Wear resistant castables are composed of high-hardness silicon carbide, corundum, premium bauxite, mullite refractory aggregates and powders, high-strength binders, and additives. They are primarily designed for high-temperature and wear resistance, and are used in linings requiring high flexural and compressive strength in high-temperature environments.
For wear resistant castables used in circulating fluidized bed boilers in power plants, they are generally formulated with fused corundum, and sometimes a certain proportion of black silicon carbide is added. The binder is pure calcium aluminate cement with silica powder.
If it is used for the lining of an alumina suspension calcining furnace, silicon carbide cannot be added; instead, sintered white corundum or fused alumina must be added in a certain proportion. If it is used for the tapping trough of a heating furnace, sub-white corundum and brown corundum must be added. For the powder, fused alumina powder is used, and for the micro powder, zircon micro powder is used.
If used at temperatures above 1500℃, it can be made into precast blocks. By adding a certain amount of SiC to the precast blocks, precast bricks for demanding applications can be made, which not only facilitates construction but also improves high-temperature wear resistance.
|
Brand/Project/Indicators |
Unit |
HX-1 |
HX-2 |
HX-3 |
|
|
Al2O3 ≥ |
% |
60 |
65 |
70 |
|
|
Bulk Density ≥ |
110℃×24h After Drying |
g/cm³ |
2.40 |
2.60 |
2.80 |
|
Flexural Strength at Room Temperature ≥ |
110℃×24h After Drying |
MPa |
7 |
8 |
9 |
|
1000℃×3h After Burning |
9 |
11 |
13 |
||
|
Room Temperature Compressive Strength ≥ |
110℃×24h After Drying |
MPa |
55 |
60 |
65 |
|
1000℃×3h After Burning |
80 |
90 |
100 |
||
|
Linear Changes After Burning |
1000℃×3h |
% |
-0.3～+0.3 |
-0.3～+0.3 |
-0.3～+0.3 |
|
Wear at Room Temperature ≤ |
1000℃×3h After Burning |
cm3 |
9 |
8 |
7 |
|
Thermal Shock Stability (1000℃, Water Cooling) ≥ |
Second-rate |
20 |
20 |
20 |
|
|
Maximum Operating Temperature |
℃ |
1400 |
1450 |
1500 |
|
|
Note: The maximum operating temperature refers to the temperature at which the linear shrinkage of the material does not exceed 1.5% after calcination for 5 hours. |
|||||
●Excellent abrasion resistance and impact resistance：
With high-hardness aggregates such as corundum, silicon carbide, and magnesium aluminum spinel as the core, combined with a dense matrix, it has low wear at room temperature and can resist the erosion of solid materials, airflow abrasion and mechanical impact, and its wear life is significantly extended compared with ordinary castables.
●High strength and mechanical stability:
It has a compressive strength of more than 60 MPa at room temperature, and its strength remains stable at medium and high temperatures and even increases with temperature. It has high flexural and adhesive strength, can withstand heavy loads and thermal stress, and is not easy to peel or crack.
●High temperature tolerance and thermal stability:
The refractoriness is generally >1700℃, and the load softening temperature is high; the linear change rate is stable, with slight shrinkage or slight expansion at high temperatures, and good thermal shock stability (≥20 water cooling cycles at 1000℃), which can adapt to rapid cooling and heating conditions.
●Anti-erosion and anti-permeability:
The low-CaO formulation reduces the eutectic phase, has low porosity and high bulk density, and has good resistance to acid and alkali slag, molten metal, alkali metal vapor and reducing atmosphere, and has strong resistance to penetration and corrosion.
●Integrity and durability:
It is integrally cast and formed without seams, with a continuous structure; it adheres firmly to the base layer, is not easy to fall off, has good durability, long maintenance cycle, and low cost.
●Adaptable to complex working conditions and has a wide range of applications
Whether in high-temperature and high-wear conditions or in working environments with alternating hot and cold conditions and frequent impacts, wear resistant castables can maintain stable performance and meet the needs of multiple industries and furnace types.
|
|
Cement industry: Decomposition furnace, feeding chute, cyclone separator, preheater cone |
|
|
Power industry: Boiler furnace, cyclone separator, economizer, etc. |
|
|
Metallurgical industry: Linings and easily worn parts of equipment such as blast furnaces, hot blast stoves, converters, and electric arc furnaces. |
|
|
Chemical and petrochemical industries: Refractory and wear-resistant linings for reactors, pyrolysis furnaces, pipelines, etc. |
|
|
Other parts of industrial furnaces that are subjected to particle impact or high-speed airflow abrasion. |
Strictly control the amount of water added to avoid affecting the density.
Vibrate thoroughly during pouring to ensure there are no voids.
Perform curing and oven drying as recommended to achieve optimal wear resistance.
|
30+ years of experience in refractory material research and engineering applications |
A complete range of wear-resistant materials products, with customizable designs. |
|
With its own automated production line, quality is stable and traceable. |
Provides one-stop service including selection, construction and technical support |
Standard packaging: 50kg individual bags/ton bags/pallet packaging/sealed packaging, customization is available;
Storage method: The storage environment should be kept dry and ventilated; the performance is stable under the specified storage conditions.
Q1：What is the shelf life of the product?
A：Under proper storage conditions (a cool, dry, and well-ventilated place, away from moisture and direct sunlight), the product has a shelf life of 6 months.
Q2：What is the minimum order quantity?
A：Our minimum order quantity is 10 tons. If you have special requirements, you can discuss them with our sales team.
Q3：What is the typical delivery time?
A：For standard models, delivery will be made within 7-10 business days after receiving the prepayment; for custom-made products, the delivery time may be extended depending on the specific circumstances, generally 15-20 business days.
Q4：What pretreatments are required before using the product?
A：Before construction, ensure that the construction surface is clean, dry, and free of oil, dust, and other debris; for the renovation of old equipment, remove any damaged or loose parts from the surface.
Q5：Are there any requirements regarding ambient temperature during construction?
A：The ambient temperature during construction should be between 5-35℃. If the temperature is too low, insulation measures should be taken; if the temperature is too high, appropriate shading and cooling measures should be taken to ensure construction quality.
Q6：How should we handle product quality issues?
A：If the issue is determined to be a product quality problem, we will replace the product for the customer free of charge and cover all related costs.
Q7：Do you provide samples?
A：Yes, we can provide free samples, but the shipping cost of the samples must be borne by the customer.
Q8：Do you support OEM/ODM cooperation?
A：Yes, we fully support OEM and ODM collaborations and can provide flexible solutions from product customization to full-chain services based on customer needs.
Hot Tags: Wear resistant castable, China Wear resistant castable manufacturers, suppliers, factory, Hot Blast Furnace Refractory Spray Coating, Refractory Ramming Mass, Refractory Repair Material, Steel Fiber Castable, High Strength and Wear-resistant Castable, Silicon Carbide Ramming Mass