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.

Castable Refractory Lining for Heating Furnace

As thermal equipment for heating billet or small ingot, the material used for lining has changed greatly. The application of amorphous castable in heating furnaces is increasing gradually. Rongsheng refractory manufacturer has rich production and sales experience of refractory manufacturers. boiler castable refractory from Risers is of high quality and good for use by customers. Compared with Mizzou castable for castable refractory lining, Risesun can customize the formula of refractory castable based on the actual production demand of high-temperature industrial furnaces. To meet the production needs of enterprises, maximize the cost of production.

Industrial Kiln Castable Refractory Lining

Heating furnace body, combustion chamber, furnace door, steel chute, ceramic slide, bottom water cooling pipe, flue, chimney, etc. The use of castable refractory lining varies by site. The normal operating temperature of the heating furnace is generally 1250 ~ 1350 ℃, while the lining castable sometimes has to withstand the high temperature of 1400 ~ 1500 ℃. Refractory castables not only need sufficient high-temperature refractory and thermal shock resistance but also have an excellent ability to resist high-temperature airflow erosion and dust erosion.

Therefore, the selection of excellent refractory alumina clinker, and three stone minerals as the main raw materials. The -Al2O3 powder and silicon powder were used as binders. With silica powder as a cobinder and three-stone mineral castable, it has good high-temperature performance and good thermal shock stability, which is more suitable for furnace lining.

Use pure binders because there are fewer impurities. After the binder, aggregate, and powder are calcined at 1200℃, the aggregate can be closely combined with the matrix, and a large number of needle mesh mullite staggered growth will be formed in the matrix, and the strength will also be improved. castable refractory lining forms calcium feldspar or calcium clinoclase at high temperatures, which makes the castables dense, and resistant to erosion and refractory shock.

The fixed beam (bottom) and the stepping beam of the furnace body are affected by air scour and thermal stress factors. The mullite castable is easy to be damaged and has strong slag corrosion resistance and good thermal shock stability.

The lining body of the heating furnace can be made of castable bricks or rammed with refractory plastic. A lining working layer of refractory removable plastic rammed according to anchors. Refractory plastic billets shall be filled in the gap parts of anchoring bricks or hanging bricks and rammed and compacted with an air hammer or tamper.

Rongsheng Refractory Castable Prefabricated Block

If it’s a refractory castable bricks(blocks). The structure of the furnace wall and the top is basically the same as that of the refractory plastic furnace body. After the anchor brick and hanging brick are installed in place, pour material (castable mix material) from one side, and then use a vibrator to vibrate and compact. Continuous construction and timely maintenance should be carried out. The castables used are advised to use low cement castable refractory castable bricks(blocks) lining the working layer, furnace bottom in high-temperature area, and soaking bed are irrigated with wear-resistant steel fiber refractory castables.

To sum up, that is, different temperatures, and different parts of the selection of different materials of refractory castables. You can’t use the same material because of different temperatures and different erosion conditions. Use the same material of castable, life will be different.

Castable Refractory Price

Boiler castable refractory. Refractory castable is an amorphous refractory that is constructed with a variety of kilns by means of casting. The evolution from previous stereotypes in boiler construction to the present boiler castable refractory is also a textural change in the boiler industry. Refractory castable is composed of a variety of refractory aggregate, powder, binder, additive, and other raw materials. The material is divided into jade, high alumina, silicon carbide, mullite, magnesium, silicon, zirconium, and so on. It is used at temperatures ranging from 500 to 1700°C. The castable refractory price is also high and low with the combination of raw materials. Rongsheng refractory manufacturers have always scientifically formulated corresponding types and models according to users’ technical requirements, so as to meet users’ working requirements of kilns.

For more information on castable bricks, boiler castable refractory, and castable refractory lining, please contact Rongsheng Refractory Castable Factory. Rongsheng factory specializes in the production of non-stick aluminum castables, low cement castables, high aluminum castables, light castables, refractory castables, wear-resistant castables, etc. It is widely used in coking, building materials, steel, non-ferrous, electric power, and other industries. Free Price for aluminum silicate series, silicon series, alkaline series, light heat insulation brick series, and other shaped products and different materials of castable, free flow material, plastic, and other non-shaped materials.