In cement production, the refractory materials used in parts such as the grate cooler’s low wall, throat, tertiary air duct bends, and gate valves suffer severe wear and short service life due to the scouring effect of high-speed airflow containing cement clinker particles and the erosion of alkali. Users frequently experience premature wear, seriously affecting the normal operation of the cement kiln. Rongsheng Refractory Precast Refractory for Cement Kilns addresses this issue by using precast refractory components. Pre-fabricated refractory materials are pre-formed at the refractory material manufacturer, shortening the time required for refractory construction, curing, and baking. After on-site installation, they can be put into immediate use.
Precast Refractory for Cement Kilns
Standardized manufacturing of monolithic refractory materials for special parts of cement kilns has been developed, offering the following advantages:
- No on-site casting or formwork required, reducing labor intensity and material costs.
- No need for heat-resistant anchors, eliminating material and installation costs.
- Precast refractory components have completed casting, curing, drying, and baking processes upon delivery, saving significant construction time.
- Unaffected by environmental or climatic conditions, solving the problem of on-site construction under natural conditions during extreme heat and winter.
- Can be manufactured into various sizes and shapes for specific applications, such as refractory materials for grate cooler walls, tertiary air duct elbows, lifting gate valves, kiln tail flue, pulverized coal injection pipes, and kiln inlets.
- Easy to replace during maintenance, minimizing waste and saving labor and time.
Precast Refractory for Tertiary Air Duct Valve Plates
Tertiary air valves primarily withstand the erosion and wear of high-speed airflow carrying dust, as well as the corrosion of alkali. Precast tertiary air valve components offer good integrity, facilitating installation, maintenance, and replacement. Prefabrication and on-site installation ensure high-quality construction. It is recommended to use corundum-mullite high-strength wear-resistant precast refractory components.
- Materials Used: Corundum, Mullite, Silicon Carbide.
- Service Life: 1.5-3 years.
- Product Features: The main feature of this precast component is the tight bonding between the valve body mold and heat-resistant steel reinforcement and refractory castable, forming a unified whole. Pre-baking ensures good overall integrity. The lining incorporates corundum, fused mullite, premium bauxite aggregate, and special wear-resistant materials, along with a certain proportion of special additives, and is formed by tamping and vibration. Therefore, the product boasts high strength, wear resistance, corrosion resistance, good mechanical impact resistance, and excellent thermal shock resistance. It has excellent resistance to spalling and cracking, a long service life, and is easy and safe to construct, greatly shortening the construction period.
Precast Refractory for Tri-duct Elbow Components
This section primarily withstands the erosion and wear of high-speed airflow carrying dust, as well as the corrosion of alkalis. Precast refractory components ensure construction quality, are pre-baked, and are high-strength, wear-resistant, erosion-resistant, and corrosion-resistant. They offer good integrity, facilitating construction, maintenance, and replacement. High-strength, wear-resistant mullite precast components are recommended.
- Materials Used: Corundum, mullite, silicon carbide.
- Service Life: 1.5-2 years.
- Product Characteristics: High strength, high temperature resistance, wear resistance, corrosion resistance, stable performance, excellent anti-stripping and erosion resistance, and long service life. Furthermore, the original heat-resistant steel anchors and castable refractory are eliminated, replaced by direct precast component construction, making construction and maintenance convenient, safe, and reliable, significantly shortening the construction period. The elimination of heat-resistant steel anchors also reduces material costs to varying degrees, improving overall economic efficiency.
Precast Refractory Components for the Low Wall of the Grate Cooler
The refractory material in this area is primarily subject to wear and tear from cement clinker, requiring frequent replacement. After the castable refractory is poured, it is difficult to bake and prone to cracking. Precast refractory components offer convenient installation and easy replacement. They require no curing or baking, saving time. It is recommended to use corundum-mullite high-strength steel fiber wear-resistant precast components.
- Materials Used: High alumina, corundum, mullite, silicon carbide.
- Service Life: 1.5-3 years.
- Product Characteristics: High strength, wear-resistant, thermal shock resistant, corrosion resistant.
The low wall of the grate cooler eliminates the need for traditional heat-resistant steel anchors and castable refractory, replacing them with precast components directly laid in masonry. This facilitates construction and maintenance, ensures safety and reliability, and significantly shortens the construction period. It also facilitates future replacement of the grate cooler blind flange, and the elimination of heat-resistant steel anchors reduces material costs to varying degrees, improving overall economic efficiency.
Precast Refractory Components for Straight and Sloping Walls of the Smoke Chamber
This area primarily bears the erosion and wear of cement raw materials, as well as the corrosion of dust containing alkali and sulfur, making it prone to crusting. Using silicon carbide anti-scabbing precast refractory components largely solves these problems. It extends the service life of the refractory material in this area, shortens the kiln downtime for cleaning crusts, and improves the rotary kiln’s operating rate. Most importantly, it avoids the safety issues caused by crust detachment from the performer or cyclone due to vibrations from vibrators and pneumatic drills during castable refractory construction. It is recommended to use silicon carbide anti-scabbing, high-strength, high-wear-resistant precast components.
- Materials Used: Silicon carbide, mullite.
- Service Life: 1.5-3 years or more.
- Product Characteristics: The precast components are baked, resulting in high strength, anti-scabbing, alkali-resistant, high-temperature resistant, and wear-resistant properties, with excellent anti-stripping and erosion resistance. The product has good integrity, is easy to construct, and is convenient to maintain.
Precast Refractory Components for the Throat of a Grate Cooler
The service life of refractory materials in this area is short, mainly due to the high dust content in the flue gas, the high hardness of the particles, and the high wind speed, which severely erodes the materials. Simultaneously, the flue gas composition is complex, making the materials highly susceptible to acid and alkali corrosion. Therefore, the selection of refractory material and the construction method are particularly critical for this area. Due to the complex structure of this area, the construction of castable refractory materials is very difficult, resulting in inconsistent construction quality, difficulty in baking, and a tendency to crack. Using precast refractory components for the throat of a grate cooler can completely solve these problems. It is recommended to use high-strength mullite precast components specifically designed for grate cooler throats.
- Materials used: Mullite, silicon carbide.
- Service life: 3-5 years.
- Product features: High strength, high temperature resistance, wear resistance, good corrosion resistance, excellent thermal shock resistance, and superior anti-stripping properties.
