Particle Size Gradation of Alumina-Based Low-Cement Castables

To optimize the particle packing of the castable, different types of aluminum oxide micropowders can be used to form the matrix. These include calcined, semi-reactive, unimodal, or multimodal alumina micropowders. Effect of specific particle size distribution (PSD) of various alumina micropowders on low cement castable properties. And compare the addition of different types of water-reducing agents to understand their impact on the finished castables.

Rongsheng Low Cement Castable

Selection of Aluminum Oxide Powder

The alumina micropowders used in the test include calcined alumina micropowder, bimodal activated alumina micropowder, and single-modal activated alumina micropowder. The test was conducted using low-cement castables with tabular corundum as aggregate, and the castable formula was optimized using the particle gradation models of DINGE and FUNK. The constant coefficient is set to 0.27. The first series studies the application of 3um calcined alumina products, which are divided into castables without silica fume and castables containing silica fume. In the second series, 3um calcined alumina and different proportions of unimodal activated alumina are added as the matrix to achieve bimodal alumina performance. The final series examines the effect of bimodal alumina on the particle size distribution in low-cement castables. When the amount of water added in each series is constant, the construction performance, fluidity, cold flexural strength, and load softening temperature of the castables are measured.

The Influence of Aluminum Oxide Powder on Castables

Research shows that not only the d50 of alumina micro-powder but also its particle size distribution curve is crucial to optimizing the rheological properties of alumina-based low-cement castables. By adjusting the shape of its particle size curve, the possibility of using 3um calcined alumina to have suitable flowability in many castables increases. In applications that require lower water additions, the calcined product can be compounded with single-modal active oxidation micron powder to achieve the desired particle filling optimization. For bimodal alumina, controlling the particle size distribution, with the presence of very fine particles in d10 and good top cut in d90, can increase flowability, reduce mixing time, and improve physical properties. In addition to the particle size distribution of alumina, additives play an important role. There are differences from one alumina to another, and additives should be selected and adjusted according to the type of alumina.

High-Alumina Castables Refractory for Sale

60 Refractory Castable GL60 High Aluminum Refractory Castable Boiler Hot Blast Stove Refractory Castable

Refractory castables made of high-aluminum raw materials as aggregates and powders, and adding binders. It has high mechanical strength and good thermal shock resistance and abrasion resistance. It is mainly used as the lining of boilers, blast furnaces, heating furnaces, ceramic kilns, and other kilns.

GL60 high-aluminum refractory castable is synthesized from high-aluminum refractory aggregates, powders, binders, and admixtures in proportions. It has the characteristics of good high-temperature performance, high durability, wide operating temperature, and no shrinkage or damage. It is widely used in hardware, smelting, chemical industry, non-ferrous metals, and other industries, especially in the steel industry. Mainly used in rotary kiln front kiln mouth, dismantling furnace, kiln head cover, and other parts. High aluminum castables are divided into conventional and low steel types and steel types.

60 refractory castable, boiler hot blast stove refractory castable, is a refractory castable made of high alumina bauxite clinker as aggregate and powder, adding binder and dispersant. The integral lining material can be poured directly or refractory prefabricated parts can be spliced together.

RS refractory material manufacturer has an environmentally friendly, fully automatic unshaped refractory material production line. Our refractory products have been sold to more than 100 countries around the world. The product quality is reliable, and the formula of refractory materials can be customized according to the customer’s actual working conditions. For product packaging, we use 25kg/bag or 50kg/bag woven bags according to user needs and then use ton bags. Contact us for a free refractory lining solution and quote.

Do You Know the Difference between High Alumina Bricks and High Alumina Castables?

High alumina bricks and high alumina castables are both commonly used refractory materials and can be used in the construction of high-temperature industrial kilns. The common feature of both of them is that they contain a large amount of Al2O3 in their composition, and both of them can resist high-temperature erosion. But the difference between the two is still very big. So what are the differences between high alumina bricks and high alumina castables? As an experienced refractory material manufacturer, Rongsheng Refractory Materials Manufacturer has accumulated rich experience in high alumina bricks and high alumina castables.

High Alumina Bricks Lining

The Difference between High Alumina Bricks and High Alumina Castables

1. Different forms

High alumina bricks are shaped refractory materials. It has a fixed shape and size. The general standard refractory brick size is 230*114*65mm. High aluminum castables are unshaped refractory materials. It has no fixed shape, generally exists in powder form, and is usually stored in bags.

2. Different production methods

The main production method of high alumina bricks is to form the well-proportioned raw materials through high pressure and then sinter them at high temperatures to form a fixed shape. The production method of high-aluminum castables eliminates the need for high-temperature sintering and high-pressure molding. It is directly bagged after the raw materials are proportioned.

3. Different construction methods

High alumina bricks can be used directly during construction, and usually need to be used with high-temperature cement during use. High-aluminum castables need to be stirred by adding water, then poured into a fixed mold, and then air-dried and shaped. After finalization, the entire kiln needs to be baked before it can be put into use.

High Alumina Castable Lining

The difference between high alumina bricks and high alumina castables. Among them, the biggest difference between the two is still in the form, one is in a fixed shape and the other is in powder form. Although both can be used as masonry for kilns, for some occasions with special shapes and difficult construction, the construction difficulty of castables is obviously lower than that of high alumina bricks.

How to Choose High Aluminum Castables?

We all know that high-aluminum castable is a refractory castable with relatively high alumina content. It is widely used in the construction of high-temperature kilns. It has the characteristics of superior fire resistance, high-temperature resistance, corrosion resistance, and oxidation resistance. Therefore, the range and frequency of use are very high. But it is very important for us to choose good high-aluminum castables when purchasing. Its quality determines the service life of the high-temperature kiln and the quality of the materials smelted during use.

First of all, we need to know that high-aluminum castables are composed of aluminates, silicates, oxides, etc. In order to ensure the effect in a high-temperature environment, we must strictly follow the requirements when proportioning raw materials. Incorrect raw material ratio will seriously affect the performance of the entire castable. Therefore, we need to confirm with the manufacturer’s technical personnel when purchasing and inform the technical personnel according to the occasion of use. Technicians will provide you with a variety of options based on your usage situation.

How to Choose High-Aluminum Castables

Secondly, we mainly look at the following aspects that affect the quality of high-aluminum castables during use. Including compressive strength, thermal stability, thermal conductivity, thermal expansion coefficient, etc. The testing agencies of these manufacturers will issue reports when they submit them for inspection, so we must ask the manufacturers for the inspection report when purchasing. From the report we will get some parameters we want if the parameters meet the standards or are above the standard line. It shows that the quality of high aluminum castable is good.

Also, when we purchase high-aluminum castables if the above two aspects meet the standards, we can first purchase some samples from the manufacturer for experiments. This can ensure to the greatest extent an effect on our future use. If the experiment is qualified, it will not be too late for us to purchase in large quantities. If we make large-volume purchases without conducting experiments in the early stage, our losses will be very large. This will not only be the cost of raw materials, but also our entire kiln may need to be reconstructed.

Everyone must know how to choose high-aluminum castables with good results. Finally, when purchasing, we must consider the overall cost and performance. In addition to considering various indicators of raw materials, understanding the manufacturer, brand, and market reputation of the product is also one of the important factors in ensuring the selection of high-quality high-aluminum castables.

In addition to the methods mentioned above, we also need to pay attention to the following points when purchasing high-aluminum castables. First of all, we must choose high-aluminum castables produced by regular manufacturers, so as to ensure the quality and performance of the product. Secondly, pay attention to the packaging method of high-aluminum castables. Generally speaking, the packaging should be tight and there should be no damage or air leakage to prevent the product from being damaged during transportation. In addition, carefully check the production date and shelf life of the product, and choose products with a recent production date and a longer shelf life to ensure product quality and performance. Finally, you should consult the manufacturer’s after-sales service to understand the after-sales guarantee and technical support of the product, so that you can get timely help and support if problems arise during use. By comprehensively considering the above factors, selecting high-aluminum castables with excellent performance and reliable quality can provide a strong guarantee for the construction of high-temperature kilns and the production of smelting materials.

High Alumina Bricks for Tunnel Kiln Trucks

High alumina bricks used in tunnel kilns and kilns are generally high alumina bricks with an aluminum content of more than 70%. Brick dimensions must be negative. This is because during production and operation, as the temperature changes, the high alumina bricks will expand. If it has been used for a long time, the joint material will loosen, which will also cause the bricks to hit the kiln wall. What should I do if the high-alumina bricks used for tunnel kiln trucks hit the kiln wall on both sides?

Grade I – High Alumina Brick For Sale

The phenomenon of high alumina bricks hitting the kiln wall is caused by many factors. First, the kiln car bricks have been used for a long time, and the joints of the refractory clay or refractory cotton are worn out, causing the gaps to increase and cause them to hit the kiln wall. Second, the size of the high alumina bricks is positive. When the size of the kiln car bricks is increased during construction, the bricks may also hit the kiln wall during the production process.

If the high alumina bricks used for kiln cars are of regular size or increased in size, the total length of the paved kiln car bricks will increase. During the movement, the kiln car will collapse if it hits the kiln wall, and the products from the collapsed parking space will fall and become blocked in the kiln. As a result, the kiln cars that circulated behind were also blocked and collapsed, making production impossible. In this case, first measure the total length of the kiln car. The total length of the kiln car must be about 6cm shorter than the kiln length, that is, one side is about 3cm shorter. Only in this way, during the production process, if the kiln car’s high-alumina bricks expand at high temperatures, production will not be affected.

But if the total length of the kiln car is longer than the kiln diameter, it must be dealt with. After laying the kiln car bricks, you can use an angle grinder to knock off about 3cm of the bricks and make them smooth on both sides. If high-alumina bricks for kiln cars that are too long are used, they must be dismantled and re-paved. Because the joint materials under high temperatures, such as fire clay, have fallen off, the joints between bricks have increased, resulting in an increase in the total length of the kiln car bricks, affecting use.

Kiln cars are paved with high-alumina bricks, and each manufacturer has different habits. Some are built from the middle seam to both sides. Some are the manufacturer’s own bricks, which can be paved according to the size of their own high-alumina bricks. As long as the total length does not exceed the kiln diameter, they can be used. Do not smash pavement tiles that are too long. Hitting them with a hammer will cause the tiles to break. Try to use an angle grinder to grind it, so as not to cause the high alumina bricks of the kiln car to break or cause the bricks inside to break. It’s just that the edges don’t look good after being polished, and it doesn’t affect use at all.

To buy high-quality high alumina brick refractory bricks, contact us to get free samples and competitive prices.

Refractory Cement with Excellent Fire-Resistant Properties

Refractory cement is a type of special cement. It has very high-temperature resistance and is usually used in buildings, industrial equipment, and furnaces in high-temperature environments. The main components of refractory cement are clinker, silicate, aluminate, and other substances. The special combination of these substances gives refractory cement excellent fire-resistant properties.

Refractory Cement Product Introduction

Refractory cement has a wide range of applications. It can be used in various fields such as construction, metallurgy, the chemical industry, and electric power. In the field of construction, refractory cement is mainly used in buildings in high-temperature environments, such as blast furnaces, electric furnaces, steel plants, aluminum plants, etc. In the metallurgical field, refractory cement is mainly used to manufacture high-temperature furnaces and refractory materials. In the chemical industry, refractory cement is mainly used to manufacture chemical equipment and storage tanks. In the electric power field, refractory cement is mainly used to manufacture chimneys, boilers, and burners.

High-Temperature Refractory Cement

Characteristics of Refractory Cement

1. Good high-temperature resistance. The main feature of refractory cement is its ability to maintain stable performance in high-temperature environments. Usually able to withstand high temperatures up to 1500°C.
2. Good chemical corrosion resistance. Because refractory cement contains a large amount of chemical components such as alumina and silica. Therefore, it can resist the erosion of strong corrosive substances such as acids and alkalis.
3. High compressive strength. Refractory cement has high compressive strength and can withstand large amounts of pressure. Therefore, it is widely used in construction, metallurgy, and other industries.
4. Refractory cement has strong plasticity. Refractory cement has better processing performance. Refractory products of various shapes and sizes can be made through different processing techniques.

The production process of refractory cement is very complex and requires the use of high-tech technology and advanced equipment. The production process requires strict screening and proportioning of raw materials to ensure the physical and chemical properties of refractory cement. The production process also requires high-temperature calcination and fine processing to ensure the quality and stability of refractory cement.

What are the Precautions for Using Refractory Cement?

1. Refractory cement and refractory clay are both types of refractory materials. The refractory degree of refractory cement is 1500 degrees Celsius. It has high strength after solidification, and the grade can reach 625. It is mainly mixed with bauxite aggregate to form refractory concrete with high refractory resistance. The refractory clay has a refractory resistance of 1000°C, has no strength after solidification, and only plays a certain bonding role. Refractory clay is usually used to build refractory bricks or to paste furnace walls.
2. If refractory cement and refractory soil are mixed and used, the use value of refractory cement will be greatly reduced. This is equivalent to mixing refractory cement and loess and using them together. The solidification strength and grade of refractory cement will be greatly reduced, the material will easily fall off, has no strength, and has a short service life. It is recommended that workers engaged in furnace construction strictly mix refractory cement and refractory soil during the construction of refractory materials.

What are the precautions for using refractory cement? Familiar with the characteristics of refractory cement and the requirements of the use environment. If you strictly follow the construction instructions, you will be able to maximize its advantages.