Low Cement Refractory Castable for Cement Kiln Lining

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.

Refractory Materials in Cement Kiln
Refractory Materials in Cement Kiln

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.

  1. Improve the wear resistance of wear-resistant castables.
  2. Improve the thermal shock resistance of wear-resistant castables.
  3. Reduce Fe2O3 content.
  4. 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.
Rongsheng Low Cement Castable Materials
Rongsheng Low Cement Castable Materials

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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
    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?

      1. 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.

      1. 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.

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        Low Cement Refractory Castable Preparation

        Low cement refractory castables preparation process requirements are very strict, so there are many factors affecting the performance, mainly ultrafine powder, aluminate cement, refractory aggregate and admixture. Refractory aggregate and water consumption are also important factors.

         

        Low cement refractory castables
        Low cement refractory castables

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          First of all, we know that the role of ultrafine powder on low cement refractory castable determines the performance of low cement series refractory castable pillar, it is no exaggeration to say, no ultrafine powder, there is no low cement series refractory castable. In low cement refractory castable, ultrafine powder plays the role of dispersing accelerator and structure compacting agent. The former makes the cement particles highly dispersed without flocculation, while the latter makes the microstructure micropores fully filled to enhance the strength. Ultrafine powder types include SiO2, a-al2o3, Cr2O3, ZrO2 and MgO. The specific surface area of SiO2 ultrafine powder is about 20m2/g, and its ergodic length is about 1/100 of that of cement particles, so it has good dispersion and filling property. With the increase of SiO2 ultrafine powder dosage, the strength increases and the fireproof decreases, and the appropriate dosage is ≥3%.

          Aluminate cement variety, variety is different, the preparation of low cement refractory castables performance is also different. For example, when the mixture ratio and process conditions are basically the same, the dosage of ca-50 cement and ca-70 cement are 5%, and the compressive strength after drying, firing at 800℃ and 1100℃, respectively, the former is 45Mpa, 51Mpa and 59mpa, while the latter is 65, 70 and 74mpa respectively. This indicates that the performance of the low-cement refractory castable prepared by ca-70 cement is better than that of the low-cement castable prepared by ca-50 cement, but the cost is slightly higher.

          The basic fit of castable remains unchanged, and the amount of refractory powder and cement is constant. The minimum amount of cement shall ensure sufficient strength at room temperature to meet the technical requirements of mold removal or hoisting of low cement refractory castables. The normal temperature compressive strength of this series of refractory castable is 15Mpa and 22Mpa respectively. Before 1100℃, the amount of cement is large, and the compressive strength after burning is high. At 1400℃ and 1500℃, the two are basically similar, and the amount of cement is slightly higher.

           

          Low cement refractory castable
          Low cement refractory castable

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            Finally, we are a professional refractory castable manufacturers, the production of a variety of unshaped refractories, full range of products, can be customized, welcome to consult.

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              Low Cement Refractory Castable Factory

              Our factory product low cement refractory castables is made of high quality aluminum aggregate, powder and high efficiency binder. With high temperature resistance, erosion resistance, peeling resistance, thermal shock stability, set most of the advantages of refractory castable in one. It also has the characteristics of high density, low porosity, high strength, low wear, heat shock and corrosion resistance.

               

              Low cement refractory castables
              Low cement refractory castables

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                Low cement refractory castable has a use good effect. Widely used in large cement kiln decomposition furnace, kiln door hood, rising flue, cooling machine, such as high temperature, alkali corrosion and other parts. The binder commonly used for low cement castable is aluminate cement, and the amount of cement can affect the overall service performance, high temperature strength, corrosion resistance of the castable.

                Generally speaking, aluminate cement as the binder of refractory castable, CaO content less than 2.5%, can be referred to as low cement refractory castables. A castable with a CaO content of 1.0-2.5% May be called an ultra-low cement castable. Low cement castable is a kind of high-grade refractory castable, because the CaO content in cement is low, so called low cement castable.

                Low cement refractory castables is mainly used in heating furnace, various heat treatment furnace, electric furnace cover, shaft kiln, rotary kiln, blast furnace outlet, ladle, ladle and other lining. This series of refractory castable is in the production process, through the adjustment of the formula, reduce the CaO content, improve the overall performance of low cement castable, increase the service life of the lining.

                Compared with ordinary refractory castables, this castable has the advantages of less water consumption, low porosity, moderate temperature strength, good resistance to spalling and erosion. Has been successfully used in power plant boiler, petrochemical, steel industry heating furnace.

                 

                Low cement refractory castable price
                Low cement refractory castable price

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                  Zhengzhou Rongsheng Kiln Refractory Co.,Ltd. is professional low cement refractory castables manufacturer, production of various refractory materials more than 200 kinds, export more than 60 countries and regions, welcome to consult and purchase. We will provide you with quality, comprehensive and considerate service.

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