Energy shortage is a reality in today’s world, and saving energy is an important task for all countries. Under this situation, lightweight refractory castables have developed rapidly, with expanded varieties, improved quality, increased output, and wide applications. In the past, in kilns with temperatures above 1000°C, lightweight refractory castables could only be used as insulation layers and were difficult to directly contact the flame. Nowadays, all lightweight refractory castables for flame kilns with temperatures below 1800°C can be produced, and some can be used as their working linings. So, as the use temperature of lightweight refractory castables increases, what will the high temperature lightweight castable refractory price be like?
RS High Temperature Lightweight Castable Refractory
RS High Temperature Lightweight Castable Refractory
Generally, the volume density is less than 1800kg/m3, and there is no requirement for refractoriness. Or castables with a total porosity greater than 45% and a linear shrinkage rate of less than 1.5% at the specified temperature. It is called lightweight refractory castable.
The raw materials for making high-temperature lightweight castable refractory are rich and diverse, including porous clinkers or lightweight waste bricks such as high alumina, mullite, corundum, siliceous, and magnesia, as well as various oxides and fibers. However, in actual industrial applications, high-alumina and mullite-based porous clinkers are widely used due to their wide sources and affordable prices. For some special use requirements, a small amount of alumina or zirconia hollow balls, high alumina fiber, and alumina fiber will be used. Of course, the higher the requirements, the higher the lightweight castable refractory price.
Lightweight refractory castables are characterized by low volume density and low thermal conductivity, so they have good thermal insulation properties. There are many varieties of lightweight refractory castables, which are generally classified according to principles such as lightweight aggregate varieties, production methods, binder types, and performance levels. The most commonly used types of lightweight aggregates are lightweight refractory castables such as lightweight brick sand, porous clinker, hollow balls, ceramsite, and expanded perlite.
lightweight castable refractory binder selection
The choice of binder for castables is equally important. Pure calcium aluminate cement, aluminum dihydrogen phosphate, aluminum sulfate, and silica sol can all play a good bonding role. It is mainly composed of mullite porous clinker with an Al203 content of 65%~72% and a volume density of 1.00~1.25g/cm³, with pure calcium aluminate cement as the binding agent, and an appropriate amount of silica powder. The prepared mullite lightweight castable has excellent physical and chemical properties. It can be directly applied to high temperature atmosphere furnace lining of 1350℃.
Alumina Bubble Castable Refractory Physical and Chemical Properties
Mullite Furnace Castable Refractory. Lightweight castable refractory price. Use alumina hollow balls with an Al2O3 content greater than 98% and a natural bulk density of 500~800g/L as aggregate. Use α-A1203 as the powder, pure calcium aluminate cement, and reactive alumina as the binding agent. The physical and chemical properties of the prepared Alumina Bubble Castable material are as follows:
Al2O3 content is greater than 96%. After drying at 110℃ for 24 hours, the bulk density is 1.3~1.6g/cm3, and the compressive strength is 3~8MPa. The bulk density after burning at 1550℃ is 1.35~1.65g/cm3, and the compressive strength is 4~12MPa. The true porosity is 55%~65%. Thermal conductivity (hot surface temperature 1100℃) 0.9~1.1W/(m · K). Alumina hollow ball castables can be directly used as the working lining of high-temperature (greater than 1500°C) atmosphere furnaces.
Lightweight refractory castables are widely used in the lining of kilns, thermal equipment, flues, and chimneys in industrial sectors such as metallurgy, machinery, petrochemicals, electric power, and building materials. As a thermal insulation (heat preservation) layer, it plays an irreplaceable role. With the improvement of lightweight refractory castable materials and the continuous advancement of preparation technology, its application scope has gradually expanded. On more and more occasions, lightweight refractory castables are directly used as the working lining of atmosphere furnaces, subject to meeting set and actual working conditions.
Generally speaking, low and medium-temperature lightweight castables are mainly used as thermal insulation linings and are not in direct contact with flames. However, most of the high-temperature lightweight castables are directly used as working linings that are not in contact with the melt or solid medium in the furnace. Especially for the working linings of various heating furnaces and heat treatment furnaces, lightweight refractory castables have shown incomparable advantages. High-temperature lightweight refractory castables can significantly save energy consumption and have high practical value.
RS Furnace Castable Refractory Factory can provide the design and construction of high-temperature lightweight refractory materials for various high-temperature industrial kilns. At the same time, we also have refractory insulation brick products with high strength and small size. Contact us for a quote for high temperature lightweight castable refractory price.
