Refractory Precast Shapes Archives - Rongsheng Refractory Castable Cement for Sale Manufacturer and Supplier

Silicon carbide castables are often used in boiler linings or linings of iron trenches in front of blast furnaces. High-strength wear-resistant castables are used in boiler linings. It is also used in the unloading part of the rotary kiln and the use effect is very good, here, it is called anti-crushing castable in this part.

Conditions for Use of Silicon Carbide Wear-Resistant Castables

Silicon carbide castables can be used under high temperatures and harsh conditions. Silicon carbide castables have particularly good wear resistance. As long as it is used in the right location, its service life will be increased by more than 50% compared with ordinary low-cement castables.

Wear-Resistant Corundum Silicon Carbide Castable — Wear-resistant Corundum Silicon Carbide Castable in Rongsheng Factory

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What is the Suitable Working Temperature for Silicon Carbide Castables?

Silicon carbide castables are suitable for use in furnace linings under reducing atmospheres, and are more effective when used at temperatures above 1500°C.

Silicon carbide castable is a composite refractory castable. A certain proportion of silicon carbide, alumina powder, corundum or high-content bauxite raw materials is added to the inner matrix. The bonding agent is composed of pure calcium aluminate cement and some other chemical ingredients.

The use temperature of silicon carbide in reducing atmosphere is as high as 2454°C. If used in an oxidizing atmosphere, oxidation reactions may easily occur. If used in an oxidizing atmosphere, silicon carbide cannot produce a protective film on the surface. If the oxidation pressure is high, the surface layer will crack or peel due to temperature changes and mechanical impact.

If the oxygen partial pressure is low, the protective layer cannot be formed and will diffuse in the pores, resulting in a reduction in the quality of silicon carbide castables.

Castable manufacturers will add a certain proportion of binder to the composite process ratio to adjust the oxidation reaction. Under normal circumstances, metallic silicon is used to regulate the oxidation reaction. It is also useful to use sodium salt solution or sol to penetrate into the open pores of the material to inhibit oxidation and increase the service life.

Therefore, silicon carbide castables are not suitable for use at low temperatures, especially in oxidizing atmospheres. When used in a reducing atmosphere, the higher the temperature, the better the effect.

Refractory Precast Shapes for Sleeve Kiln Arch Blocks

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Application of Wear-Resistant Castables and Refractory Precast Shapes in Sleeve Kiln Arch Blocks

In the arch bridge part of the sleeve kiln, both wear-resistant castables and refractory Precast Shapes can meet the requirements. Prefabricated parts have a long cycle but good results, and the construction of wear-resistant castables is complicated but has strong adaptability. Enterprises can make reasonable choices based on actual working conditions.

The arch bridge of sleeve lime kiln has always been a difficult problem to overcome. Because this part needs to be load-bearing, wear-resistant, and wind-resistant, the required refractory materials are difficult to determine with just one material.

In this case, many manufacturers use a dual method of laying refractory bricks first and then making refractory castables to increase the service life of the arch bridge. Another reason is that there are many types of refractory bricks used in this part, their weight is small, production is inconvenient, and the production cycle is long. In this case, Refractory Precast Shapes were used to meet the requirements of this part.

According to the current feedback from manufacturers, the service life of refractory prefabricated parts used in arch bridges is quite good, usually more than 3 years, while the use of magnesia bricks is only about one year. Using a mixture of refractory bricks and castables, the service life is probably more than one year.

However, the use of refractory Precast Shapes requires large molds, and the production cycle must be at least 20 days. During construction, a crane can be used to place them at the location of use. As the temperature of the kiln body rises, the refractory Precast Shapes are also baked, which can be said to be the best of both worlds. However, the model is large and the price will be higher than using wear-resistant castables.

If the production cycle of refractory prefabricated parts will be limited in the case of emergency repair, wear-resistant castables should be used. However, due to the large area and thickness of wear-resistant castables, the anchors must be changed into cage shapes according to the specifications of the parts used. Weld the cage-like anchoring material at the arch bridge part and then find high wear-resistant castables, which can also meet the use needs of this part.

In short, prefired Precast Shapes or wear-resistant castables are used for the arch bridge of the sleeve kiln, both of which can meet the usage requirements. Enterprises can decide based on actual construction time and other advantageous conditions.

Application cases of RS refractory prefabricated parts. Refractory prefabricated parts are most commonly used in small high-temperature kiln equipment. The products required at the construction site are produced in advance by the manufacturer to facilitate customer construction. Used for special-shaped or special-shaped refractory products. Refractory prefabricated parts are widely used in various industrial kilns due to their irreplaceable advantages. Its biggest advantage is that it can be pre-baked and directly hoisted, so the construction period is greatly shortened, and the quality is stable and easy to control.

Application Solutions for Refractory Precast Shapes

Refractory prefabricated parts are an important variety of refractory materials, and their applications account for an increasing proportion. Refractory prefabricated parts are made by dividing the parts of the high-temperature kiln to be constructed into small pieces in advance. And design it into a special shape, and make the mold according to the shape. In the factory, refractory castables and other materials are pre-cast, cured, and baked before being transported to the site for hanging and assembly before use.

Ultra Low-Cement Castable Precast Shapes for Iron Trough

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Castable precast shape refractories can be preformed into various shapes at will, with good thermal shock stability, high strength, and good spalling resistance. No joints, good air tightness, less heat loss, and energy saving. It can quickly repair the kiln and improve the furnace operation rate. It can realize direct hoisting and mechanized furnace construction, and the construction efficiency is high. It can solve technical problems in furnace construction for users and can be customized according to user requirements and furnace-type conditions. Consider lining body design and multiple construction options for users.

There are the following solutions for the shaping of unshaped refractory materials in cement kilns. As a result, the unshaped refractory materials used in special parts of the cement kiln are customized and produced. The product has the following characteristics:

(1) There is no need for on-site pouring construction or formwork pouring, which reduces labor costs and material costs.
(2) Heat-resistant anchors are not required, eliminating the material and construction costs of anchors.
(3) The pouring, curing, drying, and baking steps of prefabricated parts have been completed when delivered, saving a lot of construction time.
(4) It is not restricted by environmental and climatic conditions, which solves the problem that castable materials cannot be constructed on-site under natural conditions during hot summer and severe winter.
(5) It can be made into various special products with different sizes and shapes. Such as grate cooler low wall, tertiary air duct elbow, lifting gate valve, kiln tail smoke chamber, coal injection pipe, kiln mouth, and other refractory materials.
(6) Maintenance is easy to replace, has little waste loss, and saves labor and time. Corundum, fused mullite, special grade bauxite aggregate, and special wear-resistant materials are added to the material, and a certain proportion of special additives are added. Vibration forming. Therefore, the product has high strength, wear resistance, corrosion resistance, good mechanical impact resistance, and excellent thermal shock resistance. It has excellent peeling resistance and cracking resistance, long service life, convenient construction, safety, and reliability, and greatly shortens the construction period.

Application Advantages of Refractory Prefabricated Parts

Refractory Preforms refer to components with a certain shape and size made of refractory materials according to specific ratios and process conditions. The main raw materials of refractory precast shapes usually include refractory castables, refractory bricks, refractory fibers, and other special refractory materials. Refractory prefabricated parts are prepared under certain process conditions, which usually include mixing, molding, curing, and drying.

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Refractory Precast Shapes have the Following Advantages

stable quality. During the production process of prefabricated components in the factory, raw materials, proportions, and process conditions are strictly controlled. Therefore, product quality is stable and reliable.
Save construction time. The use of refractory prefabricated parts can significantly shorten the construction period and improve construction efficiency.
Reduce on-site labor. Prefabricated components are produced in factories, reducing the workload of construction workers and material handling on-site.
Good performance. Because the production process of prefabricated components is strictly controlled, their performance is often better than that of refractory materials constructed on-site.

Refractory prefabricated parts are widely used in various industrial furnaces and equipment in petrochemicals, metallurgy, building materials, electric power, and other industries. Such as heating furnaces, smelting furnaces, converters, gas generators, glass kilns, etc. Depending on the actual application environment and needs, refractory prefabricated parts can be customized with different shapes, sizes, and properties. When selecting refractory prefabricated parts, factors such as the working environment, usage conditions, performance of refractory materials, and construction requirements should be considered.

When using refractory prefabricated parts, you need to pay attention to the following points.

Storage and transportation. During storage and transportation, prefabricated parts should be protected from moisture, heat, and external force damage. It is recommended to store prefabricated parts in a dry, ventilated, and cool warehouse. And pay attention to reasonable stacking to avoid extrusion and deformation.
Install. When installing refractory prefabricated parts, design requirements, and construction specifications should be strictly followed. For different types of prefabricated parts, corresponding installation methods and connection methods need to be adopted. During the installation process, it should be ensured that the position of the prefabricated parts is accurate and that good connection and sealing properties are maintained.
Seam treatment. Seams between precast parts should be kept clean and tight to prevent heat loss and the penetration of aggressive gases. Depending on the actual working conditions and precast material, appropriate filling materials can be used for joint treatment. Such as refractory mud, refractory fiber, etc.
temperature control. During the initial heating and operation of the furnace, the heating rate and temperature should be strictly controlled. To prevent the refractory prefabricated parts from being damaged due to thermal stress caused by excessive heating. At the same time, regularly check the use of prefabricated parts to detect and deal with potential problems in a timely manner.
Maintenance and overhaul. During use, the refractory prefabricated parts should be inspected and maintained regularly. If damage, cracks, and other problems are found, they should be repaired or replaced in time. For prefabricated parts with a long service life, timely cleaning and maintenance can be carried out to extend their service life.
With proper selection, installation, and maintenance, refractory prefabricated components can provide efficient and stable performance for industrial furnaces. Save construction time and cost at the same time. In the continuously developing industrial field, the application of refractory prefabricated parts will continue to expand to meet the needs of various working conditions and environments.

Precast Shapes with Refractory Anchor Bricks for Heating Furnace Top

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What Should We Do if These Problems Arise with Refractory Castables and Castable Precast Shapes?

Unshaped refractory castables and castable refractory precast shapes have the advantages of convenient and fast construction and low labor intensity. It has been widely used in more and more high-temperature industrial kilns.

However, many corporate users have discovered some abnormal phenomena in refractory castables or prefabricated parts during storage or maintenance. For example, some have chalking, some have white hair, etc. In fact, these are caused by the contact between the high alumina cement hydration products in the refractory castable and the acidic gases in the atmosphere. As the water in the castable evaporates, salt substances continue to migrate and precipitate to the surface, and then slowly intensify the damage process of the refractory castable. Powdering occurs during the storage of prefabricated parts made from cement-containing refractory castables. Some of them have “white hair” growing on the surface, commonly known as white alkali, which causes the surface of the castable to become powdery. In severe cases, the strength of the castable will decrease.

Solution

Dry the castables as soon as possible after construction to remove moisture. Eliminate the carrier of sodium salt in the pouring body, so that the alkali stays in the construction body and no longer migrates to the surface.
When the construction conditions do not allow for timely drying, the castable environment must be sealed and the surface covered with plastic film to prevent moisture from carrying alkali from migrating to the surface.
Use refractory raw materials with low alkali content in the refractory castable to increase the viscosity and rapid hardening of the refractory castable, which can reduce the migration speed of sodium salt. Strengthen quality management and strictly control the amount of water added during construction.

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Steel Fiber Refractory Castable Precast Shapes

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RS Unshaped Refractory Castable Manufacturer

RS unshaped refractory castable manufacturer is a powerful manufacturer of refractory materials production and sales. Our environmentally friendly, fully automatic unshaped refractory material production line customizes unshaped refractory lining materials for high-temperature industrial furnaces. Extend the service life of the kiln lining, save the cost of production energy, and improve economic benefits. Customize refractory precast shapes, wear-resistant refractory castables, insulation castables, refractory plastics, refractory ramming materials, etc. from Rongsheng unshaped refractory material manufacturer. Contact us to get a free customized plan and quote.