Factors Affecting the Performance of Ceramic Fiber Products

When we choose ceramic fiber products, we will definitely ask the manufacturer for the main performance data of the product, and understand the data value for reference when choosing. But maybe customers are not clear about what the values represent, or some new customers don’t quite understand the meaning of these data. Therefore, most customers will consult us about the meaning of each indicator data of ceramic fiber.

What are insulation materials and refractory materials?

Conventionally speaking, a class of inorganic non-metallic materials with refractoriness not lower than 1580°C is a refractory material. Traditional refractory materials generally refer to heavy refractory bricks, castables, etc. The bulk density is generally 1000-2000kg/m3.

The advantages of ceramic fibers are obvious. On the premise of excellent thermal insulation performance, it also has good fire resistance and is a lightweight material. For reducing the load of the furnace body, the large amount of steel consumed in traditional installations due to supporting heavy materials is greatly reduced.

Ceramic Fiber Insulation Aluminum Silicate Fiber Blanket

Heating Linear Shrink

It is an index to evaluate the heat resistance (use temperature) performance of ceramic fiber products. The international uniform regulations stipulate that ceramic fiber products are heated to a certain temperature under no load, and the high-temperature linear shrinkage rate of 24 hours of heat preservation indicates the heat resistance of ceramic fibers.

The test temperature at which the shrinkage rate of the heating wire is ≤3% is the continuous use temperature of the ceramic fiber product. At this temperature, the amorphous ceramic fiber crystallizes, the grain growth rate is slow, and the fiber performance is stable and elastic.

The test temperature at which the shrinkage rate of the heating wire is ≤4% is the service temperature of the ceramic fiber product.

Thermal Conductivity

Thermal conductivity is a physical property of a substance and an index to characterize the thermal insulation performance of ceramic fibers.

It depends on the structure of ceramic fiber products, bulk density, temperature, furnace atmosphere, humidity, and other factors.

Ceramic fiber is a mixed structure composed of solid fibers and air, and its porosity reaches 93%. A large amount of air with low thermal conductivity fills the pores and destroys the continuous network structure of solid molecules, thereby obtaining excellent thermal insulation performance. And the smaller the diameter of the pores, the more the number of pores divided into closed states by the solid fibers along the direction of heat flow, and the better the thermal insulation performance of the ceramic fibers.

Effect of Chemical Composition

The chemical composition directly determines the heat resistance of the fiber:

• (1) Al2O3, SiO2, ZrO2, Cr2O3 and other active ingredients ≥ 99%. The high-temperature oxide content directly determines the performance of ceramic fibers.
• (2) Fe2O3, Na2O, K2O, MgO, and other impurities are less than 1%, which are harmful impurities and directly lead to the deterioration of the performance of ceramic fibers.

Ceramic Fiber Cloth

Factors Affecting the Performance of Ceramic Fiber Cloth

Ceramic fiber cloth is made of ceramic fiber plus a certain proportion of organic fiber, lined with glass wire (steel wire), spun into yarn, and then woven into cloth. What is the effect of each additive on the performance of ceramic fiber cloth?

1. The content of organic fiber determines the ablation rate of ceramic fiber cloth.
2. The type of organic fiber determines the flexibility of ceramic fiber cloth. Commonly used organic fibers include viscose, polyester, pulp, etc. Among them, viscose is better than polyester, and polyester is better than pulp.
3. Reinforcing fiber, the diameter of glass fiber determines the tensile strength of ceramic fiber cloth.
4. Reinforcing fiber, the material of heat-resistant stainless steel wire determines the corrosion resistance of ceramic fiber cloth (304 stainless steel wire > 302 stainless steel wire > 201 stainless steel wire > iron wire). Responsible manufacturers of ceramic fiber cloth use high-quality organic fiber viscose, glass fiber with reasonable fiber diameter, or 304 heat-resistant stainless steel wire to produce high-quality ceramic fiber cloth. Commonly used in high-temperature furnaces, it has a long service life and strong wear and corrosion resistance.
5. The degree of twist in the weaving process determines the smoothness of the appearance of ceramic fiber cloth.
6. The quantity of the previous batch determines the bulk density of the ceramic fiber cloth.

Rongsheng manufacturers focus on the production and application of ceramic fiber cloth and refractory fiber cloth, thermal insulation solutions, and materials. If you are looking for more high-quality insulation materials for high-temperature industrial furnaces, please contact us, at sales@refractoriesmaterials.com. Our new type of insulation material product has low thermal conductivity, almost zero shrinkage, and is not easy to deform. It can effectively improve the utilization rate of energy and save production costs.

The Option to Purchase High Temp Castable Refractory

As a kind of integral lining material that is convenient for construction and maintenance, refractory castable is used more and more in high-temperature industrial kilns and thermal equipment. There are many kinds of refractory castable, and the choice of buying high temp castable refractory, Rongsheng castable refractory suppliers reminds enterprises buying refractory castable engineering for refractory castable engineering that they must choose a reasonable price. Strong manufacturer of refractory castable and castable refractory concrete.

There are many kinds of high temp castable refractory. For example, the casting construction of clay, high aluminum, corundum, magnesium, magnesium aluminum spinel, low cement castable, and so on. Coating construction of refractory paste, refractory plastic. Spray coating, spray material, spray repair material, and so on. As for the price of castable refractory concrete of the same material, different castable refractory suppliers give different prices. This is mainly based on the raw materials purchased by the manufacturer and production equipment, the configuration process is different. I believe that every buyer will have such concerns, the high price of castable to consider again and again, the low price of the outrageous, and doubt the quality of the procurement, the price is appropriate also want to further understand the performance of more products, to see if it can be reduced. So what is the appropriate choice to buy high temp castable refractory?

Rongsheng Refractory Castables Factory

First, understand the working environment of castable refractory concrete. Refractory castable is a kind of refractory material for high-temperature industries, and its working environment cannot be separated from high temperature. The working conditions of different parts of a high-temperature kiln are different, and the refractory castables used are different. Usually, the lining structure is mainly composed of a thermal insulation layer, a permanent layer, and a working layer. The insulation layer is heat insulation castable or heat insulation refractory, aluminum silicate fiber blanket. Mainly heat insulation, and reduce energy consumption. The permanent layer is the material that protects the thermal insulation layer, and the performance is slightly worse than that of the working layer material. When the working layer material wears out, there is a permanent layer of material to resist high temperatures and protect the insulation material and the furnace shell. The working layer is mainly the part that contacts various high-temperature liquids, slag, and materials and is also the main damaged part. Usually, the maintenance of the lining is mainly to repair the working layer material and extend the service life of the lining.

Due to the need for regular inspection and maintenance of working layer refractories, extra care should be taken when choosing castable refractory concrete. Different parts of the use of castables are different, to meet the main cause of damage. Such as refractory castable for the top of the heating furnace, must first meet the requirements of high-temperature structural strength and high-temperature gas erosion resistance. The main characteristic of slag resistance should be satisfied with the refractory castable used in the slag line of the iron discharge groove of a blast furnace. In intermittent operation, where the temperature changes frequently, the characteristics of thermal shock resistance should be met. It is necessary to select high strength and anti-penetration for refractory castable at the bottom of the molten aluminum furnace. Refractory castables are subjected to various high-temperature forces, friction, and chemical erosion of slag, solids, and dust airflow during high-temperature use. Therefore, appropriate refractory castables should be selected according to different working environments.

Refractory Castable for High-Temperature Industrial Furnace Lining

high temp castable refractory working environment is complex and refractory. Some temperatures change frequently, there are high-temperature sections, low-temperature sections, charge washing, and so on. All kinds of chemical erosion. Due to the different nature of chemical erosion, the main atmosphere of the high-temperature industrial furnace lining is the acidic atmosphere, acid-base atmosphere, an alkaline atmosphere. Different working atmospheres and the use of refractory castables are different. Siliceous refractory castable is used for parts with severe acid erosion. High aluminum or corundum refractory castables are selected for acid and alkali attacks. Magnesium refractory castable is selected for alkaline attack.

refractory castable engineering uses suitable refractory castable as lining due to different working temperatures. If the use temperature is about 1000℃, clay castable is used. High aluminum castable is selected at 1200-1450℃. The use temperature is 1500-1650℃ to select corundum refractory castable.

After determining the material and performance of castable refractory concrete, the price should be selected. With high quality, low price, and long service life as the standard. As long as it can meet the requirements of the working condition, it is not necessary to use a high-grade or a low-grade castable. Choose castable with sufficient supply and stable price, do not choose castable with a shortage or large fluctuation of raw material price. Choose castable refractory suppliers be sure to buy from the castable manufacturers and not buy from middlemen to avoid additional cost increases.

Refractory Castable Lining

Rongsheng castable refractory suppliers are reminded that since the shelf life of refractory castable is about 3-6 months, improper storage is easy to cause castable and binder to agglomerate, which affects the performance. Therefore, be sure to check the product quality before use. In order to avoid the occurrence of refractory castable caking, affecting the use of performance, castable manufacturers are customized according to the user’s working conditions, there is no spot storage, on the same day of product delivery. The refractory castable products of Rongsheng manufacturers have reliable quality and can effectively extend the service life of the refractory lining. You can compare it with Vesuvius castable refractory. refractory castable refractory suppliers not only provide high-quality products but also sound customer service and refractory castable engineering design and construction.

How Often Should Fire Bricks be Replaced in Industrial Furnaces?

When it comes to industrial furnaces, fire bricks are an essential component that is critical for maintaining high temperatures and protecting the furnace from damage. Fire bricks are made from refractory ceramic materials that can withstand extreme heat, thermal cycling, and exposure to chemicals. There are generally types of refractory bricks for industrial furnaces, alumina silicate fire brick, alumina silica fire brick, alumina-silica brick, alumina fire brick, silica fire brick, magnesia bricks, graphite carbon bricks, chrome bricks, corundum bricks, etc. However, over time, fire bricks can become worn or damaged, leading to reduced performance and potentially dangerous operating conditions. This article will explore how often fire bricks should be replaced in industrial furnaces and why this is so important.

Rongsheng Alumina Bricks for Industrial Furnaces

The lifespan of fire bricks in industrial furnaces can vary depending on several factors, such as the temperature they are exposed to, the frequency of use, and the quality of the bricks. In general, well-made fire bricks can last for several years or even decades, with proper use and maintenance. However, the lifespan of fire bricks in industrial furnaces can be much shorter than those in residential heating appliances due to the high temperatures and frequent use of industrial furnaces.

As a general rule of thumb, fire bricks in industrial furnaces should be inspected regularly and replaced every 3 to 5 years, or when there is visible damage or wear. This is because industrial furnaces are typically operated at much higher temperatures than residential heating appliances, frequently shutdown and start-up of the furnace expose the refractory brick lining of the industrial furnace to high temperatures and temperature drop, which can cause the fire bricks to erode or crack more quickly.

The working conditions in high-temperature industrial furnaces contain many aggressive substances. There is also the erosion of various burning materials, the erosion of hot air, etc. In addition to regular inspections, it’s essential to take proper care of your fire bricks to ensure they last as long as possible. This includes avoiding sudden temperature changes, which can cause thermal shock and damage the fire bricks. It’s also important to follow the manufacturer’s guidelines for maintenance and replacement to ensure optimal performance and safety.

There are several signs to look out for that may indicate it’s time to replace your fire bricks. These include visible cracks, chips, or erosion of the brick surface, reduced heating efficiency, or unstable temperature control. If you notice any of these signs, it’s important to replace the fire bricks as soon as possible to avoid further damage to the furnace and ensure safe and efficient operation.

In conclusion, fire bricks are a critical component of industrial furnaces that protect against high temperatures and prevent damage to the furnace. While fire bricks can last for several years, regular inspections and replacements are necessary to ensure optimal performance and safety. By following manufacturer guidelines and taking proper care of your fire bricks, you can extend their lifespan and ensure that your industrial furnace operates safely and efficiently. Rongsheng Refractory Bricks Manufacturer can provide refractory bricks for furnace linings and also technical guidance and after-sales customer service.

Tips for Choosing the Right AZS Bricks for Your Glass Furnace

When it comes to constructing a glass furnace, one of the most important decisions is choosing the right AZS bricks. AZS bricks are made of alumina, zirconia, and silica, which make them highly resistant to thermal shock and corrosion, making them the perfect material for use in the harsh conditions of a glass furnace. However, not all AZS bricks are created equal, and choosing the wrong ones can lead to costly mistakes. In this article, we’ll share some tips for choosing the right AZS bricks for your glass furnace.

AZS Bricks for Your Glass Furnace

Know your furnace’s operating conditions

The first step in choosing the right AZS bricks is to understand the operating conditions of your furnace. This includes the temperature range, the type of glass being produced, and the chemical environment. Different types of AZS bricks are designed for different operating conditions, so it’s important to choose the right ones that can withstand the specific conditions of your furnace.

Consider the composition of the AZS bricks

AZS bricks come in different compositions, each with different ratios of alumina, zirconia, and silica. The composition of the bricks can affect their performance in the furnace, so it’s important to choose the right composition for your specific needs. For example, if you’re producing soda-lime glass, you’ll need bricks with a higher silica content to withstand the corrosive effects of sodium oxide.

Choose the right shape and size

The shape and size of the AZS bricks can also impact their performance in the furnace. The bricks should be designed to fit snugly together, without any gaps or spaces that can allow heat to escape. They should also be easy to install and remove so that maintenance and repairs can be done quickly and efficiently.

Consider the quality of the AZS bricks

Not all AZS bricks are created equal, and the quality of the bricks can vary depending on the manufacturer. It’s important to choose a reputable manufacturer that uses high-quality materials and has a proven track record of producing reliable and durable bricks. Choosing a low-quality brick can lead to premature failure, which can be costly and dangerous.

Consult with experts

If you’re not sure which AZS bricks are right for your furnace, it’s a good idea to consult with experts in the field. Glass furnace manufacturers, engineers, and other professionals can provide valuable insights and advice on choosing the right bricks for your specific needs. They can also help you with installation, maintenance, and repairs, to ensure that your furnace operates safely and efficiently.

In conclusion, choosing the right AZS bricks is a critical decision that can impact the performance and safety of your glass furnace. By understanding your furnace’s operating conditions, considering the composition of the bricks, choosing the right shape and size, selecting high-quality bricks, and consulting with experts, you can ensure that your furnace operates at its best, with minimal downtime and maintenance.

Comparing Plastic Refractory to Other Refractory Materials for Boiler Maintenance

Refractory materials play a critical role in the build and maintenance of boilers. They help protect the boiler’s interior walls from the high temperatures and corrosive environments that are produced during combustion. While there are several types of refractory materials used in boilers, plastic refractory is gaining popularity due to its unique properties. Rongsheng monolithic refractory manufacturer, providing high-quality plastic refractory for boilers. Moreover, according to the customer’s furnace type and usage requirements, it provides turnkey projects of monolithic refractory plastics and solutions for custom refractory linings. In this article, we will compare plastic refractory to other refractory materials used in boiler maintenance and explain why plastic refractories may be the best choice for your needs.

RS High-Quality Plastic Refractory

Types of Refractory Materials Used in Boilers

The most common types of refractory materials used in boilers are fire clay, high alumina, and silicon carbide. Fire clay is the least expensive of the three and is often used for low-temperature applications. High alumina is more expensive but can withstand higher temperatures than fire clay. Silicon carbide is the most expensive but also the most durable and can withstand the most extreme temperatures. While each material has its advantages and disadvantages, it’s important to consider your specific boiler’s needs when selecting the appropriate refractory material.

Factors to Consider When Choosing a Refractory Material

When choosing a refractory material for boiler maintenance, several factors should be considered. These factors include the operating temperature of the boiler, the presence of corrosive chemicals, the mechanical stresses the material will experience, and the ease of installation. Each of these factors can affect the performance of the refractory material and its overall lifespan. By taking these factors into account, you can select the most appropriate material for your specific boiler and ensure it is properly maintained over time.

Corundum Silicon Carbide Wear Resistant Refractory Plastic

Advantages of Plastic Refractory Materials for Boiler Maintenance

Plastic refractory is a type of castable refractory material that is composed of high-alumina cement and graded refractory aggregates. The material has a plastic consistency, which allows it to be molded and shaped to fit the unique contours of the boiler. This makes it easy to install, even in hard-to-reach areas. Plastic refractory also has excellent thermal shock resistance and insulating properties, which help protect the boiler from sudden temperature changes and improve its energy efficiency. Furthermore, plastic refractory has a higher density and strength than other refractory materials, which makes it more durable and long-lasting. Rongsheng plastic refractories have high performance. It provides a reliable guarantee in prolonging the service life of boiler refractory lining and saving production energy consumption.

Applications of Plastic Refractory in Boiler Maintenance

Plastic refractory can be used in a variety of applications for boiler maintenance. For instance, it is commonly used to repair the furnace lining, which can become worn and cracked over time due to exposure to high temperatures. Plastic refractory is also used to create burner blocks, which help regulate the temperature and airflow in the boiler. Additionally, plastic refractories can be used to repair the doors of the boiler, which can become damaged due to thermal stress or mechanical wear and tear. By using plastic refractory for these applications, you can improve the boiler’s performance, extend its lifespan, and reduce the frequency of maintenance.

In conclusion, plastic refractory is an excellent choice for boiler maintenance due to its unique properties and the numerous benefits it offers. While other refractory materials are available, each has its own strengths and weaknesses that should be carefully considered. Ultimately, the most appropriate material for your boiler will depend on a range of factors, including the operating temperature, corrosive chemicals, mechanical stresses, and ease of installation. By choosing the right material and properly maintaining your boiler over time, you can ensure that it operates at optimal efficiency and lasts for years to come.

Rongsheng monolithic refractory materials Manufacturer

In conclusion, plastic refractory is an excellent choice for boiler maintenance due to its ease of installation, excellent thermal shock resistance, and insulating properties. While there are other refractory materials available, each has its own strengths and weaknesses. It’s important to carefully consider your specific boiler’s needs and the demands of your environment when selecting the appropriate refractory material. Rongsheng monolithic refractory materials Manufacturer reminding, by choosing plastic refractories, you can enjoy improved efficiency, durability, and reduced maintenance costs in the long run.

Why do low cement castables add less water?

Low cement castables are divided into low cement castables, ultra-low cement castables, and cementless castables according to the calcium oxide content. Due to the low water content of low-cement castables, low-cement castables combine the advantages of various refractory castables and have the characteristics of high density, low porosity, high strength, low wear, thermal shock resistance, and erosion resistance. At the same time, it also has the characteristics of strong volume stability and low construction water consumption. Its performance is comparable to that of fired refractory bricks of the same material. According to Ronghseng Refractory, it is widely used in high-temperature fields such as ironmaking, steelmaking, steel rolling, and building materials.

Rongsheng Low Cement Castable for Sale

Low cement castables can be called high-tech refractory castables, high-performance refractory castables, dense high-strength refractory castables, low-porosity refractory castables, and low-moisture refractory castables according to their performance characteristics. According to its users, it is divided into blast furnace tapping through refractory castables and steelmaking ladle refractory castables. According to its material varieties, it is divided into aluminum silicate, mullite, corundum, spinel low cement castables, etc.

Reasons for adding less water to low cement castables

By comparing the performance of traditional refractory castables and low-cement refractory castables with the same amount of water added, Rongsheng unshaped refractory castable manufacturers analyzed that the reasons for the low water addition of low-cement castables as follows.

Low cement series refractory castables are compared with traditional aluminate cement refractory castables. The amount of cement in aluminate cement refractory castables is generally 12%-30%, and the amount of water added during construction is 9%-13%. Due to the high amount of water added, the castable has many pores and low strength. Due to a large amount of cement used, high enough room temperature strength can be obtained, but the crystal form of calcium aluminate changes at medium temperature, resulting in a significant decrease in strength. And ≥3% CaO reacts with SO2 and A2O3 in the material to form low-melting anorthite (CAS2) or calcium-aluminum-feldspar (C2AS), resulting in a decrease in high-temperature strength and erosion resistance.

When using ultra-fine powder technology, high-efficiency admixtures, and scientific particle grading, the cement content of the castable is reduced to less than 8%, and the water consumption is reduced to ≤7%. The CaO content brought in is less than or equal to 2.5%, and its performance indicators generally exceed aluminate cement refractory castables. Because the amount of cement is low, it is called low cement refractory castable. It should be pointed out that the cement content of clay-bonded refractory castables is generally < 4%, and the water content is ≤ 11%. When reducing or not combining clay and using ultrafine powder technology and high-efficiency admixtures, it can be made into low-cement refractory castables. Therefore, refractory manufacturers (https://refractoriesmaterials.com/) believe that low cement refractory castables are developed on the basis of clay combined with refractory castables. Its performance is better than that of clay refractory castables.

In addition, this type of refractory castable has good thixotropy. That is, the mixture has a certain shape, and it will start to flow with a little external force. When the external force is released, the obtained shape will be maintained, so it is also called thixotropic refractory castable. Self-flowing refractory castables also fall into this category.

Almost all CaO in low cement refractory castables comes from cement binders. Limiting the amount of aluminate cement and reducing the amount of water added can effectively improve its high-temperature performance. The types of low cement castables and their CaO content are respectively, the CaO content of traditional refractory castables is >2.5%; the CaO content of low-cement castables is 1.0%-2.5%, the CaO content of ultra-low cement castables is 0.2%-1.0%; the CaO content of cement-free castables is <0.2%.

Due to the relatively fine particle gradation of low-cement castables, the gaps between particles are filled with ultrafine powder. Therefore, the amount of water added can be reduced to about 4%-7%, the structure is dense, the porosity is low, the strength is high, and wear resistance and corrosion resistance. The dense low-cement castable improves the high-temperature performance but also brings inconvenience to the baking aspect, and if the baking is improper, it is easy to cause peeling or bursting. Therefore, explosion-proof fiber materials must be added to low-ratio cement castables and a reasonable baking curve must be established. Only in this way can the water in the pouring liner be discharged hydraulically without affecting the quality.

For more information about low-cement castables and construction instructions, please contact monolithic refractory manufacturers.

Customized mullite insulation brick, lightweight insulation brick

Mullite series lightweight bricks are new high-quality heat-insulating refractory materials containing Al2O2 50% ~ 85%, with mullite (3Al2O3 2SiO2) as the main crystal phase and binding phase. Because mullite has excellent high-temperature mechanical properties and chemical stability, mullite-based lightweight bricks have high high-temperature structural strength, low high-temperature creep rate, small thermal expansion coefficient, strong chemical corrosion resistance, and good thermal shock resistance. Generation of good performance. It can be used as the lining of the working face of the kiln in direct contact with the flame, which can significantly improve the energy-saving effect of the kiln. The use temperature of the mullite series of lightweight bricks ranges from 1350°C to 1700°C according to the alumina content and bulk density of the product. Rongsheng refractory manufacturers provide customized mullite insulation bricks and lightweight insulation bricks. A free consultation is welcome.

Rongsheng Mullite Series Lightweight Bricks

What kinds of mullite insulation bricks are there?

Classification of mullite insulation bricks. Mullite insulation bricks are mainly divided into light and heavy mullite bricks according to different densities. According to different use temperatures, it is mainly divided into 1350 mullite bricks, 1450 mullite bricks, 1550 mullite bricks, etc.

Properties and application of mullite thermal insulation bricks

High-temperature mullite insulation brick. The product is white in color, high in use temperature, small in thermal conductivity, and low in re-burning line change rate. The application of this material can reduce the masonry volume of thermal equipment, reduce weight, shorten heating time, ensure uniform rate and temperature, reduce heat loss, save energy and improve operating conditions. Thereby improving production efficiency. It is a very superior furnace lining material between dense refractory materials and traditional heat-insulating refractory materials.

High fire resistance, up to 1790 ℃ or more. The starting temperature of load softening is 1600~1700℃. The room temperature compressive strength is 70~260mpa. Good heat resistance and seismic performance. There are two types of sintered mullite bricks and fused mullite bricks. Sintered mullite bricks use high bauxite clinker as the main raw material, add a small amount of clay or raw earth ore as a combination agent, and sinter after molding.

Fused mullite bricks are made of high earth ore, industrial alumina, and refractory clay, and charcoal or coke particles are added as reducing agents. The crystallinity of fused mullite is larger than that of sintered mullite, and its heat resistance is better than that of sintered products. Its high-temperature performance mainly depends on the alumina content and the homogeneity of the mullite phase and glass distribution. Mainly used for hot blast stove top, blast furnace body and bottom, glass furnace regenerator, ceramic sintering kiln, dead angle lining of petroleum cracking system, etc.

Contact Rongsheng refractory manufacturers to customize mullite insulation bricks and lightweight insulation bricks.

Why can’t high alumina bricks be used for lining in alkaline corrosive atmosphere?

The alkali, acid and chlorine content of the lining of the alkaline atmosphere will penetrate deeply into the high alumina brick. The use cycle is short, so in an alkaline atmosphere, generally do not use high-alumina bricks as linings.

The erosion of the alkaline atmosphere will cause multiple transverse cracks in the high-alumina brick, and loose foam will appear on the surface of the high-alumina brick to the thickness of 0-10mm. It will also cause the bricks to expand, and the alkaline components are deposited on the surface of the high-alumina bricks. The hot side of high alumina bricks, that is, the use side will be more seriously eroded than the cold side. If the use surface is seriously eroded, it will inevitably shorten the service life of the high-alumina brick.

Moreover, the content of silica in high-alumina bricks is higher than that of alkaline bricks. The excessive liquid phase deforms the brick and reduces its strength. The presence of free silica in bricks can make bricks more at risk of damage.

High-Alumina Refractory Bricks

Once the free silica in the high alumina brick is exhausted, the internal crystal phase will be more severely eroded. At the same time, the thenardite and mullite in the brick will react directly to form zoisite, which will further cause destructive expansion, and the use of high-alumina bricks in the alkaline atmosphere may cause the lining to collapse suddenly.

High-alumina bricks are refractory-shaped products of neutral boundary quality and are generally used in a neutral atmosphere. If used in an alkaline atmosphere, an alkali attack will cause the brick lining to expand and reduce its strength. When the indicators are reduced, the internal changes in the bricks will occur. After the internal change, the peeling of the brick lining will occur and even the lining will suddenly collapse, causing the furnace lining to not be used normally.

Therefore, do not use high-alumina bricks for alkaline corrosive atmosphere linings. The selection of alkaline refractory bricks is consistent with the alkaline atmosphere, the atmosphere is uniform, and the alkaline-resistant refractory bricks have a long service life, reducing the frequency of changing the lining and reducing the production investment.

What effect does the thickness of high alumina brick masonry have on the furnace lining?

High-alumina bricks are used within the temperature range that they can withstand, and are not easy to be damaged and melted. It can also protect the furnace shell well. The masonry thickness of high alumina bricks will also have a great impact on the furnace lining.

Although the thicker the masonry of high alumina bricks, the slower the heat source spreads. But too thick is not scientific. A reasonable thickness of high alumina bricks will prolong the service life of the furnace lining. If it is used in high-alumina bricks for the lining of rotary kilns, the thickness is generally between 220-250mm, because too thin thickness will reduce the service cycle, and too thick will lead to a small kiln diameter and low output. Not only increases the weight of the kiln body. In addition, the phenomenon of squeezing out high alumina bricks will also occur, affecting normal operation.

If the high alumina brick is used as a permanent layer at the bottom of the calcium carbide furnace, under normal circumstances, six layers of bricks with a thickness of 75mm should be used. If you use too much, it will also affect the output of the calcium carbide furnace. If the number of layers used for high alumina bricks is reduced, it will also affect the service cycle. If the high alumina brick is used in the furnace wall of the calcium carbide furnace, it is also a reasonable thickness of 345mm. If it is too thick, it will affect the yield, and if it is too thin, it will also affect the life cycle.

If high-alumina bricks are used in hot blast stoves or large walls of blast furnaces, a reasonable thickness is the best choice. Used in the working layer, except the insulation layer, the thickness of the wall lining of the hot blast stove and the blast furnace is generally 345mm. Not too thick, not too thin.

If the high alumina brick is used in the waste incinerator, the thickness is about 230mm. If the thickness is 65mm, the service cycle will be replaced quickly due to wear resistance or erosion, delaying normal use. Reasonable thickness is the best choice.

If it is some furnace lining with low temperature, the temperature is lower than 1200℃, it can also use 114mm or 65mm thick. It still depends on the temperature and aggressiveness of the lining.

In short, no matter what type of furnace lining uses high-alumina bricks, it depends on the actual use situation and cannot be generalized. A reasonable thickness of high alumina bricks will prolong the service life of the furnace lining.

High-Alumina Low Cement Castable Alkaline Resistance Cement Kiln

Low-cement series refractory castables refer to castable refractories with calcium aluminate cement addition of less than 8%. It requires that the CaO content in the castable is less than 2.5%. Its main varieties are low cement (CaO content 1%~2.5%), ultra-low cement (CaO content less than 1%), and no cement (CaO content less than or equal to 0.2%) refractory castables. Low cement series refractory castables have the characteristics of high density, low porosity, high strength, low wear, thermal shock resistance, and corrosion resistance. At the same time, it also has the characteristics of strong volume stability and low construction water consumption. High-Alumina Low Cement Castable Alkaline Resistance Cement Kiln. high alumina castable, According to its material varieties, it can be divided into aluminum silicate, mullite, corundum, magnesia aluminum, spinel, carbon and silicon carbide, and other low cement series refractory castables. According to its users, it can be divided into refractory castable for blast furnace tap ditch and refractory castable for steel ladle.

Low Cement Castable Alkaline Resistance Cement Kiln

High-Alumina Low Cement Castable Alkaline Resistance, this castable should be called “alkali-resistant high-alumina low-cement refractory castable” according to its characteristics and chemical composition. It is prepared by adjusting and controlling the composition of the matrix. It is a kind of high-aluminum refractory castable with high mechanical strength and excellent performance of alkali corrosion resistance and a maximum service temperature of 1500 °C. It is suitable for some large dry-process cement kilns with high alkali, sulfur, and chlorine content in the raw materials and fuels used in cement production. For example, it is used in the hot end of the kiln door cover cooler, the rear of the coal injection pipe, the door of small and medium-sized kilns, and the elbow of the multi-cylinder cooler. https://refractoriesmaterials.com/high-alumina-castable/.

Application of High Alumina Low Cement Refractory Castable in the Parts of Cement Kiln

High-strength refractory castable is based on fused white corundum as aggregate and pure calcium aluminate cement as a binder. The maximum operating temperature of this castable reaches 1800°C. The thermal flexural strength at 1400 °C reaches 7.4 MPa, and it also has good wear resistance at high temperatures. It is suitable for use in the front kiln mouth, three air duct coal injection nozzles, and other parts of the new dry process cement kiln.

In addition, there is another brand of castable that also uses fused white corundum as the aggregate, which is a refractory castable with low cement consumption. The castable has high mechanical strength, erosion resistance, and abrasion resistance. The maximum operating temperature is 1600°C. Due to its own properties, this castable is suitable for use in 1000-1400 ℃, large-scale cement kiln mouth, multi-cylinder cooler elbow, and other parts with severe impact and abrasion.

Another castable of Rongsheng Company is also a low-cement refractory castable. It is prepared based on high alumina sintered bauxite clinker as aggregate and pure calcium aluminate cement as a binder. It is suitable for the kiln mouth of small and medium-sized dry process cement kilns and the elbow of the cooling machine.

Solve some prominent problems in the use of unshaped refractories in large new dry process cement kilns. Obtain a more suitable configuration scheme of unshaped refractory castables. High alumina Castables, High-quality High-Alumina Low Cement Castable Alkaline Resistance Cement Kiln. Please visit the website and leave your specific needs on the page.

Performance Requirements of High-Quality Silica Bricks on Glass Kiln Roof

According to the analysis of the corrosion mechanism of silica bricks on the glass kiln roof, it can be seen that the large glass kiln roof should meet the following requirements.

1. It has strong corrosion resistance. In particular, it is resistant to the corrosion of alkaline gases and SO3 and NOx gases in flying materials and oil fume.
2. The high-temperature mechanical properties are better. The temperature of the high-temperature gas in the glass molten pool can reach above 1615°C. The dome top bears gravity, mechanical stress, and high-temperature load, and requires good high-temperature strength.
3. Good volume stability at high temperature. The volume change of the dome at high temperature directly leads to the deformation and destruction of the dome, or even collapse.
4. High masonry quality requirements, balanced mortar joints, and good integrity.

Silica Refractory Bricks for Sale from RS Factory

According to the basic requirements of the glass kiln roof, specifically, high-quality silica bricks (https://refractoriesmaterials.com/silica-bricks/) should have good performance in the following aspects.

1. High purity and compactness. The content of SiO2 is greater than 96%, the flux index (Al2O+2R2O) is less than 0.5%, and the content of Fe2O3 is less than 0.5%. The bulk density should be greater than 1.9g/cm3, and the porosity should be less than 20%.
2. The load softening temperature is high, under the load condition of 0.2MPa, it should be above 1690℃.
3. Low reheating line change, less than 0.2% under the condition of 1500℃×2h.
4. High temperature creep resistance is good, should be less than 0.8% under the condition of 1550℃×50h.
5. The compressive strength at room temperature is greater than 65MPa.
6. Reasonable mineral facies composition. The cristobalite content is greater than 50%, the tridymite content is between 40-50%, the residual quartz content is less than 1%, and the silicate glass phase is less than 3%.
7. The true density is less than 2.34g/cm3.
8. The size is accurate.

Brick Size	Dimensional Tolerance
≤100mm	≤土1.0mm
100- 300mm	≤土2.0mm
≥:300mm	≤土3.0mm