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Production technology of refractory castable in huixinlong refractory company
Zhengzhou huixinlong refractory
With the wide application of refractory castables, the production methods of refractory castables have also been concerned. In fact, the production of refractory ramming materials, refractory spray coating, refractory repair materials, refractory coating and other materials is basically the same as that of refractory castables.
In the production process of refractory castable, some raw materials can be used directly without breaking and crushing. For example, alumina hollow ball, ceramsite, expanded perlite and industrial alumina, etc. According to factors such as production scale, raw material variety and its characteristics, main equipment shall be selected:
1. Crushing - there are three types of jaw crushers, whose specifications are expressed by the size of feed inlet, mainly including 250mm × 400mm and 600mm × 400mm, with a production capacity of 5 ~ 20t / h. Used for coarse crushing of bulk materials.
Comminution refers to the medium and fine crushing of refractory raw materials after coarse crushing, which is also used to prepare granular materials. Its equipment is cone crusher, roller crusher and dry mill.
2. Screening - to divide the crushed material into particles of different sizes according to the particle size. The equipment includes fixed inclined screen, electromagnetic vibrating screen, etc. The screening efficiency of the former is about 70%, and that of the latter is generally over 90%.
3. Fine grinding refers to the production of refractory powder. Its equipment includes ball mill, tube mill and vibration mill, etc;
4. Premixing refers to the premixing of all powders or some kinds of powders such as additives, admixtures, binders and fines, so it is called premixed powder. Its equipment is double spiral cone mixer, etc.
5. The batching scale is generally electronic and accurate; the mixer is forced mixer, and the mixture can be fed into the sub loader and then sub loaded, or directly sub packed into bags from the outlet of the mixer;
In addition, there are vertical elevator, belt conveyor and batching car and other equipment.
In the production of refractory castable, the preparation of refractory aggregate, powder, soft clay and other raw materials is basically the same as that of fired refractory brick. The difference is that the critical particle size of refractory aggregate is large and there are many grades, so there are many screening, lifting and other equipment, as well as many storage bins. At the same time, it is necessary to prepare premixed powder, which is a special process.
In the production of high-grade refractory castable, premixed powder must be used. Otherwise, it is difficult to mix the micro admixture, superfine powder, fiber and other additives, resulting in the performance instability, affecting the construction and use.
After the preparation of various raw materials, they are respectively loaded into the silo for use. The silos are divided into fixed type and mobile type. The indefinite silo is overhead. All kinds of raw materials are lifted to the belt conveyor at the bottom of the silo through the elevator, and then distributed to each silo. There are electronic scales and batching trucks under the silo, and batching is carried out according to the production mix proportion of refractory castables. Then, put the prepared material into the forced mixer for mixing, and the mixing time is about 5min. The mixed refractory castable mixture is put into the sub loading equipment from the outlet of the mixer. There is an electronic scale at the bottom of the equipment. After weighing, it is bagged or packed. After that, it is sealed with a sealing machine or with tape paper. Then the finished products are transported to the warehouse and stacked according to the brand and grade. The production line is a three-dimensional operation, with a large workshop, many equipment, high degree of automation, and stable material quality; the mobile silo is placed on the floor of the workshop, and the material is transported to the top of the silo by the elevator and belt conveyor, and is separately loaded into the silo, or loaded by the crane. A platform scale or electronic scale is installed at the bottom of the silo for batching. The prepared materials are loaded into the hopper of the mixer with a belt conveyor or trolley, and then mixed. The rest of the process is the same as before. The production line has the advantages of horizontal operation, more land occupation, less equipment, flexible operation and guaranteed material quality.
For the finished refractory castable, the mass of each bag of heavy material is generally 30-50kg, and that of each bag of light material is 20-30kg, with an error of ± 0.2kg.
In the production of refractory castable, when cement or liquid binder is used, it can be separately packed or directly shipped to the user, but its guarantee period and dosage must be indicated; for refractory castable such as clay binding and low cement series, its cement is also separately packed. If the cement is out of date, it is easy to replace. If it is used within the storage period of 3 months, it should also be mixed.
Before the proportioning of refractory castables, chemical analysis and physical performance inspection shall be conducted for refractory raw materials, cement binders, additives and other materials; chemical analysis, screening and fineness inspection shall be conducted for the crushed refractory aggregate and finely ground refractory powder.
The production mix proportion of refractory castables can only be produced when the factors such as raw materials and production process change, and it must be tested to meet the technical requirements; the mix proportion of new refractory castables shall also be retested; during the production of refractory castables, the particle grading shall be inspected, and if it does not meet the technical requirements, it shall be adjusted in time; The finished products of each batch of refractory castable shall be tested according to the technical requirements, and shall be delivered to the user according to the quality assurance certificate and construction technical requirements.
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