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Tortoiseshell Net Wear-Resistant Castable – Tortoiseshell Net Wear-Resistant Material

2023-07-05 by globalrefractory

Tortoiseshell net wear-resistant castables and tortoise shell net ceramic wear-resistant materials are actually amorphous refractory materials combined with tortoiseshell nets for wear-resistant construction of industrial equipment. Tortoiseshell net ceramic wear-resistant material is a kind of wear-resistant coating commonly used in industry. The coating has the advantages of high hardness and wear resistance. It can improve the efficiency of enterprises, prolong the service life of equipment, and reduce the operating costs of enterprises, so it is very popular in the industry.

Tortoiseshell Net Castable, Flue Anti-Abrasive Material

Tortoiseshell net castable, tortoiseshell net wear-resistant clay. It is mainly composed of wear-resistant aggregates such as brown corundum and silicon carbide and fine powder. At the same time, add sintering agents, ultrafine powder, coating additives, ceramic powder, composite material powder, composite adhesive, etc. The particles are closely packed, forming quickly and having high strength. It can reach the design strength in three days, so there are no major defects in use. The bulk density is high, and its strength at room temperature can reach more than 200Mpa.

Application of ceramic wear-resistant castables. Ceramic wear-resistant castables are mainly suitable for pipes and flues with high dust concentrations and serious acid and alkali erosion and wear in cement plants, power plants, metallurgy, and other industries. Dust collector, vertical mill equipment, feeding hopper, feeding chute, powder classifier, and other equipment and conveying pipelines. This product has been applied in more than 400 cement plants, power plants, and mining enterprises. In the cement industry, this product has been supplied to Loesche vertical mill, vertical mill, Ube vertical mill, raw material mill, clinker mill, coal mill outlet air duct, grate cooler to electric dust collector duct. And the conveying pipelines such as the upper shell of the powder classifier. It is a new generation of wear-resistant materials that replace traditional ceramic sheets, wear-resistant steel plates, and cast stone plates.

Tortoiseshell Net Wear-Resistant Castable

The Characteristics of Wear-Resistant High-Strength Tortoiseshell Mesh Wear-Resistant Castables

Wear-resistant ceramic coating is a new type of artificial material, which is a non-metallic cementitious material. It is a powdered ceramic coating produced by using acid and alkali-resistant artificial synthetic raw materials through strict process ratio and advanced synthesis technology. It can be used to form a coating on the surface of other metals or non-metals to improve its performance.

The performance of wear-resistant mortar has high mechanical strength and rigidity, which is difficult for ordinary reinforced concrete to achieve. The main reason is that the combination of the internal atoms is mainly by the combination of ionic bonds, and the force between the ions is relatively large, so the macroscopic performance is high strength and rigidity. At the same time, the wear-resistant mortar also has good toughness and shock resistance, which ensures the stability of its work, and the temperature has little influence on it. But what is also important is that the environmental compatibility of wear-resistant cement is very good, because its main component is silicate, which does not pollute the environment and does not produce harmful substances such as metal ions. It is a new material.

Wear-resistant cement refers to the general term for ceramic coatings with high-temperature resistance for various purposes. There are many kinds of wear-resistant mortar and a wide range of uses, which are all derived from its performance characteristics.

High-temperature resistance. Ceramic anti-corrosion coatings have high-temperature resistance, and composite ceramic high-temperature anti-corrosion coatings can withstand temperatures up to 1200°C. The temperature resistance of general anti-corrosion coatings is only about 400 ℃.

High hardness. The coating can form a dense ceramic structure after high temperatures, and the hardness can reach 5-6H. Wear-resistant and impact-resistant, twice as hard as traditional anti-corrosion coatings.

Wide range of acid and alkali resistance. It can withstand the corrosion of weak acids and alkali and can withstand the corrosion of alkalis. It is waterproof and moisture-proof, and can also prevent the corrosion of acid and alkali gases. The range of PH resistance is wide, and the application range is wider than traditional anti-corrosion coatings. Strong corrosion resistance and long service life.

Application Advantages of High-Strength Tortoiseshell Mesh Wear-Resistant Castables

Wear-resistant clay belongs to the field of functional coatings and is a new type of water-based inorganic coatings. It is mainly composed of nano-inorganic compounds and water as a dispersant. After coating, it is usually cured by low-temperature heating to form an insulating coating film with properties similar to ceramics. After years of joint research and experiments, the company has successfully developed high-temperature-resistant ceramic insulating coatings, whose performance has surpassed that of insulating coatings. High-temperature and wear-resistant cement have excellent properties such as insulation, temperature resistance, wear resistance, high hardness and thermal shock resistance, and medium thermal expansion coefficient.

High temperature-resistant and wear-resistant cement, using the high-temperature solution, the long-term temperature resistance can reach 1800 ℃. Water-based inorganic ceramic materials, the coating is made of pure inorganic polymer high-temperature solution, and the pigment is made of high-resistance inorganic crystal materials. Insulating coatings can work at 1700°C for a long time. The volume resistivity is greater than 1016Ωm, and the dielectric strength (breakdown strength) is greater than 104KV/m. Good chemical stability, aging resistance, and corrosion resistance. No flash point, ignition point, high hardness, hardness greater than 7H.

High temperature resistant ceramic insulating coating, temperature resistant to 1700°C. A layer with high volume resistivity can be formed on the surface of the coated object, which can withstand a strong electric field without being broken down. The coating has high mechanical strength and good chemical stability and is resistant to aging, water, and chemical corrosion. It is also resistant to mechanical and thermal shocks. The insulating coating can work continuously at the corresponding working temperature. The high-temperature-resistant ceramic insulating coating is a water-based inorganic high-temperature coating. It adopts a proprietary pure inorganic polymer high-temperature solution and is composed of high-resistance inorganic crystal materials. As α-alumina, silicon nitride, mica flakes, etc. are used as fillers. The coating has high volume resistivity (greater than 1012Ωm) and high dielectric strength (higher than 104KV/mm). It is suitable for painting high-temperature insulation on various fire-resistant cables. The paint is fired to form the insulating layer of the hard ceramic-like shell. The insulating layer of this hard ceramic-like shell can prevent the flame from spreading and protect the normal state of the substrate from damage.

SK30, 32, 34, 36, 38, 40 Refractory Bricks

2023-06-19 by globalrefractory

SK30, SK32, SK34, SK36, SK38, and SK40 are relatively common foreign refractory brands, which are different from domestic refractory bricks. Among them, SK-30, SK-32, SK-34, and SK-35 represent clay bricks, and SK-36, SK-37, SK-38, and SK-40 refer to high alumina bricks.

Refractory bricks refer to shaped refractory products made of refractory raw materials, which can withstand high temperatures above 1580°C. The main raw material is refractory clay (bauxite) mixed with clinker (calcined and crushed clay), stirred, waked up, and pressed into shape by a strong machine. After drying, it is made by calcining at a high temperature of more than 1000 degrees.

SK32 clay brick, SK34 clay brick, SK36 high alumina brick, SK37 high alumina brick, SK38 refractory brick

High-temperature-resistant bricks are called refractory bricks. It is mixed with refractory clay into clinker (calcined and destroyed clay) and then stirred and pressed into shape. The finished product is obtained by calcining after drying. There are also silica and high alumina bricks. Can be divided into SK32, SK34, SK36, SK38, SK40 refractory bricks. Refractory bricks are mainly used for furnace lining, flue, chimneys, and other parts. According to its shape and size, it can be divided into two categories: standard shape and special shape. The specification of refractory bricks is 230 mm × 114 mm × 65 mm, and special-shaped refractory bricks can be customized according to customer needs. Refractory bricks can be divided into ordinary refractory bricks according to their refractory degree, and the refractory degree is 1580-1770 ℃. For high-grade refractory bricks, the refractory degree is 1770~2000℃. According to its chemical function, it can be divided into three types: acidic, alkaline, and neutral.

Refractory bricks SK30, SK32, SK34, and SK35 refer to clay bricks. AL2O3% (≥) 30%, 35%, 38%, 45%. It is made of refractory clay and its clinker through crushing, mixing, molding, drying, and drying. Belonging to weakly acidic refractory products, the acidity increases with the increase of SiO2 content. It has a certain corrosion resistance to acidity, but poor resistance to alkaline corrosion.

SK36, SK37, SK38, and SK40 refractory bricks refer to high-alumina bricks with alumina content of 55%, 65%, 70%, and 82%. High-alumina bauxite is selected as the main raw material, and soft raw clay is added as a binder. After molding, it is fired at a high temperature of about 1500°C. High-alumina bricks contain more than 48% Al2O3. Its refractoriness, load softening point, and refiring shortening are higher than clay bricks, and its resistance to rapid cooling and heat is worse than that of clay bricks. High alumina bricks belong to neutral refractory materials, and their slag resistance function increases with the increase of Al2O3 content.

Rongsheng High Alumina Bricks Manufacturer

Now, the standards/types of refractory bricks that are widely used abroad are SK32, SK34, SK36, SK38, and SK40 refractory bricks. Our factory makes customized special-shaped bricks, which can be processed and customized according to the shape of the equipment and drawings, and the delivery cycle is short.

Refractory bricks can be divided into three types according to their chemical functions: acidic, alkaline, and neutral. It is a shaped product in refractory materials. According to its refractoriness, it can be divided into three grades with a refractoriness of 1580-1770°C, a refractoriness of 1770-2000°C, and a refractoriness of more than 2000 degrees.

The size of SK30, SK32, SK34, SK35, SK36, SK37, SK38, and SK40 refractory bricks is divided into standard size and special-shaped size. The standard size of refractory bricks for Rongsheng refractory brick manufacturer is 230*114*65mm. The special-shaped size is different according to the location of use and the audit requirements of the kiln, and the size can be customized according to the drawing. Clay bricks are roughly divided into: clay bricks for coke ovens, clay bricks for blast furnaces, clay bricks for hot blast stoves, and clay bricks for glass kilns according to their used parts. According to the volume density, it can be divided into general clay bricks, low-porosity clay bricks (dense clay bricks), and low-creep refractory bricks.

The refractory bricks produced by The Rongsheng Refractory Manufacturer has the characteristics of wear resistance, corrosion resistance, spalling resistance, low creep, and good thermal shock stability. The operating life is 1.5 times that of general products. Used in blast furnaces, hot blast stoves, carbon roasters, carbon calciners, coke ovens, steel ladles, casting systems, boilers, cement kilns, glass kilns, and various kiln linings and thermal equipment, etc. It is suitable for metallurgy, machinery, building materials, casting, ceramics, electric power, petroleum, chemical industry, and other industries. Contact us to get prices and samples for free.

Castable Refractory, Insulating Castable and Dense Castable, Low Cement Castable

2023-05-29 by globalrefractory

Regarding the question “what is the specific gravity of castable refractory?”, refractory material manufacturers indicated that what many people want to ask is actually the weight (tons) of a cubic castable refractory. Enterprises generally purchase castable refractory according to the actual working conditions of their industrial kilns. Rongsheng refractory castable manufacturer published a popular science blog on the conversion of castable refractory specific gravity. Generally speaking, refractory castables have bulk density, including mizzou castable refractory. For example, 2.0, 2.6, and so on. The higher the bulk density, the heavier the castable refractory will be. For example, a cubic 2.0 body density castable is about two tons, and a 3.0 body density is about three tons.

High Alumina Castable Refractory - Rongsheng Company — High Alumina Castable Refractory

What factors determine the weight of the castable refractory?

The density of the aggregate. The greater the density, the heavier the weight of the castable refractory unit cube.
The level of aluminum content. Generally, the higher the aluminum content, the heavier the castable refractory.

The density of aggregate depends on its chemical composition and porosity. For example, the higher the alumina content in the aluminum-silicon-based lightweight aggregate, the greater the density, the greater the porosity, and the smaller the bulk density.

Is it true that the higher the density of the castable refractory, the better?

It is ridiculous to say that the denser the refractory castable, the better. In fact, the density of the castable refractory is determined according to the performance, the parts used and so on. For example, some places need to use high-density castables, but some places need small-density castables. Therefore, it is not that the higher the density of the castable, the better. It is necessary to choose a suitable castable refractory according to the specific construction site.

insulating castable for boiler

Insulating castable is mainly made of light insulation aggregate. It is a kind of hydraulic material that is prepared by dry mixing according to the optimal ratio with bonding material. It has the characteristics of small bulk density, low thermal conductivity, high strength, and small shrinkage. It can be poured directly after on-site mixing (video of insulating castable on-site construction). Insulating castable is widely used in boilers, industrial furnaces, and other body insulation engineering fields. Insulating castable for general boilers chooses lightweight castables with a bulk density of 0.8 or 1.0.

Bulk density and thermal conductivity of castable refractory

As a refractory manufacturer, it is certain that the greater the bulk density of the castable refractory, the greater the thermal conductivity. In general, different bulk densities of castable refractory have different thermal conductivity.

The thermal conductivity of the castable with a specific gravity of 1 is about 0.26 W/(m.k);
The thermal conductivity of the castable with a specific gravity of 1.4 is about 0.8 W/(m.k);
The thermal conductivity of the castable with a specific gravity of 2.2 is about 1.45 W/(m.k);

If the metal wire is added to the castable, the thermal conductivity value will be larger.

The density of 0.8 is 0.28 W/(m.k),
The density of 1.2 is 0.4W/(m.k),
The density of 1.6 is 0.6W/(m.k).

That is to say, the smaller the bulk density of the insulating castable, the smaller the thermal conductivity, and the better the insulation function. Boiler thermal insulation linings refer to the operating temperature and thermal conductivity to select thermal insulation castables with appropriate bulk density. Generally, companies that purchase insulating castables will customize insulating castables according to their needs. The insulating castable of different materials is used for the insulation layer of boilers and low-temperature kilns at different temperatures. In order to save the production cost to the greatest extent.

The difference between dense castable and insulating castable of the same material

The biggest difference between dense castable and insulating castable is the bulk density. The body density of the dense castable is above 2.0, while the body density of the insulating castable is below 1.5.

The castable refractory of the same material, the dense castable, and the insulating castable have very different uses. The insulating castable is used for heat insulation in the heat insulation area. Dense castable is used in the working layer, mainly for fire resistance and wear resistance.

Insulating castable has low thermal conductivity, good thermal insulation performance, and a relatively low price. It is used in the heat treatment lining of thermal kilns for both heat insulation and heat preservation. Therefore, lightweight castables are also called lightweight heat-insulating castables or lightweight heat-insulating castables. Lightweight castables can only be used for thermal insulation and cannot be used in the working layer.

dense castable has high body density, wear resistance, high-temperature resistance, and corrosion resistance. Therefore, it is also called wear-resistant refractory castable, which can be used in direct contact with the flame in the kiln, so the heavy castable plays the role of high-temperature resistance and wear resistance.

During construction, heavy castables have less water, good strength, and long service life, while light castables are twice as much water as heavy castables because light castables are non-absorbent materials. When pouring, the template should be painted with waterproof paint to prevent the loss of castables. If water is lost, the fluidity of the castable will decrease, and it will be difficult to discharge air bubbles, which will affect the strength. However, if the amount of water added to the quality castable is too large, it will affect the discharge of crystal water and free water. It affects the strength of later use, which is also a major difference between heavy castables and light castables.

low cement castable LC-70

low cement castable LC-70 is an ultra-low cement bonded high-strength no-bake low cement refractory castable with a service temperature of 1350°C. It is mainly used in heating furnaces, rolling steel heating furnaces, annular heating furnaces, well-type heating furnaces, pushing steel heating furnaces, etc. The product grade of low cement castable is named after the initial letter of the ingredient content. The letters are the abbreviations “L” and “C” for “alumina” and “calcium oxide” respectively, and the representative value of the content is 70% AL2O3.

How to Use High Alumina Refractory Bricks and FireClay Refractory Bricks?

2023-05-05 by globalrefractory

High alumina refractory bricks and fireclay refractory bricks are the two most commonly used refractory materials in shaped refractory materials. High alumina bricks have high refractoriness, good slag resistance, and high load softening temperature. The refractoriness of clay bricks is lower than that of high alumina bricks, and the slag resistance, especially the performance of acid slag resistance is better than that of high alumina bricks, and the thermal shock performance is good. Manufacturers of high alumina refractory bricks can provide methods of using high alumina refractory bricks to use high alumina refractory bricks more efficiently.

High-Grade High-Alumina Bricks in RS Factory

How to Use High Alumina Bricks

The lining of important parts and parts with complex shapes should be pre-built first. For the lining with a complex structure and a large amount of refractory brick processing, it can be considered to change to the castable lining.
The exposed metal parts left in the brick lining, including brick supporting boards, brick retaining boards, etc., should be sealed with special-shaped bricks, castables, or refractory fibers. It should not be directly exposed to hot kiln gas in use.
Anchor bricks are masonry structural bricks, which should be set according to the design regulations and must not be omitted. Cracked anchor bricks shall not be used around the hanging holes. The metal hooks should be laid flat and hung firmly. The hanging hole and the hook cannot be stuck, and the gap left can be filled with refractory fiber.
The expansion joints in the refractory brick lining must be reserved according to the design and must not be missed. The width of the expansion joint should not have a negative tolerance, and no hard debris should be left in the joint. And fill the seam with refractory fiber to avoid the phenomenon of being full on the outside and empty on the inside. Generally, expansion joints may not be provided in the heat insulation layer.
When building capping bricks, joint bricks, and curve bricks, if the refractory bricks cannot meet the sealing requirements, the refractory bricks should be finished with a brick cutter, and the hand-processed refractory bricks should not be used. The size of the processed refractory bricks should not be less than 70% of the original refractory bricks. In the joint bricks and corner bricks of the plane, it shall not be less than 1/2 of the original brick. Must use the original brick lock.

How to Use Clay Refractory Bricks — Fireclay Bricks

How to Use Fireclay Refractory Bricks

The selection of the starting point should be laid sequentially from the hot end to the cold end or from the low end to the high end.
Arranging and marking the operating points.
Brick selection, according to the need to use the fireclay refractory bricks of different materials in the hot and cold sections, select qualified bricks.
If there are anchor nails or supporting bricks, weld the anchoring nails or supporting bricks.
If there is a heat insulation layer (such as silicon-calcium board, etc.), it is necessary to install the heat insulation layer first.
For mortar preparation and application, the mortar mud should match the refractory bricks.
Laying bricks.
Reserve and fill the swelling gap.

How to ash the general refractory brick?

Ashing is to pre-apply mud on the bonding surface of the refractory bricks to be built. According to the change of the type, shape, and location of the refractory bricks, the method of ashing is also different. The unevenness of the dusting process has a great influence on the strength of the masonry. When the dusted refractory bricks are opened for inspection after the masonry is completed, it can be seen that the joints are evenly covered with mud. However, refractory bricks with poor ash removal will have gaps on the contact surface, which will reduce the cohesive force of the brick body and may cause air leakage in the masonry.

(1) Clay ash with a trowel. He holds a brick in his left hand and a tile knife in his right. When the plastering method is used to make gray strips, the mortar is first taken with a trowel, and then the bricks are taken. When laying the gray strips, place one large side of the brick upwards. When laying the bricks in place, press the bricks tightly with your left hand, and tap with a mallet in your right hand until the bricks are finally tightened.

(2) Shovel ash. Hold the refractory brick in your left hand and a large shovel in your right hand. First use a large shovel to beat the mortar, and then take the refractory bricks. These operations are the same as the trowel ash. Attention should be paid to the four movements in the picture. The tip of the shovel moves backward along the edge of the refractory brick so that the mortar will naturally form a raised back for masonry.

Regarding the use of high-alumina refractory bricks and clay refractory bricks, Rongsheng refractory material manufacturers have put forward the above suggestions, hoping to help you when choosing high-alumina refractory bricks and clay refractory bricks. The refractory brick products of Rongsheng refractory brick manufacturer include special grade high alumina brick, first-grade high alumina brick, second-grade high alumina brick, third-grade high alumina brick, clay refractory brick, clay insulation brick, high alumina insulation brick, corundum brick, Corundum mullite bricks, magnesia bricks, magnesia carbon bricks, magnesia chrome bricks, etc. Rongsheng refractory brick manufacturers can also customize refractory bricks according to the actual needs of industrial furnaces or construction drawings. Contact us for free prices and samples, Email: inquiry@global-refractory.com, Tel/WeChat/WhatsApp: +8618538312977.

Boiler Refractory Cement Manufacturer

2023-04-13 by globalrefractory

Whether to use refractory mortar or refractory cement for boilers is a question full of doubts. Rongsheng refractory manufacturers, what is certain is that when laying refractory bricks on the boiler, the firebrick refractory mortar of the same material as the refractory bricks are generally used. Firebrick mortar is composed of refractory powder, binder, and admixture. Almost all refractory raw materials can be used to prepare refractory mortar. So what is refractory cement for boilers? How is boiler refractory cement used?

Boiler Refractory Cement

Boiler refractory cement is a raw material for unshaped refractory lining materials for boilers, which can be used to cement various refractory aggregates (such as corundum, calcined high-alumina bauxite, etc.). Used to prepare refractory mortar or refractory castable. Therefore, refractory cement is also called refractory castable cement.

Firebrick mortar is an ordinary refractory mortar made of refractory clinker powder plus 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 forms a ceramic bond at high temperatures. The chemically bonded refractory mortar uses hydraulic, air-hardening, or thermosetting bonding materials as a bonding agents. Before the temperature is lower than the formation of ceramic bonding, a certain chemical reaction occurs and hardens. Firebrick refractory mortar is mainly used in coke ovens, glass furnaces, blast furnaces hot blast stoves, and other industrial furnaces.

The usage of different refractory mortar is different. For casting clay, it is used at the burner of the kiln head. It is often used as a protective refractory layer, and it can also be used as a refractory material in some key parts of the preheater. The construction method is common grouting. For insulating fireclay, it can be used for trimming the deformation of the kiln shell. At this time, it only needs to be directly painted on the plane. Sometimes it also insulates the coolant ceiling. Thermosetting cement is common when laying bricks. We can directly use it for stirring and add a certain amount of glass water. In this way, the bonding strength and stability of the bricks will be improved to a certain extent.

Characteristics of Refractory Mortar

Good thermal exfoliation.
Good resistance to slag invasion.
Good plasticity and convenient construction.
High bonding strength and strong corrosion resistance.
High refractoriness, up to 1650℃±50℃.

Furnace Refractory Cement Manufacturer

How to choose refractory cement manufacturers for boilers? Before that, we must first know what type of boiler we are using in our actual production. Because there are many kinds of boilers, such as gas boilers, heating boilers, power station boilers, etc., choose the appropriate refractory lining products according to different boilers. This can not only prolong the service life of the kiln lining but also save production costs for the enterprise.

Large boilers such as utility boilers require more than furnace refractory cement. Because refractory cement is only raw material, it cannot be used alone, and it is easy to cause cracks when used alone. A series of matching boiler refractories is your best choice, including shaped refractory materials (refractory bricks) and unshaped refractory castables.

CFB Boiler Refractory

Shaped refractory materials include clay bricks, ultra-light bead insulation bricks, and cement perlite insulation bricks.
Unshaped refractory materials: thermal shock-resistant castables, corundum wear-resistant castables, high-strength wear-resistant, lightweight thermal insulation castables, and wear-resistant refractory plastics.
Other materials include anchors, aluminum silicate fiberboards, insulation cotton, blankets, etc.

As one of the refractory cement manufacturers, we can not only provide high-quality boiler refractory cement, CA50, CA60, CA65, CA70, CA75, and CA80. Moreover, our experienced technical team can provide design and maintenance of refractory lining materials for various industrial furnaces. Design and construction of refractory materials for various rotary kiln insulation layers. The purpose is to improve economic benefits for industrial kiln enterprises between production costs.

The name of refractory cement is aluminate cement, which can be used to cement various refractory aggregates (such as corundum, calcined high alumina, etc.) to make refractory mortar or concrete. Because it has a refractoriness of not less than 1580 degrees, it is widely used as a lining for cement rotary kilns and other industrial high-temperature kilns.

Corresponding aggregate should be added to refractory cement, avoid simple use, otherwise, cracks will occur after high temperatures. In addition, please note: 1. Baking is required after pouring construction, and it can be baked at least 3 days later. 2. Baking should be slow to avoid partial bursting. 3. Baking and cooling should be slow accordingly, and forced ventilation is not allowed.

Kind Tips

If you don’t know how to choose a furnace refractory cement manufacturer or have questions about refractory maintenance and procurement, please contact us. We can provide free technical guidance and a sample trial. Rongsheng refractory manufacturers have produced and sold refractory materials for many years. We have an experienced technical team and a production team that strives for perfection. Kiln insulation, kiln lining construction, kiln maintenance, escort for high-temperature industrial kilns.

How High Alumina Refractory Balls Improve Thermal Efficiency in Industrial Applications

2023-03-20 by globalrefractory

In the world of industrial manufacturing, maximizing thermal efficiency is key to maintaining productivity and profitability. One way that companies achieve this is by using high alumina refractory balls. These small but mighty balls are an essential component in many high-temperature processes, from steel manufacturing to petrochemical refining.

How do high alumina refractory balls improve thermal efficiency in industrial applications?

So, how exactly do high alumina refractory balls improve thermal efficiency in industrial applications? Let’s take a closer look.

Firstly, high alumina refractory balls have excellent thermal insulation properties. Their high alumina content, typically above 90%, means they have a low thermal conductivity. This means they are able to retain heat and prevent heat loss, which is particularly important in high-temperature processes where energy efficiency is critical.

Secondly, high alumina refractory balls are extremely durable. They can withstand temperatures up to 1800°C without any significant deterioration, making them an ideal choice for use in furnaces, kilns, and other high-temperature applications. Their durability means they require less frequent replacement than other refractory materials, resulting in reduced downtime and maintenance costs.

Furthermore, high alumina refractory balls have excellent chemical resistance. They are able to withstand exposure to harsh chemicals, acids, and alkalis without any significant degradation. This makes them particularly useful in industries such as petrochemical refining, where exposure to corrosive substances is common.

Finally, high alumina refractory balls are able to promote thermal uniformity. They are able to distribute heat evenly, reducing hot spots and ensuring that heat is transferred evenly throughout the process. This helps to reduce thermal stress and minimize the risk of damage to equipment, ultimately resulting in improved safety and efficiency.

In conclusion, high alumina refractory balls are a crucial component in many industrial applications, particularly those involving high-temperature processes. They improve thermal efficiency by providing excellent insulation, durability, chemical resistance, and thermal uniformity. By utilizing these powerful little balls, companies are able to achieve optimal productivity and profitability, while also reducing their environmental impact by using less energy and producing fewer emissions.

What are high alumina ceramic balls?

High alumina ceramic balls are small spherical objects made from a high-purity alumina ceramic material. They are typically used as a type of advanced ceramic material in a variety of industrial applications that require high-temperature resistance, wear resistance, and chemical resistance.

High alumina ceramic balls are produced by processing high-purity alumina powder through several stages, including mixing, molding, sintering, and grinding. The sintering process involves heating the molded ceramic balls at high temperatures, which causes the individual alumina particles to fuse together, resulting in a dense and uniform material with excellent mechanical properties.

One of the primary benefits of high alumina ceramic balls is their high-temperature resistance. They can withstand temperatures up to 1800°C without any significant deterioration, making them an ideal material for use in high-temperature processes such as furnace linings, kiln linings, and catalyst support materials.

Another advantage of high alumina ceramic balls is their wear resistance. They are able to withstand repeated impacts and abrasion without any significant degradation, which makes them useful in a variety of wear applications such as grinding media, wear-resistant linings, and ball bearings.

In addition, high alumina ceramic balls exhibit excellent chemical resistance. They are able to withstand exposure to harsh chemicals, acids, and alkalis without any significant degradation, making them useful in a variety of chemical processing applications.

Overall, high alumina ceramic balls are versatile and high-performance advanced ceramic materials that offer excellent thermal, mechanical, and chemical properties. They are widely used in a variety of industrial applications that require high-temperature resistance, wear resistance, and chemical resistance.

High alumina refractory balls vs. high alumina ceramic balls

High alumina refractory balls and high alumina ceramic balls are both made from high-purity alumina materials, but they have different properties and are used for different applications.

High alumina refractory balls are typically used as a type of refractory material in high-temperature industrial applications such as furnaces and kilns. They are designed to withstand high temperatures up to 1800°C without any significant deterioration and have excellent thermal insulation properties due to their low thermal conductivity. High alumina refractory balls are also highly durable and have excellent chemical resistance, making them ideal for use in harsh chemical environments.

On the other hand, high alumina ceramic balls are used for a variety of industrial applications such as grinding media, wear-resistant linings, and ball bearings. They have excellent wear resistance and can withstand repeated impacts and abrasion without any significant degradation. High alumina ceramic balls also have high hardness and high strength, making them suitable for use in high-stress applications.

While both high alumina refractory balls and high alumina ceramic balls are made from high-purity alumina materials and offer excellent properties, they are designed for different applications. High alumina refractory balls are used for high-temperature industrial applications where thermal insulation and chemical resistance are important, while high alumina ceramic balls are used for wear-resistant and high-stress applications such as grinding media and ball bearings.

In summary, high alumina refractory balls and high alumina ceramic balls are both useful advanced ceramic materials that offer unique properties for different applications. It’s important to choose the right material for the specific application to ensure optimal performance and durability.

How Many Bricks in a Pallet of Refractory Bricks？

2023-03-07 by globalrefractory

Refractory bricks are a special type of brick that is designed to withstand high temperatures and harsh environments. They are commonly used in industrial settings such as furnaces, kilns, and incinerators. If you’re working with refractory bricks, you may be wondering how many bricks are in a pallet. The number of bricks required to complete a construction project depends on the size and scope of the project, as well as the size of the bricks themselves. In this essay, we will explore the answer to this question in detail.

How Many Bricks in a Pallet of Refractory Bricks？

A pallet of bricks is a standard unit of measurement used by manufacturers and suppliers to package and transport bricks. It is a rectangular wooden or plastic platform that is used to hold a certain number of bricks. The number of bricks in a pallet can vary depending on the size of the bricks and the dimensions of the pallet.

The number of refractory bricks in a pallet can vary depending on the size and thickness of the bricks. A standard pallet of refractory bricks typically contains between 300 and 500 bricks. However, it is important to note that this number can vary depending on the manufacturer’s specifications.

Refractory bricks are typically denser and heavier than standard bricks, which means that fewer bricks can fit on a pallet. The size and thickness of the bricks can also play a role in determining the number of bricks that can fit on a pallet. Thicker and larger bricks take up more space, which can result in fewer bricks being able to fit on a pallet.

The weight of the pallet can also vary depending on the number of bricks on the pallet. A pallet of 300 refractory bricks will be lighter than a pallet of 500 refractory bricks, for example. This is an important consideration for those who need to transport bricks from one location to another.

When working with refractory bricks, it is important to know how many bricks are in a pallet. This information can help you plan your project and determine how many pallets of bricks you will need. It can also help you estimate the weight of the pallets, which is an important consideration when transporting the bricks.

In conclusion, the number of refractory bricks in a pallet can vary depending on the size and thickness of the bricks, as well as the manufacturer’s specifications. A standard pallet of refractory bricks typically contains between 300 and 500 bricks. Knowing how many bricks are in a pallet is an important consideration when working with refractory bricks, as it can help you plan your project and estimate the weight of the pallets. If you are unsure about the number of bricks in a pallet, be sure to check with the manufacturer or supplier for more information.

What is Refractory Cement?

2023-02-10 by globalrefractory

Refractory cement is a type of cement that is used in high-temperature applications. It is made from a combination of high-alumina cement, silica sand, and other materials that are resistant to extreme temperatures. Refractory cement is used in a variety of industries, including steel production, glass manufacturing, and ceramic production. Refractory cement is used to form a protective layer between the heat source and the equipment. It is designed to resist thermal shock, abrasion, and corrosion. Refractory cement is also used to fill cracks and gaps in the walls of furnaces and other equipment. It is also used to repair damage caused by thermal shock or abrasion.

Refractory Cement for Refractory Materials — Refractory Cement from Rongsheng Refractory Factory

High alumina cement is the main component of refractory cement. It is made from a combination of alumina and calcium oxide and is highly resistant to extreme temperatures. This type of cement is also known for its high strength and durability. It is used in applications where temperatures can reach up to 3,000°F. Refractory cement is an important component of any high-temperature equipment. It is designed to withstand extreme temperatures and protect the equipment from damage. It is also used to repair damage caused by thermal shock or abrasion. Refractory cement is a reliable and durable material that can be used to ensure the safety and efficiency of any high-temperature equipment.

Castable refractory cement is a type of refractory cement that is used in applications where temperatures can reach up to 3,000°F. It is made from a combination of high-alumina cement, silica sand, and other materials that are resistant to extreme temperatures. This type of cement is used in applications where the cement needs to be poured or cast into a specific shape. Castable refractory cement is a type of cement that is used to line the walls of furnaces, kilns, and other high-temperature equipment. It is designed to withstand temperatures up to 3,000°F and is composed of high-alumina cement, which is a combination of alumina and calcium aluminate. Refractory cement is also known as castable refractory cement and cement refractory. And so is Cement refractory.

Refractory cement is an important material in many industries. It is used in applications where temperatures can reach up to 3,000°F, and is made from a combination of high-alumina cement, silica sand, and other materials that are resistant to extreme temperatures. It is used in steel production, glass manufacturing, and ceramic production.

Refractory cement can be used in a variety of ways. It can be used to make castable refractory cement, which is used to line furnaces, kilns, and other high-temperature equipment. It can also be used to make cement refractory, which is used to line fireplaces and other areas where heat is present.

Refractory cement is an important material in many industries. It is strong, heat-resistant, and can withstand high temperatures. It is used in a variety of applications, from steel and aluminum manufacturing to fireplaces and furnaces. It is made from a combination of high-alumina cement, silica sand, and other materials. Contact Rongsheng Refractory Manufacturers for free price information and samples.

How to Use Low Cement Refractory Castable?

2023-01-14 by globalrefractory

Low-cement castables are mainly used in various heat treatment furnaces such as furnace walls, furnace roofs, furnace bottoms, aluminum ladles, chutes, smelting equipment, high-temperature kiln linings, heating furnaces, and soaking furnaces of aluminum melting furnaces. Low-cement castables have high refractoriness, good high-temperature performance, high medium-temperature, and high-temperature strength, and good anti-stripping and anti-erosion properties. So, how to use low cement refractory castable? What are the precautions in the use of low cement castables? Rongsheng refractory manufacturers, based on years of experience in production, sales, and construction, will answer your questions.

How to Use Low-Cement Castables?

Stir

Must be mixed with a forced mixer. Use clean water, the water temperature should be 10-25 ℃. Strictly follow the mixing ratio given in the material instruction manual for ingredients and water. In order to overcome the uneven particle size distribution of the dry aggregate during transportation, it should be dry mixed for 1 minute and then mixed with water for 4 to 5 minutes.

Pouring

The mixed castable is quickly transported to the pouring site, and the castable is poured into the mold with a small shovel and a special hopper. When pouring, the material should be cut from one side of the formwork to prevent the lower part from creating a void. When cutting the material, prevent the wrapped ceramic fiber felt from breaking and falling off. After the material is full, start the vibrator, and the material surface will sink during the vibration. Add materials in time. When the castable surface no longer sinks or the surface is flooded and no bubbles escape, the vibration can be stopped, and the vibration time is generally 2 minutes.

Demolition and repair

When the temperature in the furnace is between 10 and 25°C, the formwork can be removed 8 hours after pouring, and the castable can be cured naturally after the formwork is removed. The pouring quality should be checked in time, and general defects will not be dealt with. However, important parts and larger problems need to be repaired to make the lining meet the requirements of the production process.

Precautions for the Use of Low-Cement Castables

Adjust the castable according to the proportion

When using low-cement castables, attention should be paid to the deployment method, and the proportion must follow the corresponding regulations. Do not add water arbitrarily or blindly add castables. Once the ratio is wrong, the pouring effect will be greatly reduced. Therefore, castable operators must have rich experience and be able to complete the deployment of castables in a reasonable proportion to ensure smooth follow-up work.

The evenly stirred castable should be used as soon as possible

In the actual application of low-cement castables, many customers mixed the castables evenly and left them aside, and did not use them in time. The disadvantage of this is that the low-cement castable exposed to the air will evaporate more water, which will reduce the moisture content of the castable, which is not conducive to the use of the castable.

The storage of castables should be mainly dry

If the amount of low-cement castables purchased is large, it needs to be stored in a relatively dry environment in time, and the corresponding protection work should be put in place to ensure that the castables are not affected by the external air and avoid quality damage. Take the appropriate amount before use, and do not put all the castables on the construction site, this behavior will interfere with the preservation of castables.

Formulate a reasonable oven curve

The outstanding feature of low-cement castables is dense and high strength, which brings benefits to use, but improper baking will easily cause peeling or bursting. Therefore, it is very important to formulate a reasonable oven curve. If necessary, an excellent explosion-proof admixture can be used, so that the moisture of the low-weight cement castable can be removed smoothly without causing any side effects.

According to the use method of low cement castable, the ideal use effect can be achieved. It should be noted that the air permeability of low-cement castables is poor, and it is easy to cause peeling or bursting during the baking process. The baking system should be formulated reasonably according to its material, construction thickness, and construction site. At the same time, metal aluminum powder, organic fiber, etc. can also be added to the castable. Make it easier to remove moisture and increase the service life of low cement refractory castables. Rongsheng Refractories Co., Ltd. produces and sells various castable products such as low-cement castables, which are easy to use, excellent in performance, and wide in application. Contact us for free samples and price information.

Comparison of the Performance of Corundum Bricks and Chrome Corundum Bricks in Applications

2022-12-06 by globalrefractory

Corundum bricks are refractory bricks with an alumina content greater than 90%. Corundum bricks are divided into sintered corundum bricks and fused corundum bricks. The chrome corundum brick is a refractory brick with Cr2O3 added to the corundum. Chrome corundum bricks are divided into two types: fused cast chrome corundum bricks and sintered chrome corundum bricks.

Corundum bricks are used in industrial furnaces under high temperatures, high pressure, and other environments. Corundum bricks and chrome corundum bricks have similarities and differences.

Fire resistance

Adding Cr2O3 to the corundum material will not only reduce the fire resistance of the material but will improve the fire resistance of the material. The refractoriness of chrome corundum bricks is greater than 1790°C and the softening temperature under load is greater than 1700°C, both of which are better than corundum bricks.

Compressive strength

The normal temperature compressive strength of corundum bricks is 70~100MPa. The room temperature compressive strength of high-performance chrome corundum bricks is generally greater than 150MPa, which is significantly higher than that of corundum bricks. During the firing process of corundum bricks and chrome corundum bricks, Al2O3-Cr2O3 solid solutions are formed between the particles, between the particles and the fine powder, and between the fine powder and the fine powder. The solid solution connects the particles and fine powder together like a bridge so that the strength of the material is greatly improved.

Thermal shock stability

Adding Cr2O3 to corundum, when the Cr2O3 content is 10%-66%, the thermal shock stability of the material decreases with the increase of the Cr2O3 content. That is, chromium corundum bricks with low Cr2O3 content have better thermal shock stability than chrome corundum bricks with high Cr2O3 content. The Cr2O3 content of high-performance chromium corundum bricks is between 12% and 20%, and its thermal shock stability is improved compared with corundum bricks. Especially the AKZ chrome corundum brick produced by adding a small number of additives that cause phase change has better thermal shock stability.

Resistance to slag erosion

Corundum bricks are severely eroded by slag, and the slag will completely penetrate into the brick and penetrate to the surface along the pores inside the brick, and the brick will turn brown with almost no slag remaining. Chrome corundum bricks are hardly corroded by molten slag, there is no obvious chemical reaction between the slag and the brick surface, the boundary between the inner hole edge and the slag is clear, and the slag rarely penetrates into the brick. Only a 5-10 mm thick metamorphic layer is formed around the brick hole, and a large amount of slag remains in the crucible hole. Chromium corundum bricks have better resistance to chemical erosion and permeability of gasifier slag than corundum bricks, and their resistance to structural spalling is also superior to corundum bricks.

Application

Chrome corundum bricks are used as glass kiln lining, brushed glass flow hole cover, and plate brick, and are used for molten iron pretreatment devices, garbage incinerators, gasifier backing, etc. Corundum bricks are used in various high-temperature kiln linings and kiln furniture such as cracking and reforming furnaces in the petrochemical and chemical fertilizer industries, steelmaking furnaces in the metallurgical industry, and blast furnaces. Among them, chrome corundum bricks are more resistant to high temperatures and corrosion than corundum bricks, which can meet the common needs of industrial kilns.