Refractory Castables Materials for Rotary Kiln Insulation

Due to the structure and working characteristics of the rotary kiln, as well as the diversity and complexity of the materials it handles, the requirements for the temperature of the outer wall of the rotary kiln are also different. From the perspective of environmental protection and energy saving, reducing the temperature of the outer wall of the rotary kiln as much as possible, doing a good job in the insulation layer of the rotary kiln, and the configuration of the refractory lining material of the rotary kiln are all the enterprises that operate the rotary kiln expect. Rongsheng monolithic refractory manufacturer has rich experience in the production, sales, and application of monolithic refractory materials. We have served various types of rotary kilns, which can help you solve the problem of rotary kiln insulation lining. Get pricing information for free.

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

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    There are also various designs for the thermal insulation lining of the rotary kiln, and the types of refractory materials used are also various. According to the specific needs of customers, we can provide customers with insulating castables, lightweight castables, lightweight plastics, dense refractory plastics, heavy wear-resistant castables, phosphate-bonded composite insulation bricks, ceramic fiber products, etc.

    Working Layer and Thermal Insulation Layer of the Rotary Kiln Lining

    When the rotary kiln lining refractory material is selected, the next step is to evaluate the heat loss of the rotary kiln body.

    When we realize that the working temperature in the rotary kiln is high, and the material has serious erosion and wear on the inner lining, then the inner lining design must consider the double-layer inner lining, and the two inner linings are respectively called the working layer and the thermal insulation layer.

    The working layer is made of heavy refractory materials to meet the resistance to high-temperature flames and material erosion and wear; the heat insulation layer is made of light refractory materials to improve the thermal insulation performance of the inner lining and reduce the heat loss of the rotary kiln body.

    The inner lining of the rotary kiln has a thermal insulation layer, which can effectively reduce the heat loss of the rotary kiln and also help protect the rotary kiln shell and other shell components.

    Generally speaking, the rotary kiln lining with a thermal insulation layer is often used for rotary kilns with high operating temperatures. The refractories of the inner lining of the thermal insulation layer and the inner lining of the working layer have similar chemical compositions, and the difference between Rongsheng refractory materials lies in their respective strength and thermal conductivity. The refractory material lining the thermal insulation layer has a low density and low strength, but its thermal resistance is relatively large, which can effectively reduce the heat loss of the rotary kiln body.

    Rongsheng Refractory Castables
    Rongsheng Refractory Castables

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      What Refractory Castables are Used for Each Part of the Cement Rotary Kiln?

      Refractory castables are used as the main insulation material for the new dry-process rotary kiln. If it is properly configured, it can protect the normal operation of production equipment at high temperatures and effectively reduce system energy consumption.

      Cement Rotary Kiln Refractory Castable

      • Kiln mouth with refractory castables. At the kiln mouth in front of the rotary kiln, the clinker outlet temperature is around 1400°C, and the temperature of the secondary air entering the kiln changes frequently due to kiln conditions. With the expansion of the scale of the cement plant, the amount of clinker at the kiln mouth is also increasing, and the thermal stress and mechanical stress on the refractory castable at the kiln mouth increase accordingly. For this reason, the kiln mouth refractory castable should have sufficient refractoriness, mechanical strength, thermal shock stability, and alkali resistance under high-temperature environments. It is recommended to use high-performance kiln mouth special refractory castable or improved kiln mouth special refractory castable. The product has excellent anti-stripping performance, high temperature and alkali resistance, and cement clinker erosion resistance.
      • Refractory castables for burners. The working environment of the burner is about 1400°C, the flame temperature is about 2000°C, and it works in an alkaline atmosphere for a long time. Compared with the front kiln mouth, the temperature changes more frequently and the temperature difference is larger. Therefore, the requirements for its thermal shock resistance are higher. The front end of the burner is always scoured by the high-temperature airflow entrained with clinker dust, especially the lower part is more severely scoured. Therefore, burner refractory castables need sufficient wear resistance. It is recommended to use special castables for burners or special refractory castables for improved burners. The product has excellent spalling resistance and thermal shock stability.
      • Refractory castables for kiln hood and grate cooler. For some large rotary kilns, the heat load on the lower part of the kiln hood is relatively high. If the general high-alumina refractory castable is not well controlled for curing and temperature rise, it is prone to bursting and falling off. The top of the kiln hood is close to the tertiary air duct, and the erosion of the dusty airflow is relatively serious, and the construction of the top castable is relatively difficult, and the requirements for the fluidity and early strength of the material are relatively high. The working temperature at the top of the front end of the grate cooler is high, and the temperature changes greatly. The low walls on both sides of the front end have been worn by the high-temperature clinker coming down through the kiln mouth for a long time, and they are also damaged by certain mechanical stress and thermal stress. It is recommended that these two parts use high-strength wear-resistant castables with good high-temperature performance, strong thermal shock resistance, and wear resistance.
      • Refractory castables for tertiary air pipe elbows and air valves. This part has a large change in heat and cold and is washed by high-temperature clinker particles. The castable is prone to loosening and peeling, and it is the most prone to wear and tear during the operation of the cement plant. It is recommended to use wear-resistant refractory castables.
      • Refractory castables for C4 and C5 cones and their discharge pipes, calciner cones, and smoke chambers. These areas are prone to crusting and are difficult to remove. Cleaning needs to be done manually with iron tools, which will inevitably cause mechanical damage to the refractory castable. Once severe skinning occurs, the kiln needs to be stopped for treatment. It is recommended to use high-strength anti-skinning silicon carbide castables.
      • Refractory castables are used for other parts of the cement rotary kiln. It is recommended to use high-strength alkali-resistant castables for C1~C3, high-temperature high-strength alkali-resistant castables for C4 and C5 (except for the cone), and high-strength wear-resistant castables for the decomposition furnace.

      Rongsheng Insulation Castable Manufacturer

      The application and development of refractory and insulating castable refractory should conform to the concept of environmental protection and circular economy. Reasonable selection of thermal insulation castables can prolong the service life of the rotary kiln castable lining, effectively protect equipment, reduce system heat loss, reduce system crust blockage, reduce kiln shutdown times and maintenance time, and improve system operation rate. To achieve the purpose of stable production, high production, and low energy consumption of the kiln system. For a case study on the configuration of thermal insulation and refractory materials for the rotary kiln project, please contact us. We will provide you with the most suitable thermal insulation refractory solutions for your production needs according to your working conditions.

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        Differences between Dense Castable Refractory and Lightweight Refractory Castable

        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.

        Lightweight Insulation Castable
        Lightweight Insulation Castable
        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
          High-Quality High Alumina Castable of Rongsheng

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

            1. 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.
            2. 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.
            3. 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.
            4. 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.
            5. 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.
            6. 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.
            Lightweight Insulating Castable
            Lightweight Insulating Castable

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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.

              Rongsheng Refractory Castable Manufacturer
              Rongsheng Refractory Castable Manufacturer

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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.

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