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Given the problems such as the short service life of forging heating furnace doors, high masonry repair costs, and heavy furnace doors, we can improve the use of furnace door castables by rationally selecting the raw materials of the castables, adjusting the component ratio, and adding additives performance.
Causes of damage to heating furnace door
The main function of the furnace door masonry refractory material is to protect the cast iron frame and block the flame in the furnace. To meet the requirements, refractory materials need appropriate fire resistance, mechanical strength, and related performance, but there are no special requirements for density. Therefore, we can reduce the density of the furnace door refractory material to reduce the weight of the furnace door.
The problem of the short service life of the furnace door is mainly caused by the following reasons: poor thermal shock resistance of the refractory material of the furnace door, poor integrity of the refractory brick lining, and high temperature of the heating furnace. Due to the poor thermal shock resistance of refractory materials, serious brick breaking, and cracking will occur in the refractory brick lining under the working conditions of frequently opening the furnace door. In addition, due to the poor integrity of the refractory brick lining of the furnace door, the metal frame of the furnace door is easily ablated and damaged, resulting in the short service life of the furnace door, high consumption of refractory bricks and metal frames, and high maintenance costs for the furnace door. In addition, the high temperature of the heating furnace is the root cause of the ablation of the metal frame of the furnace door. The positive furnace pressure causes the furnace gas to overflow along the furnace door frame, resulting in the ablation of the metal frame of the furnace door.
To improve the performance of furnace door castables, we have carried out the following work:
Research and analysis were conducted on selecting raw materials for furnace door castables. We selected special-grade coke gemstones and first-grade high-aluminum clinker with high refractoriness, good thermal shock resistance, and high-temperature erosion resistance as aggregates for the castables to improve their high-temperature properties. To improve the bonding strength and volume stability at normal and high temperatures, we selected first-grade high aluminum powder as the main powder, cement and micro powder as the composite binder, and kyanite as the expansion additive. In addition, to improve the thermal shock resistance, and explosion-proof performance, and reduce the density of the castable, we selected inorganic high-aluminum fibers with excellent mechanical properties and high-temperature powder resistance as explosion-proof and reinforcing additives. In addition, to meet the construction performance and other performance requirements, we also selected a variety of organic and inorganic water-reducing agents and dispersants as composite admixtures.
In actual use, we use many cheap coke stones, thereby reducing the price of castables and the cost of furnace door pouring. This not only increases the life of the furnace door but also significantly reduces the consumption of metal frames and refractory materials for the furnace door, as well as production and maintenance costs.
Through the implementation of the above measures, we have achieved the following results:
1. Improve the refractory performance and mechanical strength of furnace door castables, reduce brick breaking cracking, and falling off of furnace door refractory materials, and extend the service life of furnace doors.
2. The density of the furnace door castable is optimized, which reduces the furnace door’s weight and reduces the heaviness of the furnace door.
3. Improve the ablation condition of the metal frame of the furnace door, reduce the ablation degree of the metal outer frame of the furnace door, and extend the service life of the furnace door.
4. Reduce the consumption of metal frame and refractory materials of the furnace door, and reduce the maintenance cost of the furnace door.
In short, by rationally selecting the raw materials of the castables, adjusting the component ratio, and adding additives, we successfully improved the performance of the forging heating furnace door, extended the life of the furnace door, and reduced the cost.
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