Abstract:
Refractory materials are indispensable in the smelting industry, directly influencing the longevity, efficiency, and quality of production in furnaces. This article delves into the specific requirements of various smelting furnaces for refractory materials and provides guidance on selecting the appropriate materials to meet these demands.
Introduction:
Refractory materials play a critical role in the smelting industry due to their high resistance to heat, chemical erosion, and physical stability. These materials not only protect furnace linings from the corrosive effects of molten materials but also ensure the continuity and stability of the smelting process.
Refractory Material Requirements for Smelting Furnaces:
Different types of smelting furnaces have distinct requirements for refractory materials. Por ejemplo, blast furnaces demand materials that can withstand chemical erosion from alkaline slag, while reverberatory furnaces require materials with excellent thermal shock resistance.
Common Smelting Furnaces and Their Refractory Material Choices:
1.Blast Furnace
Solicitud: Primarily used for the smelting of copper, lead, and zinc.
Refractory Materials: Throat and hearth areas typically use magnesia bricks, magnesia-chrome bricks, and alumina-chrome bricks due to their outstanding resistance to alkaline slag.
2.Reverberatory Furnace
Features: High operating temperatures and elevated off-gas temperatures.
Refractory Materials: The furnace bottom comprises multiple layers, including asbestos board, insulating bricks, clay bricks, and magnesia-alumina or magnesia bricks. The furnace walls often utilize magnesia-alumina bricks or magnesia bricks, with critical areas employing magnesia-chrome bricks.
3.IsaSmelt Furnace (Ausmelt Furnace)
Core Technology: Utilizes an immersed top-blown burner.
Refractory Materials: Requires materials with high compressive strength and excellent thermal shock stability. The furnace bottom and walls typically use fused rebonded magnesia-chrome bricks.
4.Kaldo Furnace
Process Characteristics: Oxygen is blown at an angle in this tilting rotary furnace.
Refractory Materials: Fused semi-rebonded magnesia-chrome bricks and direct-bonded magnesia-chrome bricks are used to withstand severe chemical erosion and mechanical wear.
5.Oxygen Bottom-Blown Furnace
Includes: QLS method and oxygen-enriched lead smelting furnace.
Refractory Materials: The upper and lower parts of the melt pool utilize fused semi-rebonded magnesia-chrome bricks or fused rebonded magnesia-chrome bricks, depending on the degree of erosion.
6.Volatilization Kiln
Solicitud: Primarily used for treating leaching slag and recovering valuable metals.
Refractory Materials: The intermediate reaction zone uses alumina-chrome slag bricks or magnesia-alumina-chrome bricks to resist molten slag and metal erosion.
7.Tilting Furnace
Features: Combines the advantages of a reverberatory furnace and a rotary anode furnace.
Refractory Materials: Uses fused rebonded magnesia-chrome bricks or fused semi-rebonded magnesia-chrome bricks, which offer high Cr2O3 content and excellent erosion resistance.
8.Flash Smelting Furnace
Components: Includes concentrate nozzles, reaction tower, settling pool, and rising flue.
Refractory Materials: Concentrate nozzles use high-alumina refractory castables, and the reaction tower employs fused cast magnesia-chrome bricks or fused rebonded magnesia-chrome bricks.
9.Noranda Furnace
Process Characteristics: Horizontal cylindrical furnace that completes the processes of concentrate drying, roasting, fundición, and slagging.
Refractory Materials: The melt pool and slag line areas use fused semi-rebonded magnesia-chrome bricks, while other areas use direct-bonded magnesia-chrome bricks.
10.Converter
Solicitud: Used for smelting copper sulfide to crude copper and also for nickel smelting.
Refractory Materials: Tuyere area, mouth, shell, end walls, and other critical areas use fused rebonded magnesia-chrome bricks or fused semi-rebonded magnesia-chrome bricks to resist both acidic and alkaline slag corrosion.
11.Anode Furnace (Refining Furnace)
Solicitud: Suitable for refining molten crude copper.
Refractory Materials: The inner surface of the furnace lining uses fused semi-rebonded magnesia-chrome bricks to resist slag erosion and molten metal wash.
Performance Indicators of Refractory Materials:
The selection of refractory materials is based not only on their chemical composition but also on their physical properties, such as compressive strength, porosity, and thermal shock resistance. These performance indicators determine the durability and reliability of refractory materials in specific applications.
Innovation and Development in Refractory Materials:
With advancements in smelting technology, refractory materials are also evolving. For instance, adding heat-resistant steel fibers to castables can improve spalling resistance, while using pre-synthesized spinel enhances thermal shock stability.
Conclusion:
The correct selection and application of refractory materials are crucial for the performance of smelting furnaces. As industrial demands increase and technology progresses, the refractory materials industry will continue to face challenges, but it will also present new opportunities for development.
Sobre nosotros:
At Rongsheng Refractory, we have been the leading manufacturer, supplier, and exporter of top-quality refractory materials for over 15 years. Our refractory products range includes high alumina bricks, corundum bricks, AZS bricks, magnesia bricks, fire clay bricks, insulating bricks, and unshaped materials such as refractory castable, refractory cement, refractory mortar, refractory ramming mass, refractory spraying mass, refractory plastic, and more. We cater to 90% of the refractory needs in industries such as Iron & Steel, Cement, Non-ferrous, Power, Petrochemical, and Glass. With our products exported to over 100 countries and regions worldwide, we are renowned as one of the top suppliers in the industry. Contact us today to learn how we can meet your refractory needs and provide you with the best solutions.