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Spesial masontry mortars

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Special protective coatings are used to cover the hot surface of refractory (acid-proof) lining of various units. These coatings (being nothing more than 1-4 mm thick) make an extra-hard refractory facing (fire resistance is over 1,900 °С) and low-porosity monolithic (seamless) coating. This "ceramic armour'' increases the service life of the refractory (acid-proof) lining considerably, and, in some cases, enables application of relatively low-cost chamotte products, rather than expensive corundum refractory materials.

Mortars and protective coatings are efficient for all kinds of refractory and acid-proof linings of heating and chemical units and their associated parts - burners, heat-treatment furnaces, pipes, gas flues, melting baths for molten metals or salts, etc.

Hot surfaces of heating units are currently brick-lined with the lining compounds.

Known lining compounds are usually composed relying on chemical similarity between the compound and the basic refractory material. This contributes to the compatibility and adhesion between the lining material and the base surface. Yet, even in case of chemical similarity, there may be some problems with the adhesion bond between the lining or repairing compound and the base material, especially when the adhesion bond is required to ensure reliable long-term operation under high static or dynamic (including cyclic) operating temperature. These conditions often lead to the peeling, spalling or popping and burning-through of lining that adversely affects the service life of the high-temperature thermal generating unit.

We have developed a range of multicomponent refractory compounds on the basis of SHS technologies which include components to enable synthesis of mullite structures in the combustion wave. Exact composition of the developed SHS compounds is our proprietary know-how. Performance of the proposed refractory compounds has been approved in true working conditions at more than 120 enterprises of different industries (ferrous and non-ferrous metallurgy, heat power industry, machine-building industry).

SHS refractory compounds are multi-purpose. In particular, these compounds may be used for lining, masonry and repair and renewal operations in high temperature thermal generating units (furnaces, boilers, reactors, etc.)

Performance properties of the compound (blend) are assured by adding a liquid component – the binding agent. All our compounds include either liquid glass or its water solutions as a binding agent.

Study the table below for the names of the masonry mortars, their operating temperatures and application ranges, performance properties of the binding agent and the consumption rate per 1m3 of the masonry.

Table for masonry mortars

No.

Name

Operating temperature [°С]

Applications

Consumption rate

Note

Binding agent

Material

1

Masonry SHS mortar KR-1

1,800°С

Linings of heating, thermal furnaces, resistor furnaces, salt-bath furnaces, melting furnace crowns, ladles, trunks, boilers, cupola furnaces, blast furnaces, air heaters of blast furnaces, sinter machines, coke-chemical furnaces, furnaces for production structural materials (cement, light expanded clay aggregate, bricks, lime burning, etc.), burner blocks, breeches and so on.

Liquid glass

ρ=1.42-1.46 g/cm3

 

0.5 l/kg of blend

40-45 kg/m3 of masonry

To be used for chamotte, mullite, mullite and corundum, corundum refractory materials

2

Masonry SHS mortar KR-L-1

1,500°С

Linings of heating, thermal furnaces, resistor furnaces, salt-bath furnaces which are used for chamotte lightweight materials.

Liquid glass

ρ=1.42-1.46 g/cm3

0.5 l/kg of blend

40-45 kg/m3 of masonry

To be used for chamotte, mullite, mullite and corundum, corundum refractory materials

3

Masonry SHS mortar KR-KhP-1

1,900°С

Linings of ladles, some areas of heating furnaces, thermal furnaces, melting furnace crowns, lime burning furnaces, lead blast furnaces, vacuum vessels and so on.

Liquid glass

ρ=1.42-1.46 g/cm3

 

0.5 l/kg of blend

40-45 kg/m3 of masonry

To be used for periclase, chrome-periclase, periclase-chrome refractory materials.

4

Masonry SHS mortar KR-D-1

1,800°С

Crowns of electric arc melting furnaces and coke-chemical furnaces.

Liquid glass

ρ=1.42-1.46 g/cm3

0.5 l/kg of blend

40-45 kg/m3 of masonry

To be used for silica, electrical silica refractory materials.

It should be noted that the application of masonry mortars does not require any special equipment or skills of regular industrial personnel, the mortars should be applied with a brush or a trowel. The optimum seam thickness is 1.0-1.5 mm.

The material of a lining or masonry joint shall demonstrate its final performance characteristics upon the drying in the course of heating-up of the thermal generating unit, each heating unit usually has its individual drying schedule depending on the masonry size and area of the lining hot surface.

Heating up to about 750-850°С (heating-up temperature of a unit) starts the SHS process in the masonry joints which further spreads as a directional combustion wave along the refractory mortar layer. Heating up to 1,400-1,800°С induces production of new mullite-type oxide-ceramic structures - 3Al2O3×2SiO2; Al2O3×SiO2 and more complex heat-proof compounds - 2Al2O3×3SiC, 5Al2O3×3TiB2, etc. in the reaction zone of the combustion wave. When these compounds are being produced the original components with the fusion temperature which is less than the maximum combustion temperature fuse. Of all the refractory mortar components developed by us the fine aluminium powder (reducing agent in fusion reaction) fuses the first. Under capillary forces some part of the fused blend penetrates to the uppermost layers of the basic material as deep as 1 mm, especially when this layer is apparently porous. This results in an extremely strong bond between the coating and the base material, or in immediate welding of masonry individual parts together in a monolithic layer.

After SHS reaction, even problematic masonry joints become durable, less exposed to aggressive gases, fused salts, molten metals and dross, and prevent penetration of salts, dross and molten metals to the refractory material that results in better thermal performance of the thermal generating unit and saves energy.

Tests performed at different Russian enterprises showed that the application of the above-mentioned masonry mortars extend service life of the thermal generating units (taking into account the type of the unit and proper operation) from 2 to 15 times.

masonry mortars

 

Video: performance properties of innovative masonry mortar

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