The basic lining material for furnaces, converters, and induction furnaces is typically made of nonsiliceous materials such as limestone, dolomite, lime, magnesia, or ferrous oxide. These materials are chosen for their properties such as low thermal conductivity, resistance to corrosion and thermal shock, ease of installation and maintenance. The choice of refractory material depends on the type of slag formed during operation, with silica being used for acidic slags, magnesia for basic slags, and alumina for neutral slags.
In some cases, only one working lining may be used, especially when processing temperatures are low or efficiency is of less concern. However, in most cases, there are two lining layers - the working lining and the insulating layer. The working lining is a higher density, stronger material that is more conductive, while the insulating layer is softer, lighter, and less conductive, providing insulation.
In rotary kilns, an optional third layer of ceramic fiber backing may be used for enhanced insulation. This thin layer is similar to fiberglass insulation found in houses but is more compressed. The choice of lining thicknesses for the working lining and insulating layer is determined by the needs of the rotary kiln and the type of material being processed.
In addition to the refractory lining, backing cloth can be used to increase the useful life of the primary sieve and offset the effects of frequent use and overloading. This is done by installing a coarser, stronger wire mesh as reinforcement under the primary mesh.
In the manufacturing process of refractory linings, additives in the form of particles, powder, and liquid can be added as activators, fillers, or oils into the base material. The mixing process involves breaking the internal macromolecular chains of the raw materials through mastication. The compositions inside the rubber compound are further dispensed to complete mixing, resulting in sheet-like materials that can be molded into desired products.
Overall, the choice of lining material and design is crucial for the smooth operation and optimal metallurgical performance of furnaces and induction heaters. It is important to consider factors such as thermal conductivity, corrosion resistance, thermal shock resistance, ease of installation and maintenance, and the specific conditions of slag formation and operating temperature.
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