Product Description of Low Cement and Ultra-Low Cement Castables
Low and ultra-low Cement Castables have the characteristics of small pore size, large density, good volume stability, high strength and small amount of water. They overcome the characteristics that the strength of ordinary castables decreases significantly at 800~1200 ℃, increase with the increase of temperature, and have excellent thermal shock resistance, slag resistance and corrosion resistance.
Features of Low Cement and Ultra-Low Cement Castables:
1. Good slagresistance
2.High load softening temperature
3.Wear resistant, High compressive strength
4.High density lowporosity
5.Long service life
6. Energy saving,emission reduction
Advantages of Low Cement and Ultra-Low Cement Castables:2.High load softening temperature
3.Wear resistant, High compressive strength
4.High density lowporosity
5.Long service life
6. Energy saving,emission reduction
Compared with ordinary refractory castables, low-water low and ultra-low cement castables have a series of excellent properties. Therefore, low cement castables are widely used in the non-ferrous smelting and steel industry.
First, because the amount of cement added is only 1/2~1/15 of the ordinary refractory castable, the CaO brought into the castable is reduced from 2.5~8% to 0~2.5%. Therefore, the amount of the eutectic phase formed in the matrix is greatly reduced. Furthermore, the refractoriness, high-temperature strength, and slag resistance are all improved. As the amount of cement increases, the refractoriness decreases linearly. On the contrary, the low melting point is reduced at high temperature, so that the wear resistance, high-temperature flexural strength, and load softening temperature of the castable are significantly improved.
Second, the water demand during mixing is only 1/2~1/3 (about 4~6%) of ordinary refractory castables. Therefore, the porosity is low and the body density is high, which is comparable to fired refractory products of the same material. The difference in the amount of water added results in different strengths of the castable.
Third, there is little or no cement hydrate after molding and curing. During the heating and baking, there is no problem that a large number of hydration bonds are destroyed and the strength is affected. Instead, as the heat treatment temperature increases, it gradually sinters and the strength gradually increases. Especially different from ordinary low cement castables, the mechanical strength is higher than the drying strength in the middle-temperature zone (900~1200℃). Both high temperature and normal temperature strength are better than ordinary castables.
Product Application of Our Refractory Castable With Low And Ultra Low Cement Castable Refractory
Refractory castables with low and ultra-low cement content are specialized monolithic refractory materials that offer excellent performance in high-temperature environments. Their applications are widespread across various industries due to their superior physical and mechanical properties, such as high strength, excellent abrasion resistance, and reduced porosity. Below are some key applications:
1. Iron & Steel Industry
Blast Furnaces: Low and ultra-low cement refractory castables are used in the lining of blast furnaces due to their high resistance to thermal shock, mechanical stress, and chemical attack.
Tundishes and Ladles: These castables provide enhanced durability and minimize the risk of contamination during the steel production process.
2. Cement Industry
Rotary Kilns: The high thermal stability and resistance to alkali attacks make these castables ideal for lining rotary kilns in the cement industry.
Preheater and Cooler Areas: The low cement content improves the lining’s resistance to wear and chemical attack in these high-stress areas.
3. Non-Ferrous Metal Industry
Smelting Furnaces: In the production of non-ferrous metals like aluminum and copper, these castables are employed for furnace linings due to their ability to withstand aggressive slags and high temperatures.
Holding Furnaces: Their excellent thermal insulation properties help maintain consistent temperatures, crucial for the quality of the metal.
4. Petrochemical Industry
Fluid Catalytic Cracking Units (FCCUs): The low porosity and high strength of low and ultra-low cement castables make them suitable for the harsh operating conditions in FCCUs.
Refining and Gasification Units: They provide long service life and efficient performance under corrosive environments and high thermal loads.
5. Power Industry
Boilers and Incinerators: These castables are widely used in the lining of boilers and incinerators where high thermal efficiency and resistance to thermal cycling are essential.
Ash Hoppers: The abrasion resistance and durability of these materials make them ideal for areas where ash and slag can cause significant wear.
6. Glass Industry
Regenerators and Melting Tanks: The high thermal resistance and chemical stability of low and ultra-low cement refractory castables are vital in the extreme conditions of glass production.
7. Environmental and Waste Management
Waste Incineration Plants: These castables are used in waste incineration due to their ability to withstand the chemical and thermal shocks caused by the combustion of various waste materials.
Thermal Oxidizers: Their application in thermal oxidizers ensures long-term performance in reducing emissions and handling aggressive chemical environments.
8. Other Applications
Foundries: The excellent wear resistance and durability make these castables suitable for lining foundry ladles and furnaces.
Ceramics Industry: They are used in kiln linings, especially where a stable thermal environment is crucial for the quality of ceramic products.
