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What Are The Commonly Used Refractory Castables

2024-12-13

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There are numerous types of commonly used refractory castables. Based on different classification criteria, they can be categorized into various types. Below are some common types of refractory castables:

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Classification by Binding Method

1.Hydraulic Binding Refractory Castables

Silicate Cement-Bonded Refractory Castables: These are prepared using ordinary silicate cement, slag silicate cement, etc., as binders, combined with refractory aggregates and powders. They are suitable for use at temperatures of 700–1200°C and can be applied in integral load-bearing heat-resistant structures and kiln linings.
Aluminate Cement-Bonded Refractory Castables: Known for their rapid hardening, high strength, good thermal shock resistance, and high refractoriness, they can be used at temperatures up to around 1800°C and are widely applied in industries such as metallurgy and petrochemicals.
Low Cement Refractory Castables: With calcium aluminate cement content below 8%, they feature high density, low porosity, and high strength, making them suitable for applications like blast furnace iron troughs and steel ladles.
Ultra-Low Cement Refractory Castables: With even lower cement content than low-cement castables, they exhibit superior performance and are widely used in high-temperature areas such as blast furnace iron troughs.

Chemical Binding Refractory Castables

Sodium Silicate-Bonded Refractory Castables: These are air-hardening refractory materials prepared using sodium silicate as a binder and various refractory aggregates. They feature minimal strength loss at high temperatures, good thermal shock resistance, excellent high-temperature wear and corrosion resistance, and a maximum service temperature of 1400°C.
Phosphoric Acid and Phosphate-Bonded Refractory Castables: These are new refractory materials made by combining phosphoric acid or phosphate solutions with refractory aggregates and powders in specific proportions, offering excellent performance.

Classification by Aggregate Material

Silica Refractory Castables: Use silica stone and quartz sand as primary raw materials.
Semi-Silica Refractory Castables: Contain silica and clay-based raw materials.
Clay Refractory Castables: Use clay and shale as primary raw materials, suitable for temperatures of 700–1200°C, and applicable in integral load-bearing heat-resistant structures and kiln linings.
High-Alumina Refractory Castables: Use high-alumina bauxite and alumina as primary raw materials. They are commonly used in kiln linings with temperatures exceeding 1300°C, offering low cost and high overall strength.
Corundum Refractory Castables: Use corundum as the primary raw material, featuring high strength, excellent slag resistance, and a service temperature of 1500–1800°C.
Magnesia Refractory Castables: Use magnesia and magnesite as primary raw materials.
Spinel Refractory Castables: Use spinel as the primary raw material.
Special Aggregate Refractory Castables: Include silicon carbide, chrome slag, zircon sand, etc.

Classification by Performance Characteristics

High-Strength Wear-Resistant Castables: These unburned refractory materials have slightly lower refractoriness than fired refractory products but feature high ambient temperature strength and excellent resistance to cracking.

Lightweight Insulating Refractory Castables: Comprising lightweight porous refractory materials as aggregates and admixtures, these mixtures are combined with binders and water during construction. They are characterized by low weight, low bulk density, and low thermal conductivity, making them ideal for furnace insulation layers and inner linings of furnace covers.
Non-Stick Aluminum Castables: Made with high-purity mullite, andalusite, and sillimanite as base materials, they feature high bulk density, high strength, and good thermal shock resistance. Adding appropriate non-wetting agents significantly reduces the wettability of aluminum and alloys on refractory materials.
Self-Flowing Refractory Castables: Known for excellent construction and usage performance, these are primarily used in complex high-temperature industrial kiln structures that are difficult to construct.

Classification by Application Areas

Special Castables for Kiln Mouths: Applied at kiln heads and tails of rotary kilns, these refractory materials feature good thermal shock resistance, easy kiln skin adhesion, and wear resistance.
Special Castables for Steel Ladles: Such as corundum-spinel prefabricated blocks made from fused white corundum, tabular corundum, and sintered magnesium-aluminum spinel, offering high strength, erosion resistance, and spalling resistance.
Special Castables for Boiler Furnaces: Made from high-quality calcined bauxite aggregates, calcium aluminate cement, and microsilica powder as binders, with the addition of silicon carbide wear-resistant particles and dispersants.

In conclusion, there is a wide variety of commonly used refractory castables, each with unique characteristics and applications. When selecting refractory castables, it is essential to consider the specific use environment and requirements to make an appropriate choice.

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