Requirements for refractory material sintering workshop

(1) According to the inspection procedures and requirements, organize technical personnel, in the implementation of control operator point examination of the refractory, and fill in the inspection report;

(2) in accordance with the construction standard,refractory material making process and technical personnel and control operator attendant operating plan, check the construction progress and quality of refractory material, refractory material construction quality control;

(3) Fill in the refractory material construction quality inspection and acceptance form; summarize the construction of the management accounting report, leaders in charge of production approval;

(4) Check out kiln burner, heating curve, refractories and approval of the organization in charge of the leadership at the company after the implementation of;

(5) According to the use of inspection of refractory materials, internal operating personnel and technology staff to discuss analysis, put forward the improvement and optimization of operation opinions; for the refractory material quality and cost for construction.

The production process of refractory materials

According to the product and density of the different shape, sintering method, casting and meltblowing process. The sintering process is part of the raw material will burn in mature, crushing and screening, and then according to a certain ratio and raw material mixing, molding, drying and firing after. Raw materials burn to the gas in water, organic impurities, sulfate decomposition and burning, to reduce product firing shrinkage, ensure the accuracy of refractories size. Raw materials need to be screened in crushing and grinding is, because the billet is graded by the powder of different particle size, can guarantee the most compact and dense body.

In order to make all kinds of raw material and clinker composition and particle uniformity, for mixing, adding binder, in order to enhance the bonding strength of the blank. Such as aluminum silicate material is mixed with clay, magnesium billets into sulfite pulp waste liquid,silicon material with lime milk. According to the material moisture, can adopt semi dry method (containing about 5% of water), plastic molding (containing about 15% moisture) and grouting molding (containing about 40% of water). And then drying and firing. Casting is the raw material through blending blending and grinding processes, directly in high temperature melting, casting, the cooling crystallization, annealing become products. As cast mullite brick, corundum brick and magnesia brick etc… Their body is compact, high mechanical strength, high temperature strength, good slag resistance, use range expanding. Melt blowing method is to put the ingredients melting, with high pressure air or steam injection, dispersing method of fiber and hollow spheres. Products are mainly used as lightweight refractory, insulation material. In addition, also can be made into powdered or granular unshaped refractory materials, the tar, asphalt, used in cement, phosphate, sulfate and chloride salt bond cementation, not forming and sintering and direct use.

New type refractory coatings improve furnace life 3 times

High temperature furnace refractory castable, including insulating brick, metal, ceramic, refractory fiber, quartz sand, silicon carbide, quartz glass. High temperature furnace refractorymaterial in high temperature, high temperature resistance, oxidation resistance, corrosion resistance, high strength, bending, expansion coefficient, wear rate is relatively serious. After long time operation of high temperature, high temperature furnace refractories is easy to appear the crisp, crack, fall off, aging, thermal insulation characteristics of the poor, to bring great security risks furnace and kiln kiln shutdown serious energy loss, not repair, serious economic losses. Now  Xinmi Changing Refractories Co., the company for many years R & D and production of ZS-1022 furnace lining protection coating, the coating selection of Xinmi Changxing special high temperature film forming solution, the ceramic oxide, silicon carbide, rare earth oxide, ceramic fiber refractory inorganic materials in high speed dispersion polymerization and. High temperature resistant, impact resistance, aging resistance, high coefficient of linear expansion, convenient construction, high adhesion. High temperature furnace refractory coating,  furnace lining to protective clothing to put on a layer of solid, protecting furnace lining refractory material good, forming a layer of high temperature refractory coating dense integration, greatly prolong the furnace lining materials using time and reduce the damage rate of the furnace lining materials, repair repair greatly shorten the time, prolong furnace the normal use of time more than 3 times, can bring considerable economic benefits to the enterprise.

Effects of organizational structure on performance of refractory materials

Influence of refractory materials under various physical, chemical reactions at hightemperature in the process of using the occurrence of corrosion, wear, or split and cause damage. Therefore, refractory material must have the ability to adapt to various working conditions, and the performance and composition and structure is closely related to the.

Chemical composition is the basic characteristics of refractory materials; the main component is the basic feature ofrefractory material, so the composition and quantity directly determines the performance of refractory materials. Refractory products at the same time, mineral composition, product properties are the comprehensive reflection of minerals and micro structure, and therefore cannot only from the chemical composition analysis of the effect on the properties of products. The refractory material of mineral composition and depends on the chemical composition and process conditions. Although the same chemical composition. If the different processing conditions. The crystalline phase and the number of mineral species will also have the difference, the different properties of refractory materials. However, it must be stressed that refractory material macro organizationalstructure is an important factor which influences the performance, and performance index and can reflect the internal structure ofrefractories. For example: – densification properties of porosity, density, true density body Zhi said gas permeation properties of the ease of permeability: properties thermal properties of linear expansion coefficient, thermal conductivity, heat capacity and thermal conductivity; representation properties mechanical properties and high temperature strength, high temperature often pits, bending strength high temperature tensional strength, high temperature creep and elastic modulus; as, refractoriness, refractoriness under load, high temperature and volume stability, thermal shock resistance and slag resistance of high temperature performance.

Therefore, the use of departments must be from the characteristics and process of thermal equipment requirements, carefully selected according to the chemical composition, mineral structure, refractory material and macro microstructure and performance indicators, in order to achieve the desired effect

Correct using method make refractories have anti damage ability

Supporting the development of refractories for the clinker rotary kiln each work with the different mining conditions, targeted to different anti damage of refractory materials, andconsidering the basic matching problem with various working lining life, reduce maintenance times to stop the kiln, each work with lining, the anti damage of independent and phase the purpose of matching cycle. Lining material preheating with good chemical stability, alkali erosion leaf wax stone brick and strong, the pyrophyllite using low alkali and high alkali bricks siliceous raw material, the raw material made of, whether or not to burn the Chengdu firing with anti alkaline strong, but the strength is high, nearly doubled than clay brick life.

The industrial trials in Xinmi Changxing Refractories Co., and recommended for coke oven chamber wall three hot repair methods: flame spraying; ceramic welding using oxygen; theexothermic material (heating material) to repair. The process is: with the help of the principle of common heat generated to form a protective layer on the surface of masonry of refractory material to repair the surface.

Flame gunning method of flame gunning refractory products, powder particles melt in the liquid or gaseous fuel to the flame, and was sent to the surface to be repaired. The masonry is nozzle flame of heating, so using this method without special restrictions on the temperature, but also can be used to refractory powder cheaper to obtain high quality spraying layer. The principle of the ceramic welding method is added to the material of strong oxidant (exothermic material: aluminum, silicon etc.). Wind transport by means of oxygen jet flames, oxidant and refractory powder to the surface to be repaired.

The characteristics of refractory fiber

1 high temperature resistant.

The highest use temperature up to 1250~2500 degrees. The most commonly used asbestos is 

only 500~550 degrees, 580~830 degrees C and slag wool, aluminum silicate fiber reaches more than 1000 DEG C.

2 conductivity is low.

Refractory fiber under high temperature thermal conductivity is very low, such as 1000 DEG C, thermal conductivity of aluminum silicate fiber only for clay brick lightweight clay brick 20%, 38%.

3 small volume densities.

Generally 0.1~0.2g/cm fand, general clay brick lightweight clay brick for 1/20~1/10, 1/10~1/5. Therefore, the application of industrial furnace refractory fiber instead of refractory brick, the furnace body weight, wall thickness. Such as heating furnace lining is reduced by 80%, the furnace wall thickness of 50%.

4 good chemical stability.

In addition to alkali, fluoride, sulphate, almost not affected by chemical erosion.

5 good thermal shock resistances.

Regardless of the fiber material or product, all brick incomparable good thermal shock resistance.

6 low thermal capacity.

1/72 heat capacity of fiber material only light refractory brick, clay brick 1/42. Refractory lining in the afternoon to do, heat loss is small, fuel saving, fast temperature rise, the intermittent operation furnace was love.

7 soft, easy processing.

Can be made into a variety of products and shape of parts, construction is convenient, the labor intensity is low, the effect is good.

Methods to decrease the porosity rate of refractory brick

Production of refractory  brick  is always encountered too many holes, how can we reduce the occurrence of this situation? Today we shall all requirements to introduce how to reduce the rate of porosity of refractory brick.

Selection of high density, low water absorption rate of the raw material, through the reasonable distribution is the key to prepare low porosity refractory brick. Refractory brick is used 50% of the soft clay and 50% hard clay clinker ingredients, according to a certain size requirements, forming, drying, firing at high temperature of 1300~1400 DEG C under the. Refractory mineral is mainly composed of kaolinite (Al2O3 – 2SiO2 – 2H2O) and 6%~7% impurities (potassium, sodium, calcium, titanium, iron oxide). The sintering process is mainly kaolinite continuous dehydration decomposition of mullite (3Al2O3 – 2SiO2) crystallization process. Refractory brick in SiO2 and Al2O3 on the sintering of eutectic of low melting point of silicate and impurities in the formation process of mullite crystals surrounded by around. In the process of baking temperature control at 1350 to 1380 DEG C, appropriate to increase the low porosity clay brick firing temperature (1420 C), refractory brick contraction increased slightly, so that the refractory brick density increases slightly, and low porosity can be reduced.