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Blast Furnace Castables

Blast Furnace Castables

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Unshaped refractory materials for blast furnaces encompass various categories, including ramming materials, spraying materials, castables, mud, and fillers. These materials can be classified into two main groups based on their composition: carbonaceous unshaped refractory materials and clay-based unshaped refractory materials tailored for iron-smelting equipment.

Why Use castables to blast furnace?

Castables are versatile, easily shaped, and offer superior thermal insulation compared to traditional refractory bricks. They provide quick and cost-effective installation, resist harsh furnace conditions, and create a durable monolithic lining. Their adaptability to temperature changes and reduced maintenance needs make them a preferred choice for blast furnace linings in the steel industry.

Brief Introduction of AGRM Blast Furnace Castables – 3 Types

TypesCastablesIntroduction
Type 1Castables for Tapping Channel and Slagging ChannelThe role of Tapping Channel Castables is to ensure the unobstructed flow of molten iron from the blast furnace, reducing resistance during the tapping process, thus enhancing operational efficiency.
The purpose of Slagging Channel Castables is to ensure effective removal of slag from the blast furnace while minimizing erosion and damage to the channel due to the corrosive nature of slag, thus maintaining the stability and sustainability of the blast furnace smelting process.
Type 2High Alumina CastablesTheir purpose is to withstand the high temperatures, corrosion, and mechanical stresses inside the blast furnace, ensuring the stability and longevity of its internal structure.
Type 3Self-Flow CastableIts role is to maintain the smooth and efficient operation of the blast furnace smelting process, reducing blockages and uneven distribution of molten iron.
Type 4Corundum CastableIts role is to provide refractory lining, protecting the internal structure of the blast furnace from high temperatures, chemical corrosion, and mechanical stress.

Type 1:Castables for Tapping Channel and Slagging Channel

This series of products are applicable to the tapping channel, slagging channel and ladle slagging line of the blast furnace. It is featured by good construction performance, stable thermal shock resistance, high strength, scouring and erosion resistance, etc.

ITEMUNITMain channel materialsMain channel tapping materials Main channel slaggingmaterials
HTYH-TGJ1HTYH-TGJ2HTYH-TGJ3HTYH-TGJ4
Chemical Components AI2O3657072~7858~60
SiC+C151212~2058~60
Bulk density110°C×24hg/cm32.72.82.92.8
bending strength110°C×24hMpa4.02.56.06.0
1450°C×3h5.05.06.56.5
compressive strength110°C×24hMpa15252525
1450°C×3h30503030
linear change rate1450°C×3h±0.5±0.5±0.5±0.5

In a steelmaking blast furnace, castables for the Tapping Channel and Slagging Channel serve essential functions

Tapping Channel Castables:

  • Tapping Channel Castables are used at the bottom of the blast furnace’s tapping channel to facilitate the smooth flow and control of molten iron.
  • They must possess refractoriness, abrasion resistance, and resistance to thermal shock since the tapping channel frequently comes into contact with high-temperature molten iron.
  • The role of Tapping Channel Castables is to ensure the unobstructed flow of molten iron from the blast furnace, reducing resistance during the tapping process, thus enhancing operational efficiency.

Slagging Channel Castables:

  • Slagging Channel Castables are used in the slagging channel within the blast furnace, which is a crucial component for handling and guiding the removal of slag (non-metallic impurities) generated during the smelting process.
  • These castables need to exhibit refractoriness, corrosion resistance, and abrasion resistance because slag may contain harmful chemical components, and the channel’s surface is often subject to wear from the slag.
  • The purpose of Slagging Channel Castables is to ensure effective removal of slag from the blast furnace while minimizing erosion and damage to the channel due to the corrosive nature of slag, thus maintaining the stability and sustainability of the blast furnace smelting process.

Both types of castables contribute to the efficient handling and guidance of molten iron and slag in the blast furnace, ensuring its smooth operation and reducing maintenance costs. They must possess excellent refractory properties and durability to withstand the extreme temperatures and corrosive environments within the blast furnace.

Type 2:High Alumina Castable

High Alumina Castables are refractory materials extensively used in the steelmaking blast furnace for various critical applications. These castables are composed primarily of high alumina aggregates and binders, offering exceptional resistance to high temperatures, abrasion, and thermal shock.

ITEMUNITHigh Alumina Castable
  JX-1JX-2
Chemical Components AI2O35070
refractoriness°C16501790
Bulk densityg/cm32.52.6
compressive strength110°C×24h Mpa2030
    1300°C×3h501400°C×3h60
linear change on reheating1300°C×3h±0.51400°C×3h±0.5

Key characteristics and uses of High Alumina Castables in a steelmaking blast furnace include

Composition:
  • High Alumina Castables are formulated with high-grade alumina-rich raw materials, such as bauxite or calcined alumina, combined with appropriate aggregates and binders.
Refractoriness:
  • These castables exhibit high refractoriness, enabling them to withstand the extreme temperatures prevalent in the blast furnace environment.
Abrasion Resistance:
  • High Alumina Castables are designed to resist wear and abrasion, making them suitable for applications where the refractory lining may come into contact with abrasive materials.
Thermal Shock Resistance:
  • The castables demonstrate excellent resistance to thermal shock, ensuring their reliability in situations involving rapid temperature changes, a common occurrence in the dynamic conditions of a blast furnace.
Applications:
  • High Alumina Castables find widespread use in lining critical areas of the blast furnace, including the furnace walls, bosh, and inner barrel. These applications demand materials capable of withstanding not only high temperatures but also the corrosive and abrasive nature of the molten metal and slag.
  1. Performance Benefits:
    • The use of High Alumina Castables contributes to the longevity and stability of the blast furnace’s internal structure, helping to maintain efficient and continuous steel production.
  2. Versatility:
    • High Alumina Castables are versatile and can be tailored to specific requirements, offering flexibility in their application across different regions of the blast furnace.

Type 3:Self-Flow Castable

  • Self-Flow Castable is a highly flowable refractory material typically composed of silicon carbide and other granular materials.
  • In the blast furnace, Self-Flow Castable is often used for casting the hearth and taphole to ensure the even flow of molten iron and separation of slag.
  • Its role is to maintain the smooth and efficient operation of the blast furnace smelting process, reducing blockages and uneven distribution of molten iron.
ITEMUNITSelf-Flow Castable
  JX
Chemical Components AI2O31670
refractoriness°C2.5
Bulk densityg/cm355
compressive strength110°C×24h Mpa10
    1350°C×3h60
linear change on reheating1350°C×3h±0.5

Type 4:Corundum Castable

  • Corundum Castable is typically made from high-purity alumina, offering excellent refractory and corrosion-resistant properties.
  • In a blast furnace, Corundum Castable is often used for the furnace bottom, throat, and certain high-temperature areas because it can withstand extremely high temperatures and corrosive environments.
  • Its role is to provide refractory lining, protecting the internal structure of the blast furnace from high temperatures, chemical corrosion, and mechanical stress.
ITEMUNITCorundum Castable
  JX-1JX-2
Chemical ComponentsAI2O39090
refractoriness°C17901790
Bulk densityg/cm32.63.0
compressive strength110°C×24h Mpa4040
    1400°C×3h801500°C×3h90
linear change on reheating1400°C×3h±0.5
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