Monolithic refractories, a kind of unshaped refractory, are made of refractory aggregate and powder with certain grain size distribution, binding agent and admixture, which can be directly used for lining of thermal equipment by baking without firing process. Monolithic refractory has the good features of simple process, energy saving, low cost and easy mechanized construction. Compared with using effect, monolithic refractory is better than firebrick for some heating equipment application.
Description for Monolithic Refractories
Monolithic refractories are used directly by mixing of refractory aggregate and powder with certain grain size distribution, binding agent and admixture without firing process. Monolithic refractory has no fixed shapes that can be made to be pulpiness, paste and loose material and used to build monolithic construction.
Aggregate and powder of monolithic refractories can be any texture for refractory materials. Monolithic refractory can be classified to be silica refractory, fireclay refractory, high alumina refractory, magnesia refractory, dolomite refractory and chrome refractory according to texture of raw material. There is a great variety of binding agents such as various cement, mineral salt and organic matter. Monolithic refractories also can be classified into castable refractory, plastic refractory, ramming mass, slinging refractory, refractory mortar, fireproof paint and etc. according to processing property.
Manufacturing Process of Monolithic Refractories
There are several methods such as ramming process, vibration molding, gunning and slinger process and etc. to make monolithic refractories. Use these refractory to replace or cold and hot repair through painting or slinging when the local of firebrick masonry or monolithic construction is damage, which is quick and economic. Monolithic refractory can be used for lining of all kinds of position of furnace or kiln and protective layer and joint sealing material for masonry based on its materials’ properties.
Classification of Monolithic Refractories
Monolithic refractories can be classified into castable refractory, plastic refractory, ramming mass, gunning mix, slinging refractory, fireproof paint and etc. according to construction method and material property.
Castable refractory is a kind of fluid unshaped refractory that doesn’t need firing after adding water, which adopts aluminium silicate clinker, corundum material or alkaline refractory clinker as the aggregate and adopts calcium aluminate cement, sodium silicate, ethyl silicate, aluminium polychlorid, clay or phosphate as the binding agent. Admixture application is subjected by service condition, which can improve the workability, physical and chemical property.
Adopt one construction method of vibration, pump casting or spray to build monolithic furnace lining with metal or ceramic anchoring parts. Add stainless steel fibre to improve mechanical vibration and thermal shock resistance. Refractory castable can be used for linings of thermal treatment furnace, molten tin bath, salt bath furnace, tapping tank or launder, reforming furnace and etc.
Plastic refractory is pug or mud with plasticity that can change shape through external force but without cracking and it will not change when there is no external force on.
Adopt construction method of ramming or vibration to repair monolithic furnace lining equipped with metal or ceramic anchoring parts. Plastic refractory can be used for linings of soaking pit, heating furnace and etc. and also can be used to bind up water cooled valve of heating furnace.
Gunning mix is a kind of refractory mix materials and is used to spray repair by gunning equipment. According to gunning process, gunning mix can be classified into wet gunning (or gunning mortar method), half dry gunning and fire flame gunning.
There are many types for gunning mix such as alumina-silica, alumina-silica zirconium, magnesia, magnesia-calcia, magnesium and chromium and etc. Binding agents have sodium silicate, phosphate, polyphosphates, pitch, resin and etc. Add fireclay, lime and etc. to improve adhesive rate. Add agglutinant such as serpentine, olivine, lime, fireclay and iron oxide to make sure that gunning mix can reach up to good sintering state.
Fireproof paint is an unshaped refractory material that coating on the firebrick lining. According to the different service conditions and construction methods, fireproof paint can be made into paste and mortar form. According to its property to choose and use binding agent material. Use basic coating such as polyphosphates, magnesium sulfate and magnesium sulfate for tundish of continuous casting. Use fireclay, aluminium dihydrogen phosphate, ACPB and sodium silicate to make high alumina coating. Add additive plasticizer to improve workability. Fireproof paint is mainly used for protective coating of heating equipment lining or repairing local damage of bricking.
Ramming mass is a kind of unshaped refractory material with low plasticity or without plasticity. There are various materials such as silica, fireclay, high alumina, corundum, zirconite, carborundum, carbonaceous, magnesian and etc. According to the material and service conditions, adopts inorganic bond or organic bond that similar to castable refractory such as hydrosoluble dextrin, carboxymethylcellulose, xylogen, sulfonate, poval and water-resistant and with plasticity paraffin, pitch, tar, phenolic resin, Atactic Polypropylene and etc.
Ramming mass adopts forced ramming construction with features of lower apparent porosity and higher bulk density. During the unshaped refractory materials, ramming mass is special suitable used for smelting furnace lining and all kinds of container lining for molten metal, such as bottom of open-hearth furnace and electric furnace, all kinds of induction furnace lining, iron runner for blast furnace, molten steel ladle and etc.
Slinging refractory is a kind of half-dry and unshaped refractory material, which is mainly used to build lining of monolithic molten steel ladle through slinging machine. There are various types such as silica, pyrophyllite, fireclay, high alumina and zirconite and etc. Of which high silica and high alumina slinging refractory are mostly common used.
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