Refractory Castables Used on High-temperature Kilns

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Application of refractory castables in cement rotary kilns

Refractory castables are widely used in new dry-process cement rotary kilns. According to the different working environments of the kilns, the applied refractory castables include ordinary refractory castables, low-cement refractory castables, ultra-low-cement refractory castables, no-cement refractory castables, steel fiber refractory castables, explosion-proof refractory castables, anti-spalling refractory castables, phosphate refractory castables, alkali-resistant refractory castables, heat-insulating refractory castables, and new types such as self-flowing refractory castables.

Application of refractory castables in glass melting furnaces

Due to the specific working environment requirements of glass melting furnaces, the applied refractory castables should have characteristics such as good high-temperature resistance, strong resistance to glass liquid erosion, and low porosity. The main refractory castables used include fused quartz castables, corundum castables, lightweight mullite castables, and zircon castables.

Application of Refractory Castables in the Metallurgical Industry

Refractory Castables for Ironmaking Systems

In ironmaking systems, refractory castables are widely used, especially in the iron tap channel of blast furnaces, where ASC refractory castables are commonly employed. ASC castables are typically low-cement or ultra-low-cement castables, composed mainly of Al2O3 aggregates, SiC, carbon, refractory cement, and various additives. The material used varies for different parts such as the main channel, slag channel, and branch channels.

Refractory Castables for Iron Ladle Pretreatment

Refractory castables are mainly used at the bottom, molten pool, and slag line of iron ladles, employing alumina-silicon carbide-carbon castables. The lance is a crucial device for iron ladle pretreatment, and nowadays, refractory materials for the lance often utilize castable materials, mainly consisting of Al2O3-SiO2. Refractory castables for lances made from these materials exhibit characteristics such as uniform structure, no joints, excellent thermal shock resistance, and long lifespan.

Refractory Castables for Electric Furnace Steelmaking

The application of refractory castables in electric furnaces mainly focuses on the furnace cover. In the electrical triangle area, castable prefabrication technology, using materials like corundum, high alumina, and mullite, may become a development trend for furnace cover materials. Prefabricated blocks are made according to drawings provided by users, specifying the usage location and temperature. The manufacturer uses suitable refractory castables to cast the prefabricated pieces, which are then cured, baked, and delivered to the user’s location for on-site assembly and use.

Refractory Castables for External Refining

  • Refractory Castables for RH Furnace: High alumina castables and alumina-magnesia castables are minimally used in the lining of RH furnaces. The upper part of the RH vacuum chamber commonly uses Al2O3-MgO·Al2O3 castables or spray-applied integral linings. The outer wall of RH furnace immersion tubes uses integral alumina-magnesia castables.
  • Refractory Castables for LF Furnace: Materials used in the baffle wall of the LF furnace cover are mainly high alumina or corundum series castables. The bottom impact area often employs high alumina-spinel castables for casting large bricks.
  • Refractory Castables for CAS Refining Device: The CAS refining device is divided into upper and lower parts, both using refractory castables. The upper part often employs low-expansion Al2O3-SiO2 castables, while the lower part uses electrically fused corundum added with MgO fine powder, belonging to the corundum-spinel series castables. In the later stages, to extend the device’s lifespan, magnesia-alumina spray repair materials are often used.
  • Refractory Castables for Ladles: The main types of refractory castables used for ladles are alumina-magnesia castables and alumina-magnesia-spinel castables.

Refractory Castables for Continuous Casting

Castables used in the tundish include lightweight castables (mainly used for insulation layers), high alumina or mullite self-flow castables, corundum castables, and magnesia castables (used for the tundish working layer).

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