Refractory castables for submerged arc furnaces

Refractory castables for submerged arc furnaces are unshaped refractory materials used as linings inside these furnaces—primarily designed for smelting ferroalloys, calcium carbide, and other similar materials. After being mixed with water or a binding agent, they are poured and shaped to form a durable protective layer. These materials must withstand severe erosion from high-temperature molten metals, mechanical abrasion, and thermal shock, while also exhibiting excellent resistance to corrosion, superior thermal stability, and robust high-temperature strength. As a result, they are ideal for safeguarding various sections of the furnace lining. Proper selection of furnace castables combined with standardized construction practices can significantly reduce the rate of lining damage, minimize the frequency of furnace shutdowns for maintenance, and ensure the efficient and safe operation of the submerged arc furnace.

Direct-blowing taphole castable

Straight-blow pipe castables are unshaped refractory materials used as linings for blast furnace straight-blow pipes—critical components connecting hot stoves to the tuyeres of the blast furnace. These materials are applied via a casting process to form a dense protective layer, designed to withstand the intense thermal shock and abrasive wear caused by high-temperature hot air (1200–1450°C), as well as coal powder jet erosion and thermal cycling. They exhibit exceptional wear resistance, thermal shock resistance, and corrosion resistance. Selecting the right straight-blow pipe castable requires careful consideration of factors such as blast furnace wind temperature, coal powder injection rate, and air supply parameters. By optimizing both the material formulation and construction techniques, it’s possible to strike an ideal balance between lining durability and overall blast furnace operational efficiency.

Iron-Molten Steel Ladle (Can) Refractory Material

Iron ladle castables are unshaped refractory materials used as linings inside iron ladles—critical vessels designed for holding and transporting molten iron. These materials are applied via a casting process to form a dense working layer, which primarily withstands the abrasive action of molten iron at temperatures ranging from 1450°C to 1600°C, along with slag erosion and repeated thermal shock conditions. They exhibit excellent resistance to slag penetration, outstanding abrasion resistance, and superior thermal stability. Selecting the right type of iron ladle castable requires careful consideration of factors such as the composition of the molten iron (e.g., levels of Si, S, and Ti), the ladle’s volume, and its turnover frequency. By optimizing the raw material mix and construction techniques, it’s possible to strike a balance between refractory longevity and metallurgical efficiency.

Castable for sintering machines

The castable material used in sintering machines is an unshaped refractory designed for equipment involved in the sintering process. It’s formulated by proportionally mixing refractory aggregates, powders, binders, and additives, then shaped through casting before use. Its core design addresses the extreme conditions of high temperatures and abrasion typical in sintering processes. Moreover, the composition of the sintering machine castable can be tailored based on the specific characteristics of the sintered materials—such as alkalinity and temperature—to achieve an optimal balance among high-temperature resistance, wear resistance, and chemical erosion protection. As a result, this material plays a critical role in extending the service life of sintering equipment.

Briquetting plant castables

The ramming material for pelletizing is an unshaped refractory designed specifically for the pelletizing production process. It is used in high-temperature, wear-resistant areas such as pelletizing kilns and conveying equipment. This material is produced by mixing refractory aggregates, powders, binders, and additives, then casting and shaping it into the desired form. By adjusting its formulation, the ramming material can be tailored to suit various pelletizing processes—such as acidic or basic pelletizing—and serves as a critical component in extending the service life of equipment on the pelletizing production line.

Burning Rotary Kiln Castable Material

The castable for rotary kiln firing is an unshaped refractory material specifically designed for lining the high-temperature section of rotary kilns. It is formed by mixing refractory aggregates, powders, binders, and other components into a pourable consistency. Tailored to withstand the unique challenges of rotary kiln operation—such as high temperatures, abrasion, and chemical erosion—the formulation of this castable is carefully adjusted based on factors like the kiln's internal material characteristics (e.g., alkali content, viscosity), temperature distribution, and rotational speed. As a result, this material plays a critical role in extending the service life of the kiln lining and reducing maintenance frequency.

Refractory castables for ferroalloy furnaces

Refractory castables for ferroalloy furnaces are specially designed, unshaped refractory materials tailored for the high-temperature, highly corrosive, and severely eroded areas of these furnaces. They are produced by mixing refractory aggregates, powders, binders, and additives, then casting them into shape. The formulation of these castables must be customized based on the specific alloy being smelted (e.g., silicon-based, manganese-based, or chromium-based), the composition of the furnace slag, and the operational process—making them a critical refractory material that ensures the long-term, reliable operation of ferroalloy furnaces.

Castable for ferroalloy ladles (tanks)

The castable material used for ferroalloy ladles (tanks) serves as the lining material inside containers designed for holding and transporting molten ferroalloys. It must withstand high-temperature molten iron erosion, slag attack, and thermal shock. Composed of a blend of refractory aggregates, fine powders, and binders, the formulation of the ferroalloy ladle castable needs to be tailored specifically according to the melting temperature of the ferroalloy type (e.g., silicon-based, manganese-based, or chromium-based) and the characteristics of the associated slag. This material is critical for ensuring safe transportation of ferroalloys and significantly extending the service life of the ladle itself.

Prefabricated Iron Gutter Components (Blocks)

Iron trough prefabricates are customized, factory-produced refractory components designed specifically for the demanding conditions of blast furnace iron troughs—channels used to transport molten iron. These preformed elements are made from refractory materials that are shaped in advance at the factory, allowing for direct on-site installation. They serve as critical protective linings within the iron trough, effectively resisting molten iron erosion, high-temperature corrosion, and thermal shock damage. Prefabricated components boast excellent dimensional stability after undergoing high-temperature baking, making them ready for immediate use while minimizing the risk of cracking—commonly caused by improper curing of castable materials during the baking process.

Mud-on-mud

Mud sleeve material is a refractory used for constructing or repairing the mud sleeves at blast furnace iron tapping openings. It boasts excellent bonding properties and high strength. Using the ramming device of a mud gun, the material is compacted onto the tap frame to form the mud sleeve, ensuring a tight fit between the gun head and the sleeve during plugging. This prevents mud leakage during the clogging process while simultaneously protecting the refractory lining of the tap opening from high-temperature oxidation and erosion by molten slag and iron.

Mud-cast prefabricated parts

The mud sleeve prefabricates are refractory components pre-molded from mud-sleeve material, designed primarily for the rapid installation and replacement of blast furnace tap-hole mud sleeves. Produced via an industrialized manufacturing process, these prefabricates transform traditional on-site construction into "assembly-based" operations, offering an efficient solution for refractory maintenance at blast furnace tap holes—especially ideal for smelting environments that prioritize high productivity and minimal downtime. They effectively address issues such as tap-hole spatter and excessive gas flames in the tap-hole area.