Pellets, Sintering Castables, Prefabricated Parts, Spraying (painting) Materials

Pelletizing and sintering refractory castables and prefabricated blocks are amorphous refractory materials. They are suitable for high temperature environments with acidic corrosion, alkaline corrosion, wear resistance and erosion resistance. Suitable refractory castable products should be selected according to the different environmental properties mentioned above. They can be produced according to the specific size and specifications of customers, customized according to the use environment requirements, material requirements, and the size of the drawings provided by customers!
The number and size of prefabricated blocks of pelletizing and sintering refractory castables should be determined according to the size of the furnace and the thickness of the furnace lining. Not only the shape and size should be considered, but also the convenience of management and construction. Generally, the unit weight of refractory prefabricated parts for hoisting and installation of furnaces should be 1-3 tons, and the unit weight of prefabricated blocks for kiln masonry that need to be manually carried should not exceed 30-50kg.
The refractory material specially developed by our company for the lining of the pelletizing rotary kiln in the RKEF process of smelting nickel iron from laterite nickel ore has better wear resistance and higher compressive strength than general castables, and its service life is more than doubled.
① Steel fiber wear-resistant castable: used for the feed port and preheating zone of the rotary kiln, its product features good wear resistance.
② High-strength steel fiber wear-resistant material: used for the transition zone of the rotary kiln, its product features good wear resistance and high density.
③ Anti-ringing silicon carbide castable: used for the firing zone of the rotary kiln, its product features good anti-ringing and anti-stripping performance, high compressive strength and wear resistance.
④ Special castable for kiln mouth: used for the discharge port of the rotary kiln and the retaining ring of the high-temperature belt, its product features are erosion resistance, excellent thermal shock stability, wear resistance and high compressive strength.

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Description

Pelletizing rotary kiln process flow

1. Raw material preparation: After a series of treatments such as crushing, screening, and grinding, iron ore concentrate powder containing a large amount of water is obtained, and then the excess water is removed by a dryer, and then transported to the blade grinder via a belt to make the ore powder particles finer so that it is easy to form balls.

2. Batching and mixing: The batching silo is designed according to the size and quantity of the production line capacity. Except for one for bentonite, the rest are iron concentrate powder, and the proportion of bentonite is usually less than 2%. The dried material enters the moist grinder or a strong mixer for further fine grinding to facilitate ball making, and at the same time, the material can be fully mixed.

3. Ball making and screening: The dried and ground material enters the ball making disk through a belt conveyor for ball making, and an appropriate amount of physical and chemical water is added. The finished balls are screened, and qualified pellets enter the next process.

4. Drying, preheating and roasting: The qualified balls screened are arranged in the receiving section of the chain grate. After drying, preheating and partial oxidation by the chain grate, the moisture is removed and the strength is improved. Then it enters the rotary kiln through the head of the chain grate machine for high-temperature roasting, so that the pellets undergo a consolidation reaction.

5. Cooling: After roasting, the pellets are cooled by a ring cooler to gradually reduce their temperature to a state that can be transported and stored. In addition, the pelletizing rotary kiln process also includes other links such as material distribution, coal making system, raw material system, dry mixing system, etc. These links are interrelated and affect each other. In the entire process, the parameters and operating conditions of each link need to be strictly controlled to ensure the quality and output of the pellets.

Material grade project		HX-GM70	HX-GM65	HX-M60	HX-PT1.7	HX-PT2.0	HX-PT2.3
Al₂O₃％≥		70	65	60	35	40	45
Bulk density (gm³)		2.70	2.60	2.50	1.7	2.0	2.3
Pressure resistance：(MPa)≥	110℃×24h	80	60	50	20	40	60
	1100℃×3h	90	70	70	40	60	80
Flexural strength：(MPa)≥	110℃×24h	10	8	8	4	6	8
	1100℃×3h	14	12	10	6	8	10
1100C×3h Line change rate 1%		(1350℃×3h) ±0.3	±0.5	±0.5	(1000℃×3h) ±1.0	±0.5	±0.5
Long-term use temperature ℃		1500	1450	1400	900-1000	1200	1300
Usage Environment		Pelletizing rotary kiln, sintering machine ignition furnace and other high temperature wear-resistant parts	Pelletizing rotary kiln, sintering machine ignition furnace and other high temperature wear-resistant parts	Pellet chain grate preheating section, ring cooler cooling section II and III	Pelletizing ring cooler low temperature smoke hood, sintering low temperature section smoke duct Construction method: spray or apply	Pelletizing, sintering high temperature pipes Construction method: spraying or painting	Pelletizing, sintering hood, special parts that are difficult to construct Construction method: spray or apply

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