Introduction to The Production Process of Refractory Castables

We all know that refractory castable material is used to build high-temperature kiln linings, but many people want to know how to produce refractory castable material. Today, the editor will take you to understand the production process of refractory castable materials.

1. Crushing and crushing: A jaw crusher is used for the coarse crushing of raw materials, mainly for the coarse crushing of large pieces of materials. Medium and fine crushing equipment for refractory raw materials includes cone crushers, drum crushers, and dry crushers.

2. Screening and fine grinding: Screen the crushed materials according to particle size. The equipment includes a fixed inclined screen and an electromagnetic vibrating screen. Manufacture of refractory powders, including ball mills, tube mills, and vibration mills.

3. Pre-mixing: Pre-mix admixtures, admixtures, binders, fine powders, and other powders. The equipment is a double-spiral conical mixer, etc.

4. Ingredients scale: Electronic weighing is generally used to ensure the accuracy of weighing.

5. Mixing: Use a forced mixer to stir the material. The mixed material can be input into the packaging machine and then packaged, or it can be packaged into bags directly from the outlet of the mixer.

6. Distribution and sealing: Use dispensing equipment for dispensing, and then use a sealing machine to seal the bag mouth or tape to seal the box mouth.

7. Finished product storage: Transport the finished products to the warehouse and stack them separately according to brand and grade.

8. Raw material inspection and finished product inspection: Before batching, conduct chemical analysis and physical performance inspection of refractory raw materials, cement binders, and additional materials. When producing refractory castable materials, their particle gradation should be checked. If it does not meet the technical requirements, it should be adjusted in time. The performance of each batch of finished refractory castable materials should be measured according to technical requirements, and a quality assurance sheet and construction technical requirements should be issued and sent to the user.

During the production process, high-grade refractory castable materials should use pre-mixed powder to ensure that additives such as ultra-fine powders and fibers are evenly mixed. After the raw materials are prepared, they should be put into the feeding bin separately for later use. Silos are divided into fixed and mobile types. The fixed silo has a high degree of automation and stable quality; the mobile silo occupies a large area, has less equipment, is flexible in operation, and can also ensure material quality. The mass of each bag of finished refractory castable materials for heavy materials is generally 25/50kg, and that of lightweight materials is 30~40kg, with a large error of ±0.5kg.

When producing refractory castable materials, when cement or liquid adhesive is used, it can be packaged or directly transported to the user. Still, the shelf life and dosage must be indicated. Cement for refractory castable materials such as clay binders and low cement series are also packaged. If the cement expires, it is easily replaced. It should also be mixed if used within the 3-month shelf life.

When raw materials, production processes, and other factors change, the production mix ratio of refractory castables must be tested and can only be produced after meeting technical requirements. The production mix ratio of new varieties of refractory castables should also be re-examined. When producing refractory castables, their particle gradation should be checked. If it does not meet the technical requirements, it should be adjusted in time.

In short, the production process of refractory castable materials includes raw material crushing, crushing, screening, fine grinding, pre-mixing, batching scales, mixing, packaging and sealing, and finished product warehousing. During the production process, the quality of raw materials, ingredient proportions, and finished product properties should be strictly controlled to ensure the quality and stability of refractory cast materials.