Tech Team · Kintek Solution

The materials used in a refractory kiln primarily consist of refractory linings, which can be made from various types of refractory bricks or cast refractory concrete. These materials are chosen based on the temperature inside the kiln and the chemical nature of the material being processed. Common types of refractory materials include fireclay, magnesite, silica, and zirconia, each with specific properties suited for different applications. The thickness of the refractory lining typically ranges from 80 to 300 mm, ensuring a temperature drop of over 1000 °C between the hot and cold faces. This setup protects the steel shell from high temperatures and corrosive materials, maintaining shell temperatures below 350 °C to prevent damage.

Key Points Explained:

1. Refractory Lining Purpose and Composition:

   • Purpose: The refractory lining insulates the steel shell from high temperatures and protects it from corrosive process materials.
   • Composition: It can be made of refractory bricks or cast refractory concrete, and may be absent in zones below 250 °C. The choice of refractory depends on the kiln's internal temperature and the material's chemical nature.

2. Types of Refractory Materials:

   • Fireclay: Made of hydrated aluminum silicates, it is inexpensive and widely used.
   • Magnesite: Composed of at least 85% magnesium oxide, it is suitable for metallurgical applications due to its resistance to lime and iron slag.
   • Silica: Typically contains at least 93% SiO2, offering high mechanical strength and used in glassmaking and steelworking.
   • Zirconia: Known for its high-temperature stability and resistance to thermal shock.

3. Thickness and Temperature Management:

   • Thickness: The refractory lining is generally 80 to 300 mm thick.
   • Temperature Drop: A typical refractory can maintain a temperature drop of over 1000 °C between its hot and cold faces.
   • Shell Temperature: The shell temperature is maintained below 350 °C to protect the steel from damage, monitored by continuous infrared scanners.

4. Advantages and Disadvantages of Refractory Types:

   • Castable vs. Brick: Castable refractories and brick refractories are comparably priced but have different installation costs. Brick is more labor-intensive to install but is more wear-resistant, making it suitable for abrasive materials.

5. Application-Specific Refractories:

   • Cement Kilns: Refractory life is prolonged by maintaining a coating of processed material on the refractory surface.
   • Iron Ore Reduction Kilns: Low-iron alumina or magnesium-spinel bricks are used.
   • Cement Kilns: Magnesite brick lining in the clinker zone and acid-insulating brick in the preheating zone are typical.

6. Mechanical Stability and Lining Techniques:

   • Mechanical Stability: The service life of the refractory lining is influenced by the mechanical stability of the shell.
   • Lining Techniques: Interlocking bricks and monolithic refractories are used in large diameter rotary kilns, improving the service life of linings.

By understanding these key points, a lab equipment purchaser can make informed decisions about the appropriate refractory materials for their specific kiln application, ensuring optimal performance and longevity of the kiln.

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