Refractory Mortar

What Should I do if the High Alumina Refractory Mortar Dries too Fast during Construction?

High alumina refractory mortar (KHLN-55) is prepared from high alumina bauxite clinker, binding agent, and admixture. It is usually delivered in bulk and dry, and it is mixed with water during use. [Solemn reminder] Refractory mortar is different from refractory cement. Refractory mortar is mainly used as the joint material or brick joint material for the construction of refractory bricks. The adjusted refractory mortar is also called refractory mortar. Refractory cement is used as a binder for making refractory castables or refractory plastics. Refractory cement is also called high alumina cement or aluminate cement.

Refractory Mortar for Sale
Refractory Mortar for Sale

Use of High Alumina Refractory Mortar

The high-alumina refractory mortar is correctly configured according to the material of the refractory bricks. Usually, it is mainly used for laying high alumina bricks and corundum bricks.

How to Use High Alumina Refractory Mortar

The refractory slurry used for refractory bricks is made of powdered refractory materials. It should have good masonry performance and high-temperature performance to bond the refractory bricks into a dense overall furnace lining.

The masonry performance of mud refers to the work performance of refractory mortar that helps to ensure the quality of masonry during the masonry process. If there are good fluidity and plasticity. It has a certain water retention performance and can maintain a uniform state without segregation and precipitation. It has proper consistency and viscosity during masonry and does not dry out during the brick kneading time to achieve the required thickness of the brick joints, and the mortar in the brick joints is full.

The chemical composition similar to that of refractory bricks should be taken into consideration when selecting fire clay. The thermal expansion of the mud is consistent with the thermal expansion of the refractory bricks to ensure that the masonry can be reliably bonded.

The Use of Wet Refractory Mortar for Sale
The Use of Wet Refractory Mortar for Sale

What should I do if the high alumina refractory mortar dries too fast during construction?

Can refractory clay fail to condense or dry too fast on the construction site and cannot be built with refractory bricks? The answer is yes.

What if this situation is reproduced on the construction site? It is necessary to add an admixture, otherwise, the https://refractorycastablecement.com/high-alumina-mortar/ refractory mortar will dry too quickly and affect the construction. So, what is the proportion of joining? Many construction companies are very clear, some say an increase of 1%, and some say 0.5%. There is no clear regulation on this amount of addition, it depends on the construction site.

RS High-Alumina Refractory Mortar for Sale
RS High-Alumina Refractory Mortar for Sale

The role of high alumina refractory mortar additives

The soft clay is added to the high alumina refractory mortar to improve workability, such as spreading and adhesion. Using soot silica powder instead of soft clay can lower the sintering temperature. Additives mainly include precipitation agents, stabilizers, plasticizers, and anti-shrinking agents. The role of the precipitation agent is to reduce the amount of water added. The stabilizer prevents the solid-liquid separation phenomenon of the adjusted refractory mortar during the standing process. Adding plasticizers improves the spreadability of the mud and prevents flow. The anti-shrinking agent is to prevent cracks or peeling caused by volume shrinkage after sintering.

  • Refractory material itself is an applied science, and it depends on the situation during use. If the construction is cold in winter, add 2%, if it is hot in summer, add 0.5-1%.
  • In the construction process of refractory mortar, drinking water must be added at a ratio of 25-30%. Can’t add too much, it depends on site usage.
  • Add yellow dextrin and methylcellulose, add powder. Yellow dextrin is a yellow-white powder, and it is easily soluble in water, and it has strong viscosity when dissolved in water. At a certain temperature, it will be decomposed by heat.
  • If at the construction site, yellow dextrin and methylcellulose add one of them, it can also play a sticky effect.
  • If the refractory mortar https://refractorycastablecement.com/refractory-mortar-for-sale/ is the phosphoric acid refractory mortar and the construction site appears to dry too fast, yellow dextrin or methylcellulose must be added to adjust it. The added bonding agent has evaporated after high temperature and will not affect the later use.

To learn more about the precautions for the use of unshaped refractory materials and the solutions to various problems, please visit our website: https://refractorycastablecement.com/.

Wear-Resistant Castable

How to Choose a Suitable Wear-Resistant Castable?

Wear-resistant castable is a refractory castable commonly used in high-temperature industrial kilns. In the high-temperature working environment, how to choose the refractory castable lining mainly focuses on the following points. For example, high-temperature resistance, wear resistance, thermal shock resistance, chemical resistance, etc. Different use environment, different choice of refractory castable. This article mainly introduces how to choose suitable wear-resistant castables with so many kinds of wear-resistant castables.

Wear Resistant Castable
Wear Resistant Castable

Introduction of Wear-Resistant Castable

Wear-resistant castable is an unshaped refractory that can resist high-temperature solid particles and airflow. The main performance of wear-resistant castables is strong wear resistance. Wear resistance mainly refers to the ability of refractory castable lining to resist the friction and wear (grinding, friction, impact, etc.) of hard materials or gases (containing solid particles) without being damaged, or the characteristics of low wear rate. It is an important indicator to predict whether it can be used in abrasion and erosion environments. Generally, the higher the bulk density, the higher the compressive strength and the stronger the wear resistance.

Corundum Self-flowing Wear Resistant Castable
Corundum Self-flowing Wear Resistant Castable

Main Application Parts of Wear-Resistant Castables

The use environment of wear-resistant castables is mainly aimed at various feed ports, discharge ports, various flue linings, etc. These parts have high requirements on the wear resistance of the lining material. In order to prolong the service life of the lining, it is necessary to choose high-quality wear-resistant castables.

Wear-resistant castables are classified according to different materials. Such as high-strength wear-resistant castable, high-alumina wear-resistant castable, steel fiber wear-resistant castable, corundum wear-resistant castable, etc. The wear-resistant castables selected for different parts of use are different. Such as:

The materials selected for the feed port and the discharge port must not only have to wear resistance but also have thermal shock resistance. When feeding or discharging, the temperature fluctuates greatly and the thermal stress is strong. It is not enough to only choose to have abrasion resistance, but also to have excellent thermal shock resistance. The steel fiber wear-resistant castable can be selected as the inner lining, and the use effect is better.

Corundum High Strength Wear Resistant Castable
Corundum High Strength Wear Resistant Castable

Wear-Resistant Castable for Power Plant Boiler

In the furnace lining of power plant boilers, not only the scouring of various high-temperature gases and materials but also the characteristics of high-temperature resistance and chemical corrosion resistance are required. At this time, corundum wear-resistant castable lining or high alumina wear-resistant castable with an alumina content of about 75% can be used. The current circulating fluidized bed boilers have high thermal efficiency and low pollution emissions, and most of them are used in thermal power plants and heating projects. The furnace lining temperature is 800℃~1100℃ after long-term strong dust erosion. Therefore, higher requirements are put forward for the wear resistance of the castable at the location. Manufacturers producing wear-resistant castables are also constantly adjusting the process, correspondingly reducing the addition of fine particles, so that the wear resistance is continuously improved.

To sum up,

The flue of various high-temperature kilns is mainly damaged by various air currents and chemical erosion, and the use temperature is different. At this time, there is no need to choose corundum wear-resistant castable for sale. According to the analysis of the specific use temperature and corrosive medium, it is more appropriate to choose high-alumina wear-resistant castables that are resistant to wear and acid and alkali.

Refractory Castables

Application Characteristics of High-quality Lightweight Mullite Castables

Lightweight mullite castables are a type of main material used in heating furnaces. It not only requires good high-temperature performance but also requires a smaller bulk density and thermal conductivity. Lightweight mullite castable is a refractory material with excellent high-temperature performance and a good thermal insulation effect. Because it uses high-quality synthetic raw materials and is combined in the form of low cement or micro-powder, it can be directly applied to high-temperature parts in contact with the flame.

Lightweight Insulating Castable
Lightweight Insulating Castable

Application Characteristics of High-quality Lightweight Mullite Castables

  • (1) Choose high-quality lightweight mullite aggregate as the main raw material. Adding an appropriate amount of fine powder and using low cement bonding can produce high-quality lightweight mullite castables. This castable can be directly applied to the high-temperature part of the heating furnace.
  • (2) Lightweight aggregates with different bulk densities have a greater impact on the index of the castable, and which grade of raw material should be used carefully.
  • (3) It can be proved by using that this castable has better flow properties. Peeling resistance and heat preservation performance, suitable for application in high-temperature parts of the heating furnace. It has obvious effects on improving the service life of the furnace body, reducing the thermal conductivity of the heating furnace body, and improving the thermal efficiency.

Structural Composition of Lightweight Mullite Castable

1: Selection of lightweight mullite aggregate

As the main component of the castable, lightweight mullite aggregate has a vital influence on the performance of the castable, and its selection should be carried out carefully. Properly increasing the critical particle size of the aggregate is beneficial to enhance the compressive strength of the castable, but if the critical particle size is too large, it will have an adverse effect on the construction performance of the material. Through experiments, we determined that the critical particle size is 12mm. The ratio of particles to a fine powder should be controlled at 65%~70%, or 32%~40% is more appropriate.

2: The choice of cement

Because this castable is used in the high-temperature part of the heating furnace, the use temperature is about 1350°C. Therefore, pure calcium aluminate cement with excellent performance should be selected, and its AL2O3 content should generally be greater than 70%. If the cement has a high impurity content, it will easily react with the castable at high temperatures to produce low-melting substances, which will affect the high-temperature performance of the castable. The dosage is generally controlled at 5%~10%. If the dosage is too large, it will reduce the medium temperature strength of the castable. At high temperatures, it will adversely affect the high-temperature strength and spalling resistance of the castable.

3: Choice of micro powder

Compared with compact castables, lightweight castables have lower fluidity. Especially for this kind of castable used in high-temperature parts, due to the restriction of use conditions, the added amount and variety of some subdivisions are restricted to a certain extent. In order to enhance the flow properties of this castable, the form of adding composite micro-powder is adopted. After comparative tests, it is believed that it is difficult to achieve good fluidity and performance of this castable by adding only a single alumina powder or silica powder. For this reason, two kinds of micro powders are selected for compounding. In order to improve the construction performance and high-temperature strength index of the castable, we increased the amount of superfine powder added. Considering comprehensively, it is more appropriate to control the total amount of superfine powder at 10%-18%.

4: Determination of the amount of kyanite added

Because the compactness of lightweight castable aggregates is poor, if the proportion is not properly controlled, it is easy to cause the high-temperature linear shrinkage of the castable to increase. The castable is prone to cracks and peeling when used at high temperatures, which seriously affects the high-temperature performance of the castable. For this reason, we add an appropriate amount of kyanite to control the linear change of the castable, and the appropriate amount is 4%~6%.

Factors Affecting the Performance of Castables

1: Lightweight aggregates with a larger bulk density of raw materials of the same variety have higher compressive strength and flexural strength for their refractory castables. Different manufacturers have different production processes, and the strength of the lightweight aggregate itself is also quite different. The choice of raw materials should be determined by inspecting test blocks.

2: Increasing the amount of cement added will obviously increase the normal temperature strength of the castable. However, because calcium aluminate cement contains more silica, it can make the castable produce more crystal phases such as CA6 and CAS2 at high temperatures. It is easy to have a negative impact on the medium temperature, high-temperature strength, and peeling resistance of the castable. Therefore, the amount of cement should be 5%~10%.

Get more information about the Advantages and Applications of Lightweight Insulating Castables: https://refractorycastablecement.com/advantages-and-applications-of-lightweight-insulating-castables/.

Refractory Castables

Application of Self-flowing Refractory Castable in Kiln Repair

Self-flowing refractory castables are used in narrow parts of the kiln lining, or when repairing damage to various kilns. Self-flowing castables are characterized by high-temperature and hot self-flow pouring.

Self-flowing Refractory Castable

Self-flowing refractory castable material is a kind of refractory castable that has fluidity, filling property and stability, and can rely on self-flow to form a dense lining. In general, the self-flow rate of self-flowing material is controlled between 50% and 100%. If the self-flow value is too small, the material fluidity is poor, and the castable cannot fill the model during construction, forming a dense lining. If the self-flow value is too large, materials may segregate during construction.

Application of Self-flowing Refractory Castable in Kiln Repair

Due to the characteristics of the self-flowing refractory castable, it is convenient to be used for repairing the furnace. In most impressions, the maximum particle size of the self-flowing castable is 5mm. Because this facilitates the flow of the castable. Different types of refractory aggregates used in self-flowing refractory castables have different degrees of self-flowing. It is also based on different temperatures to determine the different materials used for self-flowing castables.

Rongsheng Self-flow Refractory Castable for Sale

White corundum, brown corundum, alumina-based corundum and high alumina are used as refractory aggregates. When the proportion of various materials and the proportion of water are the same, the self-flow rate of the castable is different. Because the bulk density of the raw materials of self-flowing refractory castables is large, the water absorption rate is low and the impurities are few are the biggest factors of fluidity.

Factors Affecting the Quality of Self-flowing Castables

1. Reasonable aggregate particles and aggregate gradation. Refractory aggregates generally use spherical, low water absorption raw materials, with a particle size of 5-8mm. The ratio of aggregate to powder is 6:4, and the ratio of coarse, medium and fine aggregate is 20:45:30.

2. Suitable binding agent and water reducing agent. Choose reasonable binding agent and water reducing agent.

3. Proper water consumption. Strictly control the water consumption, too much water can reduce viscosity and improve fluidity.

For self-flowing refractory castables, the selection of critical particle size is very important. However, in recent years, with the continuous improvement and research of castable manufacturers, the addition of large particles in the particles has increased the strength of the self-flowing castable. Moreover, the castable flows uniformly and does not sink, which makes the self-flowing castable have a longer service life in repairing the furnace lining. Learn more about the refractory castables for the kiln lining, https://refractorycastablecement.com/.

Refractory Castables

What is Epoxy Refractory Castable?

Epoxy castables are liquid mixtures made of resin, curing agent, filler, etc. It is a castable made into barrels with resin as binder. This is the first time I have seen this refractory castable.

Epoxy refractory castables work normally at high temperatures and have strong resistance to high and low temperature impacts during the cooling process. High temperature resistant epoxy castables are constantly evolving and improving with the requirements of epoxy cast body insulation. On the one hand, the working environment temperature is relatively high. On the other hand, as insulating parts become smaller and smaller in actual use. Therefore, the requirements for the heat resistance of the cast body are getting higher and higher. Epoxy castables are high-grade refractory castables and are not widely used.

Epoxy Refractory Castable

Important Component Compositionof Epoxy Refractory Castable

Resin is an important part of epoxy castable. The resin plays a stabilizing role and has good electrical insulation properties. It is widely used in composite materials, high-performance adhesives, electrical insulating materials and other fields.

Epoxy castables have good fluidity and less volatile matter at the pouring temperature. Epoxy castables cure quickly and shrink after curing. It is an insulating product integrating insulation, moisture-proof, mildew-proof, anti-corrosion, fixation and isolation.

Silicon powder is also one of the important components of epoxy castables. Silicon powder has an irreplaceable effect on reducing shrinkage, reducing costs, and improving performance. However, if the content of silicon powder is too high, its insulation and mechanical properties will be greatly reduced, which will seriously affect the safe and reliable operation of the power system. If the content of silicon powder is too low, the overall performance will be reduced. Therefore, the proper proportion of castable is very important. Because the amount of this castable is not large, it is necessary to continuously test the amount of addition in the production process to make a suitable epoxy castable.

The production process of epoxy refractory castable is to test out the proportions of filler, silicon powder, resin, and curing agent first, then mix the materials, auto-pressure gel molding, and cure after molding. After the epoxy castable is made, it is added to the mixing tank in proportion. Add fillers of different mass fractions into the mixing tank and add 0.2% accelerator. Stir and defoam for 2 hours at a stirring speed of 30-40°C, so that the epoxy castable can be used.

Learn more details about refractory castable for sale, https://refractorycastablecement.com/.

Refractory Castables

Causes of the Bursting of Refractory Castables for Cement Kilns

In order to improve the operating rate and production efficiency of the rotary kiln, reduce production costs. Most cement manufacturing companies have problems with heavy production tasks and short kiln shut down for maintenance.

Cement Kiln Repair

For cement manufacturers, the time for intermediate and overhaul is generally controlled within 8-15 days. However, cement kilns in my country mostly use low cement series refractory castables based on the hydraulic combination, and their construction, curing, and baking must meet a certain period. Therefore, when the construction period is short and the kiln is fast, the bursting of the castable is prone to occur. In particular, some special bidding castables burst during the baking and feeding of the production line, and the kiln has to be stopped and re-poured, causing unnecessary losses to the enterprise.

Causes of the bursting of refractory castables for cement kilns

There are generally four reasons for the explosion of refractory castables (https://refractorycastablecement.com/refractory-castable-manufacturer/) used in cement kilns.

First, the production tasks of each cement production enterprise are heavy. A production line with a daily output of 5,000 tons of cement has a daily production value of about 1 million yuan. Therefore, most cement plants need time for maintenance. In order to open the kiln as soon as possible, the curing and baking time of the castable has to be reduced.

The second is that the current refractory castable materials for cement kilns in my country are mainly SiO2 and Al2O3 systems. The binder is fast-hardening and high-strength cement-based on aluminate cement. This requires that the castable has sufficient curing time and a reasonable baking system after the construction is completed, which requires a longer time.

Third, the maintenance of my country’s cement industry is basically entrusted to furnace construction companies. The professional level of the construction team and whether the construction is standard or not will affect the construction quality and use the effect of refractory castables.

Fourth, some special parts of the cement kiln, such as the front kiln product, the kiln head cover, the top of the cooler, and the sidewall, have the problem of difficult baking. For these parts, some cement companies do not use wood for baking at all, and some companies just bake for a short time. In the kiln drying stage with burners, due to the control of the cement kiln process parameters, the hot air flow is transmitted and radiated to the kiln tail system at a certain speed, while only part of the radiant heat energy is radiated to the kiln headcover and the cooler, which is not enough The free water in the castable is fully discharged. When the production starts, the hot airflow in the system flows back to the kiln head in a short time. At the same time, high-temperature clinker begins to accumulate on the kiln headcover, causing the temperature of the kiln headcover and cooler to rise sharply. At this time, the pouring material bursts and falls off most easily.

The above-mentioned many factors have caused the problem of castable bursting during the maintenance period of various cement manufacturers to be more prominent. As a result, every year in our country, the kiln headcover and the chiller castable burst and collapse due to the failure of the explosion-proof measures for the castable and the unreasonable baking system. For more information on the maintenance of refractory castables for cement kilns: sales@refractorycastablecement.com.

lightweight castable

Precautions for the Construction of Lightweight Thermal Insulation Castables

A high-quality refractory castable manufacturer, the light-weight insulation castable produced by it has the advantages of moderate strength and good insulation performance. Lightweight thermal insulating castable is made of aluminate cement, high alumina fine material, ceramsite, and some additives. Lightweight thermal insulation castable, mainly used for the lining of thermal equipment such as the thermal insulation layer of high-temperature industrial kilns.

Insulating Castables Can Be Applied To Kilns To Save Energy

Construction of light-weight thermal insulation castable

Because the lightweight insulating castable(https://refractorycastablecement.com/insulating-castable/) is made of certain refractory materials, such as alumina and other powdered and granular refractory materials added with some binders. It has high liquidity. In terms of construction, it is mainly formed by pouring.

Precautions for mixing lightweight castables

The variety of lightweight castables is different, and the mixing is also different. The amount of the hydration liquid binder must be accurate, and the various raw materials must be weighed and poured into the mixer without missing or adding more. When mixing cement, clay binding and low-cement lightweight castables, dry bulk materials such as bagged materials, additives and admixtures are first poured into the mixer for dry mixing for 1 minute. After uniformity, add water and wet mix for 3-5 minutes. The material can be discharged after the material is uniform in color.

Lightweight castables combined with water glass can be first poured into a mixer for dry mixing, and then water glass solution is added for wet mixing. After the particles are wrapped by water glass, add refractory powder and other materials. Wet mixing is about 5 minutes, and it can be used for discharge. If the dry ingredients are mixed together, pour them into a blender and mix for 1 minute, then add 2/3 of the water glass solution and mix for 2-3 minutes. Then, add the remaining binder and wet mix for 2-3 minutes before use.

Insulating Castables Has Low Bulk Density

The mixing of resin bonded castables is the same as the mixing of water glass bonded castables.

The mixing of phosphoric acid and phosphate combined with lightweight castables is to pour the dry materials into a mixer for dry mixing for 1.0 minute, add about 3/5 of the binder and wet-mix for 2-3 minutes before discharging. And it needs to be covered tightly with plastic film for trapping, and the trapping time is more than 16h. After weighing the trapped material, pour it into the mixer for secondary mixing, and add the remaining proportion of binder to wet mix for 2-4 minutes before use.

When mixing lightweight castables, if additional materials such as refractory fibers and organic fibers are required to be added to the materials, they should be sprinkled into the mixer for mixing continuously and uninterrupted during the wet mixing of the castables, mixing while sprinkling. After the lightweight castable is mixed out, if it is too dry and too thin, the castable can no longer be used.

Precautions for the construction of lightweight thermal insulation castables

For the construction of lightweight refractory castables, formwork must be supported first. The working surface of the template should be painted with oil or stickers. The height should be moderate each time the template is installed to facilitate material loading and vibration forming.

The surface of the lightweight castable should be covered with a plastic film to prevent water absorption from affecting the performance of the castable. If the furnace wall is high, the light castable construction should be carried out in layers to prevent the overturning of the insulation layer when the castable shakes.

If it is a light-weight refractory castable furnace roof construction, it must be in accordance with the design size requirements. First, the entire template is firmly supported and then oiled. The distance between the bottom end surface and the template surface is 0-10mm. When the amount of lightweight castable is small, it can also be mixed manually.

For more information about lightweight insulation castables, please visit our website: https://refractorycastablecement.com/.

Low Cement Castables

Where To Buy Low Cement Castable Refractory?

When you are currently working with alumina cement, or any type of mixture that may be reduced in cement, you will discover a castable refractory that will work perfectly for whatever it is that you will be making. Regardless if you are creating bricks, or another type of shape with this material, it is going to appear perfect whenever. You will need to hold the right low cement castable refractory mix to the project you are planning. This is the best way to find these mixtures at discount prices when you know where you can search on the net.

Low Cement Castables Refractory Has Good Wear Resistance

How To Find Discounts About This Product

Discounts about this https://refractorycastablecement.com/low-cement-castables are available at a variety of stores. You can get all of the ones that sell them by searching on the net. You will discover a number of different companies that have the ideal mixtures, nevertheless, you can only determine this by either trying them out yourself or taking a look at reviews on the internet. The reviews that there are actually will probably be produced by people that have actually make use of the mixtures. They could show instances of what they have formulated using this product. This gives you some confidence that it will be the best mixture for that project you will be working on to ensure that it may come out right each and every time.

Steps To Make Your Purchase Online

Once you find 2 or 3 of these companies, it is advisable to place an order. Our recommendation is that you end up picking the corporation that has the greatest amount of feedback. You can even stick within your budget by ordering from among the more low priced companies that are providing these kinds of products. By the end throughout the day, your order will be placed and you will anticipate to start creating whatever you have to at the end of the week.

Refractory Cement

Overview Of High Alumina Refractory Cement

There are actually certain applications where you can actually use alumina refractory cement. It is a type of cement containing aluminum oxide. The phrase refractory essentially implies which it will retain its overall strength at high temperatures. It is sometimes referred to as a type of clay which is used in places that high temperatures happen constantly. As an example, when you have a place similar to a furnace, you will notice these bricks being utilized. This is basically the primary application for such bricks, yet there are several others. Find cement from http://refractorycastablecement.com/refractory-cement-suppliers.

Refractory Cement Materials Can Withstand 1580℃

Where Else Could You Start Using These Bricks?

When you have ever gone zoo a spot where they can be cooking pizzas, or should they be firing clay, you are going to see these being used. Brick ovens, or perhaps places where these are incinerating bodies, they are used so that they can keep going for a much longer time. In case you have not been able to get an area to buy them, there are several firms that sell them every single day. All you want do is select a business that sells them, and somebody who can set them up, and it is possible to get this done right away.

In which you find these firms?

You will discover these firms refractorycastablecement.com that sell alumina refractory cement bricks, and there are several applications on their behalf. Wherever you are going to have high temperatures, it will probably be present with discover them. It is because of the substance inside it that it may withstand the larger temperatures, with alumina being the primary component. You are able to locate businesses that are able to install them also if you have to have this done efficiently away. On top of that, you need to be able to find companies that will give you a price reduction by simply comparing the numerous companies that sell them.