molding and curing, it can be used directly. Generally, it is also called refractory castable.

Refractory castable is a kind of monolithic refractory that is widely produced and used. It is mainly used to construct the overall structure such as the lining of various heating furnaces. Certain high-quality varieties can also be used in smelting furnaces. For example, aluminate cement refractory castables can be widely used in various heating furnaces and other thermal equipment without slag and acid and alkali corrosion. The parts that are corroded by molten iron, molten steel, and slag have a high working temperature, such as tapping groove, ladle and blast furnace shaft, tapping ditch, etc. In some parts of metallurgical furnaces and other vessels that are in direct contact with slag and molten metal, repairing with high-quality phosphate refractory castables also has excellent results.

castable refractory concrete — High-Alumina Castables Refractory

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Refractory concrete can generally be divided into two categories, shaped refractory products, and bulk refractory materials.

Shaped refractory products. Including prefabricated components, prefabricated blocks (unit weight less than 30 kg), and unburned bricks produced by vibration, machine pressing, ramming, and vibration pressing. Such products are generally factory-produced, with stable quality, regular size, and less template consumption.
Bulk refractory materials. Including refractory aggregate, refractory powder, cement, etc., as well as the mixture of the above-mentioned several raw materials in proportion, and leaves the factory in bulk form. During construction, appropriate water or liquid binder should be added to the bulk material, which can be formed by any method.

An important feature of refractory concrete is that it does not require pre-calcination, and can be used to directly build a furnace, or it can be assembled with prefabricated components and used after baking. Therefore, refractory concrete has many advantages over fired refractory bricks.

Advantages of Refractory Concrete

The production process of refractory castable concrete is simple, usually, only construction equipment such as concrete mixers and vibrators are used, and there is no need for huge brick presses and firing equipment. Therefore, the construction of refractory concrete plants requires less investment, a quick start, and great results. And it can save a lot of fuel and electricity, the production cycle is short, and the production efficiency is high.
The refractory concrete is easy to construct and manufacture, can be arbitrarily shaped and can meet the various requirements of production for thermal equipment. Some special parts of thermal equipment are difficult to be made of fired bricks, and refractory concrete can be used. In addition, refractory concrete can be made into a composite lining that is light and heavy. This reduces the thickness and reduces the overall weight of the kiln. It not only saves materials and fuel but also uses less steel. Refractory concrete can also be equipped with a small number of steel bars, which are both used as linings and load-bearing. The steel envelope can be partially or completely removed.
In addition to the commonly used vibration molding process, refractory concrete can also be constructed by various process methods such as spraying, ramming, or machine pressing according to engineering characteristics and production needs. Suitable for new construction, renovation, and hot and cold repair of furnaces and thermal equipment. Especially when using prefabricated components and spraying, the furnace construction can be mechanized, greatly shortening the construction period and speeding up production and construction. In the process of kiln and thermal equipment production, the damaged prefabricated components can be replaced without stopping, and the furnace lining can be thermally repaired by spraying a new process, thereby improving the operation rate of the kiln.
Kilns and thermal equipment made of refractory concrete have strong integrity and good airtightness. The reasonable application can increase its service life by 30~150%, and some are as high as 8~5 times. This not only improves the operation rate but also reduces the consumption of refractory materials and saves the cost of building the furnace.
The raw materials used in refractory concrete, in addition to the raw materials for making bricks, can also use some industrial slag, waste refractory bricks, and local or natural materials. That is to say, it uses a wide range of materials, which is convenient for comprehensive utilization of resources, and opens up a broadway for the refractory industry.
The production and construction of refractory concrete furnaces have good working conditions, low labor intensity, and high efficiency. Furnace builders can get rid of the tile knife, creating conditions for the realization of mechanized furnace construction.

From the above, we can see that although the three products are all monolithic refractories, their uses are quite different. And each product is divided into different models and types. Therefore, when purchasing, you can consult professional technicians and choose suitable products, so as not to delay the construction period and cause unnecessary losses.

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In a word, the development and adoption of new refractory concrete materials can promote the technological innovation of refractory production and kiln structure, save fuel, power, financial resources, and manpower, and realize mechanization of production and construction. Achieve the purpose of prolonging the life of the kiln, reducing the consumption of materials, and increasing production. Therefore, refractory concrete is a new type of refractory material with broad development prospects. Rongsheng refractory manufacturer has rich experience in the production and design of various unshaped refractory materials. Provides high-quality, long-life refractory lining materials for a variety of furnace types. Rongsheng refractory manufacturer will become your best choice for purchasing unshaped refractory materials.

Refractory Mud VS Refractory Cement?

November 23, 2021 by rsrefractorycastable

High alumina refractory mud is different from high alumina cement.

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The difference between them is: high alumina refractory clay is a refractory material used in the joints of refractory bricks, and the sheet material is high aluminum powder plus a certain proportion of binding agent and coagulant. After adding water or adding liquid binder, stir it into a slurry, and apply it on the surface of the refractory brick to adjust the size deviation. It can make the refractory bricks form a tight whole to prevent the damage of high temperature and external force. In other words, it is the fire clay for bricklaying. It is a finished solid powder.

High alumina cement is a kind of binder in the application of refractories. High alumina cement is also called aluminate cement. It is clinker with 50% alumina content calcined with bauxite and lime. Aluminate cement is yellow or Brown, high grade high alumina cement is white. The labels are 625#, 725#, 925# and CA70, CA80.

High alumina cement is closely related to refractory materials and can be used as a binder for various castables. In addition, some 525# and 425# refractory cements are equipped with gypsum bauxite for construction and special projects. High alumina cement has a good coagulation effect in the castable, which will make the castable have high temperature resistance and good strength. It is a raw material for refractory materials.

The high alumina refractory clay cement is also divided into multiple grades, and is used for building a variety of multi-material refractory bricks. It is divided into high alumina refractory mud and phosphoric acid refractory mud.

Although both high alumina refractory mud and high alumina cement are powdered materials, there is a big difference between high-alumina refractory mud and high alumina cement. High alumina refractory mud is processed into powder with high-alumina particles smaller than 180 mesh, plus some binders. , A synthetic material made of coagulant. The high alumina cement is the finished material after calcining bauxite and lime.

Therefore, high alumina cement and high alumina refractory mud are completely different products, but they are closely related to refractory materials. It is also one of two varieties with a large proportion among refractory products.

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the appropriate amount of water added to monolithic refractory castables

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Alkaline castable magnesia refractory castable for rotary kiln

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Matters needing attention in the construction of light acid-resistant castables

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Industrial Kiln Insulation Refractory Castable for Sale

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Classification of Industrial Kiln Insulation Refractory Castables

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Properties of thermal insulation castables for industrial kilns

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Buy High-Quality Insulation Castables for Industrial Kilns

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The Difference Between Three Different Amorphous Refractories

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Refractory Mortar

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Refractory Cement

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