Comparison of the used refractory bricks and refractory insulation casting

Refractory materials are widely used in thermal industry. The share of fire-resistant insulating castings is constantly growing, but fire brick still has a certain position. Below is a comparison between refractory bricks and refractory castings used.

Which fire bricks are more widely used?

Functional refractories play an important role in regulating steel consumption in continuous steel casting. In other applications, high-quality refractory casting materials have not yet been developed, Therefore, fire brick products are still the main choice. In most cases, when basic refractory linings are used (dolomite, magnesium, magnesian carbon, magnesium chromium), preference is given to products made of refractory bricks. For example, Converter inner lining, slag brick ladle, electric furnace firebox wall, firing zone and transition zone of rotary kiln for cement kiln, non-ferrous metal smelting lining (copper, lead, zinc, etc.).

Application of refractory casting material

Refractory insulating castings are used not only for the production of new shapeless refractory linings, but also widely used for repairing and maintaining refractory linings in working condition. There are various methods for making refractory castings, including vibrating and non-vibrating (self-flowing) filling, shotcrete, tamping and pressing. – Certain steel making methods will continue to be the leading methods for making refractory castings. According to traditional method, refractory insulating casting material is used as the bottom of traditional electric arc furnace (basic refractory), drilling fluid, blast furnace outlet chute and some materials for repair and maintenance. In some cases, products of complex shapes were replaced by shapeless refractory materials, resulting in composite claddings. An example is waste incineration plants..

Refractory castings for furnace maintenance

Refractory castings play an important role in furnace maintenance, since major repairs can be carried out with minimal downtime, and in some cases during operation of the furnace. Systematic repair of the lining can extend the life of the furnace. A successful example is the repair of alkaline cladding, purged with oxygen (brick MgO-C). Using alkaline mixtures to spray regularly and precisely control slag formation, Sprinkling slag to protect the furnace can increase the life of the internal furnace lining by more than 2000 once, while the consumption of refractory materials per ton of steel can be reduced to less than 1 kg.

Problems with refractory insulating casting material

Although the design of refractory casting material is simple, it often cracks when used.

Advantages of refractory castings over refractory bricks

1. Less energy consumption during production, total 1/15~1/20 fire brick.
2. Labor costs are low, and the production efficiency when used is 3~8 times higher, than fire bricks.
3. The finished refractory casting is easy to store and transport.
4. This allows for mechanized construction of the furnace. Construction efficiency in 5-15 times higher, than with brickwork.
5. It can be given any shape and made of one-piece cladding, which can increase its service life by 30%~150%, and for some it may be several times more.
6. At the same time there are no seams, good air tightness, less heat loss and the possibility of significant energy savings.
7. This allows you to repair the stove, extend its service life and increase the speed of the furnace.