Deciphering the Distinctions: Refractory Cement vs. Refractory Mortar

Difference between refractory mortar and refractory cement. The lining material of high-temperature industrial furnaces can be made of refractory bricks/wedges or by pouring refractory castables.

When the refractory brick or refractory wedge lining is installed, the bonding material between the pieces is mortar. The type of mortar selected must have characteristics quite similar to the material of the refractory brick used in the construction of the lining. Therefore, in Refractory Solutions, we, Rongsheng Kiln Refractory Company have mortars for all brick qualities. Refractory castables, on the other hand, need a binder to bind the raw materials together. The binder used in this case is generally refractory cement. This high alumina cement is mainly composed of calcium aluminate (CaO – Al2O3).

High-Temperature Refractory Cement – RS Calcium Aluminate Cement

What are the differences between refractory mortar and refractory cement? In conclusion, the difference between refractory mortar and refractory cement is that mortar is used to join shaped materials and on the other hand, refractory cement is used as a binder material for refractory castables. In Refractory Solutions, RS Kiln Refractory Company, we advise you on any material need you may have. Contact us for free quotes or samples.

Refractory Cement: What it Is, Plus 3 Things You NEED to Know

In helping businesses and homeowners select the correct refractory product to use for their application a few common questions kept coming around about refractory mortar their uses. Because these questions are common to so many we speak with the following article is here to address the basics about refractory cement.

What is Refractory Cement?

Refractory Cement is a heat-resistant material designed to line fireboxes and withstand very hot environments (2,000-3,000*F) such as firebox linings, forges, kilns, ovens, incinerators, crematoriums, and other high temperature equipment. Refractory cement is commonly combined with other products like firebrick and other ceramics to further increase thermal resistance.

Keep reading to understand just how refractory cement also known as castable refractory or fire cement is used and how it differs from other similar products.

1. What is Refractory Cement Made of?

Refractory cement is made from a combination of materials like calcined alumina, ganister/silicon carbide, zirconia, ceramic clay, and lime among other materials.

It is typically made from a mixture of refractory aggregates, bonding agents, and other materials that are designed to withstand high temperatures. The specific composition of refractory cement can vary depending on the intended use of the product,

These materials are chosen for their ability to withstand high temperatures and their low thermal expansion coefficients, which helps to prevent cracking or other damage to the cement. Refractory cement is often used in the construction of furnaces, kilns, and other high-temperature equipment, as well as in the manufacture of firebricks and other refractory products.

2. Where is Refractory Cement Used?

Refractory cement is a high-temperature resistant material that is used in various industrial applications where it is subjected to extreme temperatures.

Some common uses of refractory cement include:

• Lining furnaces and kilns: Refractory cement is often used to line the inside walls of furnaces and kilns, where it helps to insulate the equipment and protect it from the high temperatures involved in the manufacturing process.
• Fireplace and wood stove construction: Refractory cement is  used in the construction of fireboxes and wood stoves, where it helps to protect the structure from the high temperatures generated by the fire.
• Pizza Ovens: Wood fire pizza ovens typically include castable refractory cement in their construction.
• Boiler construction: Refractory cement is sometimes used in the construction of boilers, where it helps to insulate the equipment and protect it from the high temperatures and pressures involved in steam generation.
• Furnaces for Industrial Manufacturing: Refractory cement is used in the construction of furnaces, where it helps to insulate the equipment and protect it from the high temperatures involved.
• Crematoriums: The extreme temperatures required for the incineration of remains require refractory castables to help insulate and maintain hot operating temps.
• Other high-temperature applications: Refractory cement is also used in a variety of other high-temperature applications, such as in the manufacturing of ceramics, in the petrochemical industry, and in the production of iron and steel.

High Alumina Refractory Cement

3. Refractory Mortar vs. Refractory Cement, What’s the Difference?

Refractory cement and refractory mortar are both high-temperature resistant materials that are used in various industrial applications. However, there are some key differences between the two:

Composition: Refractory cement and refractory mortar are made from different materials and have different compositions. Refractory cement is typically made from a mixture of refractory aggregates, bonding agents, and other materials, while refractory mortar is made from a mixture of refractory cement and fine refractory aggregate.

Use: Refractory cement is typically used for constructing or repairing the structural elements of a furnace or other high-temperature equipment, while refractory mortar is used for filling in gaps and joints between refractory bricks or other masonry units.

Consistency: Refractory cement is typically thicker and more paste-like in consistency, while refractory mortar is thinner and more pourable.

Setting time: Refractory cement typically has a longer setting time than refractory mortar, which allows for more time to shape and form the material during construction.

Overall, the main difference between refractory cement and refractory mortar is in the intended use and application of the materials. Refractory cement is used for constructing or repairing the structural elements of a furnace or other high-temperature equipment, while refractory mortar is typically used for filling in gaps and joints between refractory bricks or other masonry units.

Dense High-Alumina Refractory Castables

How Long Does It Take Refractory Cement to Cure?

Refractory cement manufacturers such as Rongsheng Kiln Refractory Company recommend at least 24 hours to cure before exposing it to high temperatures.  The exact curing time for refractory cement depends on several factors, including the specific type of refractory cement being used, the ambient temperature and humidity, and the thickness of the cement layer. In general, refractory cement begins to harden within a few hours of being mixed and poured, and it can take anywhere from a few days to several weeks to fully cure.

Refractory Castables for Construction or Repair of Furnaces

What is Refractory Castable?

Refractory castable is a type of refractory material that is made from a mixture of refractory aggregate, bonding agents, and other additives. It is a type of refractory concrete that is used in various industrial applications where it is subjected to extreme temperatures. Refractory castable is typically poured into place and allowed to harden, rather than being molded or shaped like traditional concrete. It is often used in the construction or repair of furnaces, kilns, and other high-temperature equipment, as well as in the manufacture of firebricks and other refractory products.

Refractory castable has several advantages over other types of refractory materials. It is easy to install, can be poured into place, and can be shaped or formed to fit various applications. It is also relatively inexpensive compared to other types of refractory materials. However, refractory castable is not as strong as other types of refractory materials, and it may not be suitable for use in applications where high mechanical strength is required.

The 24 hour initial curing allows the cement to fully harden and achieve its maximum strength. In some cases, it may be necessary to allow the cement to cure for longer periods of time, particularly if the cement is being used in a high-temperature application or if it is being applied in a thick layer. It is important to follow the manufacturer’s recommendations for curing times to ensure that the cement is fully cured and ready for use.

Castables Refractory for Cement Kilns

The cement kiln is divided into two major systems: preheater and rotary kiln. The preheater system is generally a five-stage air duct, and the rotary kiln system is divided into a front transition zone, a firing zone, and a cooling zone.

With the continuous improvement and improvement of castable technology, the amount of castables used in cement kilns is also increasing. The cyclone cylinder uses alkali-resistant bricks, and many manufacturers use alkali-resistant castables instead. The kiln tail preheating system of dry-process cement kilns also uses alkali-resistant castables. The properties of alkali-resistant castables are divided into ordinary alkali-resistant castables and high-strength alkali-resistant castables. Generally speaking, ordinary alkali-resistant castables are bonded with ordinary cement, while high-strength alkali-resistant castables are bonded with low cement.

Magnesia Refractory Castable for Rotary Kiln

Refractory castables for cement kiln preheating system

It is more suitable to use alkali-resistant castables for the preheating system. In the decomposition zone at the end of the cement kiln, low cement wear-resistant castables should be used.

In the cone of the preheater, the discharge pipe, and the parts at the end of the kiln that are prone to crusting, anti-crushing castables are used.

The alkali-resistant insulating castables used at the end of the kiln are now basically made of calcium silicate boards. As a castable manufacturer, we do not recommend the use of insulating castables because of their high density and poor wear resistance as calcium boards. It is also inconvenient to set up molds. Therefore, for the sake of users, it is still a good choice to use calcium silicate boards for heat insulation parts.

Refractory castables for cement kiln rotary kiln system

In the rotary kiln system, magnesia series bricks are used. The only parts where castables are used are the kiln mouth and coal injection pipe. The castable requirements for coal injection pipes are relatively high-end because this part is highly corrosive. Some use silicon carbide castables, some use magnesia-aluminum spinel castables, and some use corundum mullite castables. But no matter which type is used, the density of coal injection pipe castables is generally around 2.9. In addition, the compressive strength is greater than 100 Mpa, because the use conditions of this part are quite harsh.

In general, cement kilns should use high-aluminum refractory castables for kiln door covers. The grate cooler uses high-strength alkali-resistant castables, and wear-resistant castables should be used in parts of the grate cooler that are prone to wear.

Wear-resistant castables can also be used at the rear entrance of the cement kiln, but they must be alkali-resistant. Steel fiber reinforced refractory castables are also available. The front kiln mouth is also a relatively demanding part. It uses high-end castable corundum mullite castable, but it must have wear resistance. But the dosage is not very large, usually 8-10 tons.

For the decomposition furnace at the end of the kiln, low-cement castables must be used, the alkali resistance must be level two or above, and the aluminum content must not be less than 70%. However, alkali-resistant castables must be used at the cone, and alkali-resistant castables can also be used at the top. The strength requirement of alkali-resistant castables cannot be less than 60Mpa.

There are also coal-injection pipes. Although the amount is not large, the requirements are extremely demanding. Corundum-mullite castables are used, high-grade castables containing silicon carbide can also be used, and magnesium-aluminum spinel castables are also used.

The tertiary air duct must use wear-resistant castables with a strength of 100Mpa. High-aluminum and low-cement castables are also used for parts with light wear, and the bulk density requirement is 2.6.

There is also a mix of steel fiber castables and wear-resistant bricks used in the single-cylinder cooler mixing zone.

To purchase high-quality refractory castables for cement kilns and to learn about construction issues of refractory castables for cement kilns, please contact us. We can provide high-quality refractory castable products and cost-effective refractory lining design services.

Fused Quartz Refractory Bricks for Alkali-Free Borosilicate Glass Pool Furnaces

Quartz refractory material refers to a refractory material composed of amorphous quartz (quartz glass). Fused quartz refractory bricks are mainly used in melting low-alkali or alkali-free borosilicate glass pool furnaces.

RS Customized Fused Silica Bricks

Fused Quartz Refractory Bricks

Fused quartz refractory bricks are pure SiO2 refractory bricks that contain higher SiO2 content than silica refractory bricks. Its chemical composition is determined by the purity of the raw materials.

In fused quartz refractory bricks, there is actually a small amount of cristobalite or tridymite crystallized in the center due to the slow cooling rate. Quartz refractory bricks contain a large number of bubbles due to their high viscosity and poor clarification when melted. Some of the bubbles come from the gas generated by the reaction between graphite rods and SiO2.

The advantage of fused quartz bricks is good thermal shock resistance. This is due to the small expansion coefficient of quartz glass (the lowest among all refractory materials). Therefore, its thermal shock resistance is very good below 1000°C. Above 1000°C, thermal shock resistance decreases due to crystallization.

Its thermal conductivity is very good, and its thermal conductivity is higher than that of magnesia bricks. The mechanical strength is high due to the dense nature of quartz refractory bricks. In addition, when the quartz brick is eroded, it will cause little pollution to the glass liquid. Therefore, it is better to use quartz bricks as the structural material for the bottom of low-alkali or alkali-free borosilicate glass pool furnaces.

Quartz Ceramic Refractory Bricks

Quartz Ceramic Refractory Products

Fused quartz ceramic refractory products are refractory bricks made from quartz glass as raw material, which are crushed, batched, shaped, and then sintered at a certain temperature. Its chemical composition is SiO2 99.5%, most of which is glass phase, with only a very small amount of cristobalite crystals. The bricks are white and opaque.

Quartz ceramic refractory products have many excellent properties. If the thermal expansion coefficient is small, the thermal shock resistance is good. It has the characteristics of high viscosity at high temperature, high strength, strong slag resistance, and erosion resistance, low thermal conductivity, and small drying and firing shrinkage.

Fused quartz refractory bricks are used in alkali-free borosilicate glass pool furnaces and are a technological advancement for refractory manufacturers. It also provides protection for high-purity glass. To purchase high-quality silica bricks and fused silica bricks for glass kilns, please contact us.

Why does the Strength of Refractory Castables Decrease During Construction?

There are many reasons why the strength of refractory castables decreases during construction. But there are no more than two reasons, namely temperature and the amount of water added during construction.

Why does the strength of castables decrease during construction?

Refractory castables are constructed in summer and winter. Due to different temperatures, the strength of the castables will decrease. When constructing at temperatures below zero degrees Celsius, the castables will generally not condense and the condensation speed will slow down. Therefore, during winter construction, the temperature of the construction site must be kept above 5°C. Only in this way can the construction proceed smoothly and the strength of the castables can be ensured.

High Alumina Castable Construction

In addition, the amount of water added is very important during the construction of refractory castables. Generally, the amount of water added to low-cement castables is 6-7%, and the amount of water added to lightweight castables is about 20%. The amount of water added to high-aluminum castables is about 12%. If too much water is added, it will cause dehydration and crystallization effects at medium temperatures, destroy the internal structure of the castables, and cause the strength of the refractory castables to drop sharply at medium temperatures. As a result, the porosity of the castable increases and the density decreases, which will seriously affect the strength of the castable when used.

In general, the calcium content of cement-bound castables will be high, which will reduce the load-softening temperature of refractory castables and worsen the thermal shock index. In particular, castables with high cement content have higher calcium content, and the amount of water added during construction is also larger than that of low-cement castables, and the strength will be affected to a certain extent.

Low cement castables have a lower cement content and a lower calcium content than ordinary refractory castables. The strength will also be better than ordinary refractory castables, which is also the advantage of low-cement castables. Because low-cement castables have a dense structure, low porosity, high refractoriness, and good thermal shock stability. Therefore, the current high-aluminum castables basically use low-cement castables.

However, low-cement castables have low cement content and will take a long time to set. During construction, we must pay attention to the temperature during winter construction, to ensure the stable strength of the castables. Take high-aluminum castables, which are used in large quantities, as an example. The strength is basically caused by chemical reactions. The reason for the chemical reaction is improper storage or the occurrence of pores.

In short, during the production process of high-aluminum castables, we must pay attention to the reasonable proportion during the process to overcome the expansion caused by medium temperature. To achieve the stability of strength during use.

Refractory Castables Construction

Effect of cement addition amount in refractory castables on strength

If too little cement is added to the refractory castable, the early strength of the castable will be low and the hardening time will be too long. Especially in winter, non-condensation will occur. If too much high-alumina cement is added, the calcium in the cement can react with the aluminum and silicon in the raw materials at high temperatures to form low-melting products, which will affect the later use strength of the castables.

Generally speaking, the cement addition amount of high-aluminum castables will be higher than that of low-cement castables, and the proportion will be 10-12%. The cement addition amount of low cement castables is 6%-7%, and the cement addition amount of ultra-low cement castables is 2-3%. Therefore, with the development of actual usage, high-aluminum castables are basically no longer used on the market, and low-cement refractory castables are mostly used for lining.

When the additional amount of high alumina cement is less than 5%, the density of refractory castable particle accumulation gradually increases. The amount of cement added is small, and after the cement is dried, the effect on the reduction of bulk density is weak. However, as the amount of cement added increases, the bulk density tends to increase. If the cement addition amount is greater than 5%, a large amount of cement hydration products will lose free water and part of the bound water after drying, and the pores of the refractory castable will increase. As pores increase, the corrosion resistance of the refractory lining will decrease.

The amount of cement added has a great influence on the compressive strength of castables. When the cement addition amount is less than 5%, the total amount of pores left by the complete dehydration of the cement hydration product will be small, and the impact on the strength of the refractory castable will also be small. When the cement addition amount is greater than 5%, as the cement addition amount increases, the degree of close packing of castables gradually decreases due to excess cement fine powder. At the same time, the pores left by the complete dehydration of cement hydration products gradually increase. As a result, the density of the castable material decreases, and the loose structure strength also gradually decreases. At a high temperature of 1450°C, the gelling effect of cement will disappear, and a large amount of eutectic liquid phase will produce a liquid phase to fill the gaps. The formation of needle-like and columnar mullite in fine powder in the internal structure of refractory castables. The bonding between fine powder and granular materials is strengthened, and the compressive strength is generally improved.

When the refractory castable is at 1450°C and the cement content is greater than 5%, the compressive strength gradually decreases. This is related to the gradual increase of the liquid phase at a high temperature of 1450°C, which leads to the weakening of the supporting effect between particles in the castable.

Are You Choosing the Right Insulation Material for Regenerative Organic Waste Gas Incinerator?

With the continuous development of surface treatment processes in the manufacturing industry, volatile organic compounds are increasingly used in industry. The configuration of regenerative exhaust gas incinerators is becoming more and more urgent. Most volatile organic compounds (VOCs) have special odors, can cause various discomforts to the human body, and are toxic, irritating, and carcinogenic. Under sunlight, photochemical reactions occur between nitrogen oxides, hydrocarbon organic compounds, and oxidants in the atmosphere. Generate photochemical smog, endanger human health and crop growth, and destroy the ozone layer. In recent years, people’s awareness of environmental protection has continued to increase, and their requirements for controlling air pollution have increased. The economical and effective treatment of waste gas containing volatile organic compounds has become an urgent problem that needs to be solved. Then the question arises, how do we complete this waste gas treatment process?

RTO Regenerative Organic Waste Gas Incinerator

Waste gas treatment of RTO regenerative organic waste gas incinerator

The burned organic waste gas undergoes a thermal oxidation reaction at 760℃~1000℃ to generate carbon dioxide and water. If the organic matter contains other elements such as halogen, the oxidation products will also include hydrogen halide, etc. The exhaust gas is first heated by the regenerator to a temperature close to the thermal oxidation temperature and then enters the combustion chamber for thermal oxidation. The temperature of the oxidized gas increases. The organic matter is essentially converted into carbon dioxide and water. The purified gas passes through another heat storage body, the temperature drops, and can be discharged after reaching the emission standard. Different heat storage bodies are switched over time through switching valves or rotating devices to absorb and release heat respectively.

Seeing the above intuitive analysis, the answer appears. RTO regenerative organic waste gas incinerator can complete the waste gas treatment process.

Insulation Furnace Lining Ceramic Fiber Module

Configuration of insulation materials for RTO regenerative organic waste gas incinerator

The operating temperature of the RTO regenerative organic waste gas incinerator is around 1000°C. In response to the national call for energy conservation, the thermal insulation material in the furnace was originally designed to use ceramic fiber modules with low thermal conductivity and low bulk density as the furnace lining. The traditional dense refractory bricks are abandoned.

Ceramic Fiber Module Aluminum Silicate Fiber Module

Why choose ceramic fiber modules as the lining when designing the lining of the RTO regenerative incinerator? What are its advantages over duty refractory bricks?

The RTO furnace lining uses a ceramic fiber insulation structure, which can save about 60% of energy compared to brick furnaces according to theoretical calculations. The ceramic fiber module uses high-quality long fiber needle-punched blankets as raw materials, which can achieve rapid heating and high-precision temperature control. Get rid of the disadvantages of dense materials and no need for an oven. This is due to the excellent chemical and thermal stability of the high-quality long-fiber needle-punched blanket used for compressed ceramic fiber modules. Able to resist the effects of rapid cooling and heating on the product itself. The low heat capacity and low thermal conductivity of ceramic fiber modules prevent the module itself from collecting too much heat. It can better distribute heat evenly inside the furnace body. The overall energy-saving effect of the RTO regenerative organic waste gas incinerator is improved.

Ceramic Fiber Mold Blanket Aluminum Silicate Fiber Blanket

Rongsheng refractory material manufacturer can provide refractory materials for RTO furnace regenerative exhaust gas incinerator insulation engineering. And we already have multiple delivered RTO furnace projects. During the construction process of the full-fiber structure of the RTO regenerative organic waste gas incinerator, staggered joint splicing is used to fix it, forming a seamless overall sealed structure. The energy-saving effect of the stove in use is even more superior.

Why is Refractory Plastic with Plasticity?

In order to ensure smooth construction and normal use at high temperatures, refractory plastics should generally have the following basic properties. ① Have a certain plasticity to facilitate construction. ② Have a certain storage period to ensure that the molding performance remains unchanged during the specified storage period. ③ After curing at room temperature, it will have a certain strength, so that the frame can be dismantled or transported after construction. ④ Have certain high-temperature volume stability to prevent damage to the furnace lining structure due to excessive deformation. The reason why refractory plastic is called refractory plastic, is what does its plasticity have to do with it?

High-Quality Wear Resistant Plastics

The plasticity of the plastic has a direct impact on the characteristics and dosage of the clay. It is also related to the amount of water added. Plasticity increases as the amount of water added increases. But it cannot be too high, generally 5~10%. Improving plasticity means controlling the amount of clay and water in the plastic, and adding plasticizers.

The role of plasticizers in refractory plastics. ① Improve the hygroscopicity of clay particles so that the clay particles are dispersed and coated with a water film. ② Solve the clay particles. ③ Increase the electrostatic repulsion between clay particles and stabilize the sol. ④ Exclude ions that hinder solization from the system as insoluble salts. ⑤ Increase the viscosity of the water in the clay to form a strong water film, etc. Commonly used plasticizers mainly include pulp waste liquid, naphthenic acid, lignosulfonate, lignophosphate, lignochromate, etc. At the same time, the binders used in refractory plastics also have a certain impact on plasticity.

Soft clay is an important raw material for refractory plastics, and the main performance characteristics of plastics are also derived from soft clay. In refractory plastics, soft clay not only functions as a binder but also as a plasticizer and sintering agent. It has a great influence on the plasticity, water retention, construction ability, normal temperature, and high-temperature fire resistance of refractory plastics. Therefore, the soft clay used to prepare fire-resistant plastics should have good plasticity, hygroscopicity, moderate viscosity, fire resistance, and sintering properties. Its fineness: less than 0.09mm accounts for more than 85%, and the dosage is 10%~15%.

The chemical binding agent is an aluminum sulfate solution with a density of 1.2~1.3g/cm³. After mixing with this binder, the material should be trapped for more than 16 hours. Because the sulfate radical in aluminum sulfate reacts with the iron in the powder, iron sulfate is generated and hydrogen gas is released. This will cause the mud to bubble or bulge, so the material should be trapped.

Refractory plastic is a high-temperature material that is usually composed of a variety of raw materials. The specific proportions and material types of its formula can vary depending on different manufacturers, products, and application environments of refractory plastic. Below are some common components of a typical refractory plastic formulation.

1. Aluminum silicate can be used in plastic formulations. Aluminum silicate fiber, adhesive, filler (such as clay, expanded perlite, etc.), modified resin, etc.

2. High aluminum plastic formula. High-aluminum raw materials (such as high alumina, alumina, etc.), binders (such as phosphates, sulfates, etc.), fillers (such as calcium carbonate, wollastonite, etc.), etc.

3. Zirconia can be used in plastic formulations. Zirconia powder, binders (such as silicate, borate, etc.), reinforcing agents, fillers, etc.

4. Silicon carbide can be used in plastic formulations. Silicon carbide powder, organic binders (such as resin, asphalt, etc.), fillers (such as kaolin, talc powder, etc.), etc.

5. Aluminum borate can be used in plastic formulations. Aluminum borate fiber, fillers (such as kaolin, talc, etc.), binders (such as expanded mica, etc.), modified resin, etc.

6. Aluminum phosphate can be used in plastic formulations. Aluminum phosphate fiber, clay, adhesive, reinforcing agent, anti-slump agent, etc.

It should be noted that the above are only typical components in some common refractory plastic formulas. The specific formula proportions and types may vary depending on the manufacturer and product type. When using refractory plastics, preparation and construction should be carried out in strict accordance with the product instructions and technical parameter requirements.

What is the Density of Blast Furnace Carbon Bricks?

The health and longevity of blast furnaces is the eternal pursuit of smelting enterprises. Regardless of the application of new materials, new technologies, new equipment, or innovative processes, the ultimate goal is to ensure that the blast furnace is in good condition. It can work efficiently, with low consumption and safety, and the longer the continuous operation period, the better. Blast furnace carbon bricks are a commonly used refractory brick product in Gaul. With the development and progress of related technologies, in recent years, the restrictive links that affect the life of the blast furnace have become more and more concentrated in the bottom and hearth of the blast furnace.

Blast Furnace Carbon Bricks

Refractory Linings’ Working Environment for Blast Furnaces

For a long time, various types of carbon bricks and ceramic cup materials have been mainly used for the lining of the blast furnace hearth. By continuously improving their quality performance to meet the requirements of extending the life of blast furnaces. However, high-intensity smelting and the continuous decline in the grade of raw materials entering the furnace have led to a large accumulation of impurities such as alkali metals and zinc in the blast furnace. The environment of the hearth is becoming increasingly harsh, which poses more severe challenges to the lining materials at the bottom of the hearth.

What is the density of blast furnace carbon bricks? Carbon brick density is the volume density of carbon bricks, which refers to the mass per unit volume of carbon refractory bricks. The bulk density index of carbon bricks is an important indicator of the density of carbon bricks. The density of carbon bricks is relatively easy to detect. In production, the density of carbon bricks is used as a test to judge the degree of sintering of carbon bricks. The higher the density of carbon bricks, the better its resistance to slag erosion. Generally, the density of carbon bricks is expressed in g/cm3 or kg/m3.

Bulk Density of Blast Furnace Carbon Bricks

According to the different parts of the blast furnace lining, blast furnace carbon bricks are divided into blast furnace semi-graphite carbon bricks, blast furnace microporous carbon bricks, and blast furnace carbon composite bricks. Blast furnace carbon bricks made of different materials have different physical and chemical indicators and different volume densities.

• Blast furnace semi-graphite carbon bricks are generally used to build the blast furnace bottom. Its bulk density is 1.5g/cm3.
• Blast furnace microporous carbon bricks are generally used for blast furnace hearth wall masonry. Depending on the part used, the bulk density is 1.65-1.7g/cm3.
• Blast furnace carbon composite bricks are generally used in the construction of blast furnace ceramic cups. According to different physical and chemical indicators, its bulk density is 2.7-2.85g/cm3.

The density of blast furnace carbon bricks is one of the important reference indicators for customers to purchase carbon bricks. Carbon bricks for different uses have different physical and chemical indicators and different bulk density requirements.

The factors that affect the bulk density of blast furnace carbon bricks include the following two aspects. One is the particle size of the refractory raw materials of the blast furnace carbon bricks and the bulk density of the raw materials. On the other hand, is the control of the production process. Therefore, when producing blast furnace carbon bricks, it is necessary to strictly select the grade of raw materials and control the particles. During the production process, the pressure of the brick press to press the bricks is controlled, and the firing of the blast furnace carbon bricks is reasonably controlled.

When purchasing blast furnace carbon bricks, more physical and chemical indicators need to be provided. Such as main component content, compressive strength, flexural strength, etc. Only in this way can refractory material manufacturers provide high-quality carbon brick products for the refractory lining of blast furnaces.

Advantages and Disadvantages of Using Refractory Precast Shapes

What are Refractory Precast Shapes? Refractory Precast Shapes are refractory components that are baked or cured after on-site construction. It is a commonly used building material for high-temperature equipment. Refractory precast offers superior performance and better quality control than traditional on-site masonry. Usually, Refractory Precast Shapes are cast or pressed on-site, then dried or sintered and solidified in the factory, and then transported to the site for installation.

Refractory Precast Shapes with High-Temperature Resistance

There are many types of Refractory Precast Shapes. According to different uses, it can be divided into various types such as high-temperature resistance, acid and alkali corrosion resistance, wear resistance, etc. Among them, Refractory Precast Shapes with high-temperature resistance are the most widely used. For example, tunnel kilns, oil refineries, metallurgical industries, glass industries, power industries, etc. all need to use Refractory Precast Shapes for thermal insulation.

Common Refractory Precast Shapes include refractory bricks, refractory panels, refractory balls, etc. Different precast shapes come in different shapes and sizes and can be selected according to different needs. They have good heat insulation, wear resistance, corrosion resistance, and other characteristics in high-temperature environments. It can effectively protect equipment, extend equipment service life, and reduce equipment maintenance costs.

Refractory Precast Shapes for Electric Stove Roof Tiles

With the continuous development of unshaped refractory castables, Refractory Precast Shapes are becoming more diverse and larger in proportion. However, using Refractory Precast Shapes also has certain advantages and disadvantages.

Advantages of Precast. Because it is made into different shapes according to the size specifications of special parts of the furnace, the construction is convenient and quick when in use. And the oven time is short. Because there are many manufacturers that bake drains at a certain temperature after producing them, so they can heat up quickly.

In addition, precast shapes have good thermal insulation properties. Because it is precasted and molded according to the shape of the parts, there are no gaps, good heat insulation effect, and strong air tightness. Refractory Precast Shapes are made of different materials. However, baked preforms have good creep properties and strong wear resistance.

Advantages and Disadvantages of Using Refractory Precast Shapes

Disadvantages of prefabs. The added high-alumina cement has a large binder dose, high calcium content, and strong density, and at the same time, bad thermal shock may occur. High calcium content and many impurities will also reduce the refractoriness of precast shapes. Moreover, some manufacturers do not use low and medium-temperature barbecues during the production process, and the crystal water is not fully discharged at all. It is extremely easy to explode during use. Some even crack when reaching a certain high-temperature area during use, making the Refractory Precast Shapes no longer usable.

Many manufacturers will add a certain proportion of explosion-proof fiber in the process of producing Refractory Precast Shapes. However, the drainage process is short, and the crystal water is not fully discharged before being transported and used. Then during the transportation process, explosions have already occurred.

Some precast shapes seem to take a long time to drain, but unbaked Refractory Precast Shapes will shrink after passing a certain temperature during use. Resulting in some changes in the size of the used part.

In short, the production of Refractory Precast Shapes still requires barbecue at a certain temperature. The most reliable method is to fully discharge free water and crystal water.

RS Kiln Refractory Factory is a powerful manufacturer and seller of refractory materials. Our refractory material factory specializes in the production of Refractory Precast Shapes. We strive to provide long-life refractory materials for the refractory linings of high-temperature industrial kilns!

Advantages of Ceramic Fiber Modules for Brick Kiln Thermal Insulation

Ceramic fiber modules for brick kiln insulation. Ceramic fiber modules are also called aluminum silicate fiber modules, refractory fiber modules, and refractory insulation cotton blocks. In order to simplify and speed up kiln construction and improve the integrity of furnace lining, new refractory lining products that can replace traditional heavy refractory materials have been introduced, which has promoted the progress of kiln masonry technology. RS Kiln Refractory manufactures high-quality ceramic fiber modules for the insulation of industrial furnace linings. At the same time, our new inorganic heat insulation board products can also be used in the insulation layer of industrial furnaces. Good heat preservation effect, and at the same time can effectively reduce the weight of industrial furnace lining.

Ceramic Fiber Module

Features of ceramic fiber modules for brick kiln insulation

Ceramic fiber modules have excellent chemical stability, excellent thermal stability, and excellent elasticity. The module is in a pre-compressed state. After the furnace lining is built, the expansion of the module makes the furnace lining seamless and can compensate for the shrinkage of the fiber furnace lining. In order to improve the thermal insulation performance of the fiber furnace lining, the overall performance is good. Excellent thermal stability and thermal shock resistance. Ceramic fiber modules (aluminum silicate fiber modules, refractory fiber modules) are installed quickly. In addition, the anchor is arranged on the cold surface of the wall lining, which can reduce the requirements for the material of the anchor. The RS Kiln Refractory manufacturer can design the insulation layer material according to the different furnace types of customers.

Advantages of Ceramic Fiber Module Lining

Ceramic fiber modular furnace lining, as a light and efficient thermal insulation furnace lining, has the following technical performance advantages compared with traditional refractory material furnace linings.

(1) Low bulk density. Ceramic fiber modular furnace lining is more than 70% lighter than the lightweight insulating brick lining, and 75% to 80% lighter than the lightweight castable lining. It can greatly reduce the steel structure load of the kiln and prolong the service life of the furnace body.

(2) Low heat capacity. The heat capacity of the furnace lining material is generally proportional to the weight of the furnace lining. Low heat capacity means that the kiln absorbs less heat during reciprocating operation, and at the same time, the temperature rises faster. The thermal capacity of ceramic fiber is only 1/7 of that of lightweight heat-resistant lining and lightweight clay ceramic tiles. The energy consumption in the furnace temperature operation control is greatly reduced, especially for intermittently operated heating furnaces, which can have a very significant energy-saving effect.

(3) Low thermal conductivity. When the average temperature of the ceramic fiber module is 400°C, the thermal conductivity is less than 0.11W/(m·K). At an average temperature of 600°C, the thermal conductivity is less than 0.22W/(m·K). At an average temperature of 1000°C, the thermal conductivity is less than 0.28W/(m·K). It is about 1/8 of the lightweight clay brick and 1/10 of the lightweight heat-resistant lining (castable) and has a remarkable thermal insulation effect.

(4) Excellent thermal shock and mechanical vibration resistance. The ceramic fiber module is flexible and has particularly good resistance to severe temperature fluctuations and mechanical vibrations.

(5) The construction is simple. Its special anchoring method solves the problem of slow installation speed of traditional modules. The folding modules press against each other in different directions after unbundling without gaps. The furnace lining does not need to be dried and maintained and can be used directly after installation.

At present, energy saving, environmental protection, and prevention of global warming have increasingly become the focus of attention of countries all over the world. Fuel costs will become a bottleneck for the development of the steel industry. Therefore, people are more and more concerned about the heat loss of industrial furnaces. According to statistics, after using ceramic fiber modules in the refractory lining of general continuous industrial furnaces, the energy-saving rate is 3% to 10%. The energy-saving rate of batch furnaces and thermal equipment can reach 10% to 30%, or even higher. The use of ceramic fiber module lining can prolong the life of the furnace and reduce the heat loss of the furnace body. The application of a new generation of crystalline ceramic fiber composite modules can not only improve the cleanliness of the furnace, and improve product quality, but also achieve a better energy-saving effect. Therefore, industrial furnaces, especially heating furnaces in the iron and steel industry, should be designed with ceramic fiber modules as the furnace lining as much as possible. The old heating furnace should make the best use of the maintenance time, and change the refractory brick or layer carpet lining to the ceramic fiber module structure. This is also an important measure to realize the sustainable development of the steel industry.

RS Kiln Refractory Manufacturers

High-efficiency kiln insulation will greatly reduce the fuel consumption of industrial furnaces and improve the utilization rate of heat energy. RS Kiln Refractory manufacturers aim to provide high-quality refractory services for high-temperature industrial furnaces. Whether it is the design and construction of refractory materials for the working layer of industrial furnace lining or the solution for refractory materials for the insulation layer. We will provide you with the most suitable refractory products for your production needs on the premise of directly saving costs.

RS500 Inner Insulation Coating Material for High Temperature Industrial Furnace

RS500 internal thermal insulation coating for high-temperature industrial furnaces. High-temperature industrial furnaces are resistant to high-temperature corrosion and heat insulation, and the method of preparing high-temperature resistant linings with coatings is used to solve the problem. Specifically, the high-temperature-resistant smear is prepared by smearing on the inner wall of the boiler as a fireproof lining, sealing paint, and preparing a protective layer. However, during construction, it is necessary to paint a layer of specific mud on the base surface, and then apply high-temperature-resistant plaster evenly on the base surface, air-dry and solidify, and then bake to complete. RS500 internal thermal insulation coating is a kind of refractory material with certain plasticity and is in the form of mud paste. Using it to prepare the inner wall of the boiler can protect the boiler. It has high strength, excellent resistance to melt or gas erosion, good spreadability and adhesion to protected materials, good thermal shock stability, and chemical stability. No cracking, no peeling in use.

RS500 Inner Insulation Coating Material for High-Temperature Industrial Furnace

Rongsheng RS500 type internal thermal insulation coating

Rongsheng RS500 type internal thermal insulation coating is a long-term and safe thermal insulation coating at 500 ℃ launched by Rongsheng Kiln Refractory Company according to the special working environment. It is suitable for coating in multiple industries, in various working conditions, and on the surface of various substrates. It has many advantages such as fire, flame, corrosion, acid resistance, alkali resistance, and insulation protection. The coating uses the latest nanotechnology, which can reduce the heat loss rate by more than 60%. After the coating is fully cured, an ultra-low thermal conductivity coating is formed, thereby achieving the effect of reducing heat loss during operation.

This product is composed of high-temperature adhesive, high-temperature nano-insulation material, various high-temperature fillers, and special additives. It can work in an environment below 500°C for a long time, and it can insulate equipment and reduce heat loss. Heat insulation paint is used for heat insulation, and it can reduce heat loss by 60% compared with before and after paint spraying. The coating can effectively prevent the erosion of acidic and alkaline gases when painted on the inner walls of cement kilns, fluidized sulfuric acid furnaces, and other kilns.

What are the common refractory materials for the lining of high-temperature industrial furnaces?

There are many types of high-temperature industrial kilns, and the types and materials of refractory materials used in kilns with different functions are different. The high-temperature industrial kiln is lined with refractory materials to protect the normal operation of the high-temperature kiln. What are the common refractories for the lining of high-temperature industrial kilns?

Reasonable refractory lining structure is the basis for stable production of high-temperature industrial furnaces. Commonly used refractory materials for the lining of high-temperature industrial kilns include refractory brick masonry, unshaped refractory materials, heat-insulating ceramic fiber refractory materials, and other refractory materials.

1. The selection of refractory brick masonry for industrial kilns is the lining made of refractory bricks and refractory mud. It is the most widely used lining structure for kilns. When choosing refractory bricks to construct the inner lining of the kiln, it is necessary to select refractory bricks of appropriate material and size to build the inner lining according to the structure of the kiln body.
2. Unshaped refractory materials are the most popular refractory materials used for lining of industrial kilns at present, mainly including refractory castables, refractory spray coatings, refractory ramming materials, etc.

During the construction of refractory castables, the refractory materials can be poured to the parts that need to be constructed after mixing according to requirements. Good fluidity, convenient construction, shortened construction time, good use effect, wide application range, and can also be used in parts where refractory bricks are not easy to build.

During the construction of refractory spray coatings, the selected spraying tools can be sprayed from multiple angles and unlimited positions, and high-quality refractory materials are used to spray the kiln lining as the kiln lining.

The construction methods of refractory castables and refractory spray coatings are different, and the essential requirements for refractory materials are slightly different. For example, refractory castables require good fluidity, and refractory spray coatings require low springback. However, in order to better combine the spray coating with the kiln lining, it is generally necessary to install anchors on the kiln lining during construction, so that the construction effect after spraying is good.

Refractory ramming materials are generally used in tiled or relatively flat high-temperature kiln parts. After being rammed with ramming tools, the inner lining has good compactness, high strength and good use effect.

Refractory castables, refractory spray coatings, and refractory ramming materials are different forms of unshaped refractory materials. It is also the refractory material used for the lining of various industrial kilns. Because of its convenient construction, it is used in various industrial kilns.

3. Ceramic fiber heat insulation material is a kind of heat insulation material, which is mostly used in industrial kilns that need heat insulation to avoid heat loss. Ceramic fiber insulation materials include fiber blankets, fiber cotton, fiber felts, fiber boards, and other fiber materials.

According to different uses, different types of refractory materials are used as linings for high-temperature industrial kiln linings to protect the kiln shell from erosion and play an important role in the normal operation of high-temperature kilns.

Rongsheng refractory material manufacturer is a refractory material manufacturer with rich experience in the production and sales of refractory materials. Our refractory products cover working lining refractory materials and insulation layer refractory materials for high-temperature industrial furnaces. We (https://kilnrefractory.com/) can customize refractory solutions according to the actual needs of high-temperature industrial furnaces.