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Composition and application of high-strength and wear-resistant castable

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Industry News

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2024-04-15

High strength and wear-resistant castables are mainly composed of wear-resistant aggregates such as brown corundum and silicon carbide, as well as ultrafine powder. At the same time, sintering agents, ultrafine powder, coating additives, ceramic powder, composite material powder, composite adhesive, etc. are added. The particles are tightly packed, forming quickly, and the strength is high. It can reach the design strength in three days, so there are no major macroscopic defects during use. The volume density is high, and its strength at room temperature can reach over 200Mpa. It is more than 50 times the service life of ordinary concrete and refractory pouring materials.

The raw materials mainly use ionic compounds and some artificially synthesized covalent compounds. According to solid theory, ionic bonds and covalent bonds belong to strong bonding bonds. The bonding system, due to the use of composite strengthening measures and special treatments, forms chemical bonds, which have high strength and stiffness and can effectively resist the high-speed impact and shear stress of the material.

Due to the use of special raw materials that are acid and alkali resistant, the performance is stable and will not react with the medium. At the same time, the raw materials for wear-resistant ceramic coatings are mostly high-temperature synthetic materials, with well-developed crystals and complete structures, which are not affected by environmental factors. They are one of the inert materials and can effectively resist environmental media and various chemical corrosion.

1、 Wear resistance of wear-resistant ceramic coatings: In order to demonstrate the wear resistance of wear-resistant ceramic coatings, comparative experiments were conducted.

(1) Comparative materials: wear-resistant ceramic coatings, 16Mn wear-resistant steel, 65Mn wear-resistant steel, refractory castables, and wear-resistant ceramic sheets. (2) Experimental conditions and process: Time: 15 minutes; Medium: 0.5-1mm diamond sand; Speed: 120m/s; Distance from nozzle to sample block: 230mm; Angle between nozzle and sample block: 90 °. (3) Conclusion: The wear resistance of room temperature wear-resistant ceramic coatings is 10 times that of 16Mn steel, 9 times that of 65Mn steel, and 50 times that of refractory castables. The wear resistance of wear-resistant ceramic coatings changes little with the increase of usage temperature. (4) Physical and chemical indicators: volumetric density (g/cm3) 2.99; Thermal conductivity coefficient (W/m.k) 1.5; Pressure resistance strength (110 ℃ x 24h) 161; Pressure resistance strength (850 ℃ x 3h) 135; Bending strength (110 ℃ x 24h) 17.8; Bending strength (850 ℃ x 3h) 16; Wear resistance (g/cm2) 1.1* Use temperature (℃) 1000.

2、 Widely used in cement plants, coal-fired power plants, steel industry, and petrochemical industry
1. The cyclone separator in the cyclone or dust collector air duct from the vertical mill outlet to the bucket machine bucket body ore, raw coal conveying silo, and hopper catalytic cracking unit
2. The upper, middle, and lower shells of the vertical mill, as well as the bottom plate of the belt conveyor, hopper trolley, three-way hopper, and receiving hopper reactor
3. Vertical mill upper cone, lower cone hopper, and feed chute raw coal hopper (silo) coking ingredient mixing silo regenerator
4. Vibration screen for the sintering system of the shell coke bin of the vertical mill powder selection machine; Material trough and beneficiation hopper flue
5 vertical mill sealed air duct coal mill outlet pipeline, long-distance beneficiation material bin, hopper catalyst transportation pipeline
6. Raw material combination powder selection machine inlet duct and cyclone cylinder shell, medium speed grinding cylinder body and separation baffle dust collector shell and pipeline, carbon monoxide waste heat boiler
7. All cyclone separator shells and inlet and outlet air ducts, including cyclone drum coarse and fine powder cyclone separator shells, cone buckets, and inlet and outlet pipelines, coal-fired boiler flue
8. Fan cooler to electric dust collector air duct, primary and secondary air ducts, coal-fired boiler conveying duct
9. The shell of the electric dust collector and the top sintering material bin coarse and fine powder separator shell, as well as the inlet and outlet air ducts
10. Triple air ducts and high-temperature valves. High temperature fan casing, powder exhaust machine casing, and inlet and outlet air ducts
11 C1 cyclone outlet air duct and bent pipe powder exhaust machine casing and air duct sintering feed chute
12. Dust collection system for wear-resistant straight pipes and bent combustion gas cone sintering bed for coal powder conveying at the kiln head and tail
13. High temperature fan casing and inlet/outlet air ducts, circulating fluidized bed boiler combustion chamber, high temperature cyclone separator, blast furnace feed chute
14. Circulating fan casing, inlet and outlet air ducts, boiler flue, blast furnace stone water quenching flow, and stone material bin
Other strongly worn and eroded parts of the feeding pipe of the 15 media grinding head and the coal powder conveying pipeline of the raw coal bin storage hopper
16. Shell and inlet/outlet air duct of coal mill powder selection machine, dust collector pipeline and elbow
17 Coal mill high-temperature fan casing and inlet and outlet air ducts Coal slag and coal conveying pipelines
18. Cement mill powder selection machine shell, inlet and outlet air duct dry ash air selection machine inner shell
19 Cement mill dust collector inlet duct and inlet duct