During the operation of the kiln, sometimes refractory materials fall off, but this is not because of the poor quality of the refractory materials. Many times it is because the construction is not carried out according to the formal procedures.
The most common situation is that when the construction personnel cast the irregular parts of the kiln, the castable particles are fine due to the limitation of the position; another common situation is that the anchor is not installed firmly. When the kiln is in operation, the anchor is detached from the root, causing the castable to fall off.
So, in the face of the fall of refractory castables, do we have any remedial solutions?
We can first check the size of the refractories castable falling part. If the falling part is not large, we can choose to use ramming material or plastic for repair; but if the falling part is large, we need to knock near the falling part first, knock off the loose refractory material castables around, and then repair it with new refractory castables.
However, these are only temporary solutions. In order to prevent the refractory materials from falling off, the most important thing is to pay attention to the installation details during the first construction, so as to effectively prevent the refractory materials from falling off and extend the service life of the refractory materials.
What are the main installation details worth noting?
1. When selecting anchors and welding rods, the same material as the steel plate of the furnace equipment should be selected to avoid cracking of the welds due to different expansion amounts.
In addition, try to use a single anchor with more welds or increase the length of the welds to improve the welding firmness. The "Y"-shaped anchor can be replaced with an "L" shape, or even the "L" shape can be crossed into an "X" shape for welding, which can also increase the fixing ability of the anchor when the castable is very thin and prevent it from falling off.
2. For areas with severe wear, we generally choose to use corundum refractory castables, but the thermal shock resistance of corundum castables is weak. To make the refractories castables have a longer service life, corundum wear-resistant castables with high thermal shock resistance can be selected, which will more effectively extend its service life.
3. Of course, no matter how good the quality of castables is, the construction must follow the regular operating procedures. Construction should be carried out according to the furnace, site conditions and corresponding construction environment to effectively exert the true protection ability of refractory materials.
4. Furnace baking is the last process of refractories castables and the key to the operation of various furnaces. Therefore, when maintaining and baking castables, time and temperature need to be strictly controlled to ensure better performance of refractory castables.
