All Kind Of Refractories And Anti Corrosive Applications, Refractory Materials, Refractories, Fire Bricks, Acid Proof Lining, Silicate Based Cements, Castables, Insulation Materials, Mortars, Thane, India Refractory materials must be chemically and physically stable at high temperatures. Refractory spray coating is one of the unshaped refractories repaired by lining of kiln and lining of kiln.It is widely used in various kiln furnaces because of the convenience of construction.According to the different construction methods, the construction technology of fire-resistant spray coating is slightly different.The following is refractory spray construction technology: No. continuous casting, dam, Refractory, Spray lining, Tundish, weir, Tundish and its role in Continuous Casting . After the insulating layer has been spray applied, a layer of binder 20, diluted or not, may optionally be sprayed over the fiber binder layers. Muchos ejemplos de oraciones traducidas contienen “refractory lining” – Diccionario español-inglés y buscador de traducciones en español. By way of further characterization, but not by way of limitation thereto, the invention is a method for applying refractory fibers with an aluminum chloride binder. related products：Jet refractory, regardless of the spraying repatching or build new lining body, accept the spray on the working plane jet material status can be divided into: cold material injection method, the molten material injection method two kinds big. The whole body is encased in a metal shell. A refractory lining usually comprises a safety or backup layer behind the working lining in contact with the furnace contents. Refractory Spray coating from Rewell Refractory Zhengzhou Co., Ltd.. Search High Quality Refractory Spray coating Manufacturing and Exporting supplier on Alibaba.com. 3, a side sectional view of the layer is shown. 2, a partial cutaway view of the furnace wall is shown. Macrospray is used as a thin refractory parting layer for the removal of slag, steel and non-ferrous metals. Sometimes it is also called shotcreting. Canada Spray Grouts is an amorphous refractory which is constructed by mechanical spraying with pneumatic tools. An alumina containing binder, preferably aluminum chloride, is used in a spray method to bond the fiber to itself and to a substrate surface. The Refraxe line of energy-enhancement coatings are designed to increase the emissivity of refractory surfaces. Furnace Mineral Products Inc. Referring to FIG. Heatec Ceramic fiber Spray combines bulk refractory fiber made from alumina-silica Constituents and other refractory oxides with an inert, high temperature inorganic binder. ~ ound of the Invention Conventionally, the spray method of refractory material has been used only for lining th0 inside of small constructions such as chimneys and ducts. That is, as is known in the art, the thermal conductivity of refractory fiber increases rather sharply at mean temperatures of approximately 1800° F.-2000° F. By utilizing the present invention the thermal conductivity of the refractory layer can be reduced. Substrate (16), which in this case includes refractory brick such as dense refractory brick or insulating fire brick as is known in the art is coated with two layers of refractory fiber and binder utilizing the method of the present invention. Home → Refraxe – Emissivity Coatings for Refractory, RefraxeTM Series– High temperature ceramic based refractory coating. All of these products provide a lightweight, joint-free, corrosion-resistant, disposable working lining that has been Powerful. Raw refractory ceramic fibres are white or gray fibrous materials supplied in bulk fibre, blanket form, or contained in a solid product. A refractory layer comprised of fiber and binder produced by the method of the invention is also disclosed. Thus, a refractory layer is produced which does not require mechanical fastening, which can withstand extremely high temperatures and which will not debond from the substrate upon repeated thermal cycling. Such a system may suffer from weak bonding at the substrate interface. Spray-applied Fire Resistive Materials (SFRM) Subliming, Intumescent, and Ablative Mastics; Lightweight Castable Cementitious Products; Pre-formed Inorganic Panels or Masonry ; Endothermic Wraps; Refractory Services. The coating system offers excellent penetration and adhesion to the refractory surface. & Terms of Use. Its primary function is to close and seal all openings or gaps so that the fire, heat, gas, and fly ash will not escape the confines of the boiler. Macrospray Parting Layer Spray. Has a very high energy reflectivity quality which gives energy saving properties . Our refractory lining and cement products have excellent adhesion, thermal resistance, dielectric strength, wet gas erosion resistance, … 4) refractory linings - with bricks, castables. generation, Method for applying a layer of fiber on a surface, Refractory coated and conductive layer coated flame resistant insulating fabric composition, Field-installed insulation and apparatus for and method of making and installing the same, Method of protecting a surface from a heat source, Process and apparatus for the production of parts from synthetic materials of any kind reinforced with fibres, Method and apparatus for spraying a mixture of fibers and resin material, Method for producing reinforced plastic, resinous, or like structural bodies, forms,linings, and coatings, Fibre mats and method of and apparatus for making the same, Process for damping mineral fibers to be sprayed in air, <- Previous Patent (Heat-settable sealan...). Pipe System Assessment. Get in touch today to … and lining, wrapping and coating of under ground pipe lines. "New Sprayable Ceramic Fiber with Special Binder Provides Economical System for Insulating Furnaces" by Jerry Barrows; Industrial Heating; Apr., 1986, vol. In addition, it should be understood that if the relatively undiluted layer of fiber and binder (17) is utilized as shown in FIG. It should be expressly understood that layer (17) is optional and that the more diluted solution of binder and fiber which forms layer (18) may be applied directly to the substrate in many applications. 4, pp. Fibrecoat binds the surface fibres forming a skin over the ceramic fibre lining. Keywords cast linings, refractory lifespan, lining engineering and design, lining supply, lining installation, curing, dry-out. All of these products provide a lightweight, joint-free, corrosion-resistant, disposable working lining that has been engineered for easy deskulling. While suited for its intended purpose, such a system would be unsuitable for use in high temperature applications and may be unsuitable for applications in which a refractory lining is sprayed onto a brick substrate. APPLICATION KC2000 should be applied by trained engineers, using a high-pressure spray gun. Refractory coatings are made of certain grain composition of refractory fine aggregate, powder and add water or other liquid binder and additive. For example: A furnace with new refractory lining may take 3.5 hours to achieve a temperature of 1250 deg. Variable Output Dry Spraying Refractory Shotcrete Gunning customized variable output dry spray type refractory gunning REED Concrete Pumps Shotcrete Pumps and Guncrete Gunite Machines. For spray application, it has to be thinned with water. Ultra-Z is a thin coat, spray-on insulation used to seal up degraded ceramic fiber and small hard refractory cracks.Ultra-Fill is used as an insulating filler to damaged linings, while Ultra-Z operates as an insulating sealant. Gunite – REED Concrete Pumps & Shotcrete Equipment. PROBLEM TO BE SOLVED: To provide a monolithic refractory for a spray repairing capable of preventing the peeling and falling in the spray repairing application of the monolithic refractory. $119.96 $ 119. Upon curing, the chlorides and the water are driven off leaving a crystalline alumina bond between the fibers and between the fiber layer and substrate. That is, the binder comprises a liquid containing approximately: 63% alumina; 6.2% soluble chlorides, 0.02% SiO2 ; 0.02% Fe2 O3 ; 0.02% CaO and MgO; 0.25% Na2 O3 ; and approximately 30% water. RefraXE coating systems are water based, inorganic chemistries that offer temperature resistance up to 2800 oF. Each panel measured 3'×3'×4", and were identified as panel A and panel B. Presently this share is above 95 percent. Archived. Referring to FIG. directing a stream of refractory fibers toward said substrate; spraying a liquid binder into said stream during said step of directing so as to substantially coat said fibers with said binder, said binder capable of forming alpha alumina (Corundum) crystals upon curing; and. Referring to FIG. effect on the liquid features, it also affects the refractory lining. u/manofredgables. Thermal cycling was accomplished by exposing the test panels to a temperature gradient starting at approximately room temperature and increased to a hot face temperature of approximately 2400° F. over an 8 hour period once a day for six days. Hardworking. Shotcrete is typically a low-cement, low-moisture refractory that is fully tempered and mixed with water (or special additives), and then applied through a machine that uses a piston pump and air to spray the wet material from a nozzle like gunite. Swabbing can reach into deep cavities and recesses, where it may be difficult to brush or spray. Mississauga, ON L5S 1M2 In addition, this is a two part system in which the fiber is pre-coated thus potentially suffering from the dry binder separation limitations discussed above. Ceramic based refractory coatings to enhance energy efficiency in furnaces and kilns. More particularly, the invention relates to a plural direction application of coating materials by simultaneously applying fiber and binder from different sources. IRON MAKING REFRACTORY SYSTEMSIRON MAKING REFRACTORY SYSTEMS Advantages of Carbon lining:• Increase in overall compaign life of the furnace.• A refractory layer comprised of fiber and binder produced by the method of the invention is also disclosed. A cylindrical preheat furnace that measured approximately 400 square feet and which was lined with nine inches of castable refractory material as is known in the art was sprayed using the method of the present invention. After spraying, the fiber-binder insulation layer was coated with a light spray of binder-only solution. All rights reserved. Refractory bricks for lining of BOFs were made in the past from doloma (decomposed calcium–magnesium double carbonate, dolomite); but during the latest decades, doloma has been substituted by magnesia (MgO) and the inner refractory lining (working lining) in present oxygen converters is based on tar/carbon-bonded magnesia bricks. Ultimately, this will improve the service life of the refractory material. In still greater particularity, the invention relates to a spray application of refractory fibers to a surface with an alpha alumina crystal forming binder. The method is adaptable for the construction and repair o~ the industrial and metallurgical furnaces~ and the like refractory equipments. A lining gun for spraying a refractory lining on the interior of deep walled refractory bodies such as ladles and the like comprising: 2. Strengthens existing refractory and will add years to your refractory lining. Spray Lining and Coatings brand products include affordable, high quality polyurea, poly-hybrid, and epoxy coatings for truck beds, garage floors, koi ponds, boats, trailers, and more. Spray In Place Solutions specializes in the rehabilitation of piping systems for water, sewer, industrial, commercial and storm drains. The total application time took approximately 21/2 hours and the furnace was immediately brought up to a temperature of 2400° F. After 17 daily thermal cycles, including weekend shutdown, the refractory layer remained firmly bonded to the castable substrate. The method disclosed in that patent utilizes an aluminum phosphate based binder. This embodiment gives extremely strong adhesion of the refractory layer to the substrate. FIG. Read more. It is composed of refractory aggregate, powder, binder (or admixture). [email protected] Spray Grouts Features. LII, No. Making a spray-on refractory liner I'm not happy with my melting furnace performance. That is, as opposed to previous methods of relining furnaces, requiring either manual replacement of brick or mechanically attaching refractory fiber linings, spray insulation may be easily and quickly applied to the surfaces. 1 is an illustration of an operator applying the refractory material to a brick substrate; FIG. Screen Printers; Furnaces; Mixing & Dispensing Tools . 3 is a side sectional view of the refractory material applied to the brick substrate; and. 2) ANTICORROSIVE TREATMENT - PAINTING OF STRUCTURES, PIPE LINES, TANKS, EPOXY COATING AND LINING, WRAPPING AND COATING OF UNDER GROUND PIPE LINES. Download Specifications. Thus, temperatures up to 3000° F. and more may be achieved. There are other monolithic and specialized refractories used such as insulating castables, refractory mortars, fettling mixes, and tap hole mixes. BOF vessel capacities can range from 70 to 300 tons. After spraying with fiber, the insulation was coated with a light spray of binder-only solution. FIG. Other Types. FLOW COATING. As can be appreciated by one skilled in the art, the use of anchors increases cost and furnace down time. One suitable aluminum chloride binder is available from KEITH Refractories, Ltd., of Kent, England. BASILITE* : A range of sprayable, disposable Tundish working lining coatings that can be applied through our state of the art BASILITE* spray equipment or can be also be applied manually. This bond is preferred to bonds such as clay, phosphates, and silicates which tend to debond from the substrate as discussed above. However, none of these previous methods or applications result in a refractory lining which adheres to the substrate upon which it is applied and remains there during thermal cycling and exposure to elevated temperatures of 2200° F. or more. Heatec Ceramic fiber spray is applied to furnace and wall, kiln shells, boilers, ducts, and processing equipment by delivering a predetemined mixture of fiber and binder with a fiber spray machine. The superior performance of this binder is believed to result from the disassociation of the chlorides and water at temperatures in excess 700° F., leaving high purity alumina as the sintering bond. The thermal conductivity limitations of refractory fiber insulation alone can be reduced with the present invention. Most refractory materials of a refractory layer of the present invention employing aluminum chloride binder and refractory fiber sold by Manville Corporation under the trademark CERACHEM® and sprayed to a density of 35 lb/ft3 is as follows: Thus, it can be appreciated that the present invention offers superior thermal conductivity performance. refractory lining gun Prior art date 1977-11-21 Legal status (The legal status is an assumption and is not a legal conclusion. Refractory ceramic fibres (RCFs) belong to a class of fibres called man-made vitreous fibres, which are primarily valued for their insulating qualities. Samples were taken from the tundish slag line area and from the steel/refractory contact area. A second panel was sprayed with undiluted aluminum chloride binder alone directly onto the brick and then sprayed with a 4-5 inches of 40% aluminum chloride-water solution by volume used as a binder with the fiber. That is, while the method may result in bonding of the refractory fiber one to another, the bond between the fiber-binder layer and the substrate upon which it is sprayed may be deficient. All our furnace lining products, including Foamfrax® insulation, provide fast installation, exceptional energy and fuel savings, and overall cost savings. They were allowed to air dry for 18 hours prior to being placed in the hearth. Pyro-Paint™ 634-ZO. We can also offer a complete service including casting, ramming and brick work installations. The fiber and binder combination are sprayed onto the surface to be treated and cured in place,it's asbestos free. Concrete and refractory spraying machines TTS have been designed for spraying of concrete and refractory mixtures in the so-called dry way when the transported mixture gets moistened at the moment of spraying. The binder is a liquid binder which is sprayed into the stream of refractory fibers which have been directed toward the surface to be insulated. Since the majority of furnaces and kilns are brick lined, such a system may find little application in these areas. It has a creamy consistency and can be applied directly. © 2004-2020 FreePatentsOnline.com. intensive repair work of refractory lining of iron- and steel-making facilities. Any such solution which forms alpha alumina (Corundum) upon curing at approximately 700° F. or more may be utilized. The Aliva-555 is a compact, easy to use spraying system for the repair of refractory linings of converters in steel production. Our traditional families of materials include DOSSOLITE and NARSPRAY ® mixes for spray linings, the NARCOTUN product line for dry vibe, and CLEANCOAT products for trowelable linings. The first, T1, was a standard spray material; the second an ‘active’ spray material applied on to the standard spray material (T2); and thirdly, a ‘dry-vibe’ material (T3). Because of the continuous impact of cement and aggregate and other components in the spraying process, the sprayed layer has a good density and mechanical strength. Click here to contact us. Owing to refractory lining wear due to above factors, the time and fuel required to reach a certain temperature increases over a period of time. The liquid binder which is employed with the method is preferably an aluminum chloride based binder. ... All of our pipe lining solutions follow a similar process, custom tailored to your infrastructure's specific needs. This work describes the technology necessary to optimize the performance of any refractory lining. Close. Product. The substrate (16) may be a bare metal wall of a furnace or it could be a brick substrate as is shown in FIG. FC-Cement provides a range of consistencies for brush, spray, and towel-on applications at a 2,300°F (1,260°C) temperature grade. The share of continuously cast steel around the world has increased significantly in the last 35 years or so. While suited for its intended purpose, this method utilizes a dry cementitious binder which is limited in its temperature range to a stated maximum of 2200° F. In addition, a cementitious binder such as calcium aluminate or calcium phosphate may adversely affect silicate based brick products at temperatures in excess of 2000° F., thus effectively reducing the maximum service temperatures of these cementitious refractory materials in such applications. Gunform is acknowledged as one of the pioneers in gunning installation and technology, specialising in refractory linings by gunning, shotcrete, pumping and grout injection. The coating system stabilizes the surface’s emissivity throughout the temperature range and seals the furnace’s firebox to reduce heat loss. The real cost benefit of our patents come from their heat saving properties. * AnMar-BRS Africa. Refractory lining lifetimes are usually limited by chemical corrosion, physical erosion, thermal shock failure (Section 4.12.4.3), or a combination of these. A number of spray methods and applications have been previously disclosed. It may be appreciated that the present method may also be utilized with any substrate such as refractory castables or other materials as are known in the art. The present invention is directed to a method for spray applying a refractory material to a surface utilizing an alpha alumina (Corundum) crystal forming binder material and to the refractory layer produced thereby. refractory lining’s lifespan is outlined here, a few key points are highlighted, with an emphasis on the various installation parameters. If you are going to buy refractory lining in kilns, furnace or electric arc furnace, please contact RS Kiln Refractory Company! Densities of up to 40 lb/ft3 or more are achievable by practicing the present invention with 12-35 lb/ft3 being the preferred density range. In addition, these applications disclose a system utilizing a dry composition which is more difficult to control in a spray method than applicants' liquid binder. That is, it is possible to spray fiber, for example, with a binder solution of approximately one part aluminum chloride by volume to four parts water by volume directly onto the substrate without the layer of binder (19) or the less dilute layer of binder and fiber (17). Furnace Mineral Products Inc. is a technology driven ceramic coatings development and application services company focused on delivering surface protection solutions to the power generation, downstream oil and gas and chemical processing markets. Layer (18) was sprayed with approximately 8-12 lbs per cubic foot density using both a 25% by volume dilution of aluminum chloride with water and with a 33% dilution of liquid monoaluminum phosphate to water. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.) 3) internal/external lining of pipes, vessels, structure - with frp / fre. It is composed of refractory aggregate, powder, binder (or admixture). The main physical mechanisms of attack include abrasion on loading ore and scrap materials or erosion by particle-laden vapors moving rapidly past the solid refractory. 4,547,403 issued on Oct. 15, 1985. Guniting maintenance – Guniting maintenance consists of mixing water with a magnesite based gunning mix and spraying this mixture onto the refractory lining. The invention relates to the field of coating processes. Similarly, substrate (16) may be refractory fiber modules which have been mechanically attached as is known in the art. Upon curing, the liquid is driven off, thus resulting in an alpha alumina crystal forming material which provides a strong bond for attaching the refractory layer to the substrate. The approximate 2:1 dilution produced a layer with approximately 30-40 lbs per cubic foot density. F: 1 866 591 9018 Zircon Paint Coating-Dry Powder 1750°C . Privacy Policy At this mass, depending on the kind and structure of the bookmark, for example, pneumatically spray or poured, or sprinkled, or contribute by spreading. Making a spray-on refractory liner . I'm not happy with my melting furnace performance. 4.4 out of 5 stars 605. Nos. At the end of each 8-hour period, the furnace was shut off and the panels allowed to return to room temperature. A method of applying refractory coating by using a low pressure fluid stream to flood the sand surface. Slag splashing provides a refractory coating over the existing lining. 1) SURFACE PREPARATION - SHOT / GRIT BLASTING. 1, an operator (11), dressed in suitable protective clothing (12), including an enclosed breathing apparatus (13), is shown holding a spraying apparatus generally designated as (14) from which a stream (15) of binder coated refractory fiber is being directed onto a substrate (16). The lining is exposed to extremely high temperature and radiation intensity from the combustion flame. A method for spray applying refractory fiber to a surface. Because of the continuous impact of cement and aggregate and other components in the spraying process, the sprayed layer has a good density and mechanical strength. That patent also discloses a colloidal alumina-clay binder which suffers from the same weak bond line at the substrate interface. BASILITE* can be used cold or hot with custom designed high efficiency drying equipment. Tough. 6) supply and application of hot insulation of pipes, esp, boilers exchangers, columns, Refraxe offers the ability to transform the substrate surface to absorb and re radiate heat energy, improving the thermal efficiency and performance of furnaces and kilns. Spraying of unshaped refractory has been the principal method of mechanizing refractory repair, wherein it is important to enhance the durability of the sprayed material while enjoying the advantages of mechanization. Preferably, the fiber is blown by air pressure from a suitable pneumatic apparatus (not shown). The lining gun of claim 1 wherein the mixing discharge nozzle includes two opposed orifices and further including means disposed adjacent each orifice and centrally of the first conduit to divide the flow of dry refractory material equally between each orifice. All our products can be customized to suit your specific needs. Coating refractories are primarily used to protect refractory linings against any forms of chemical attack. 8. This process blasts the slag mixture over the existing refractory lining. Repair thus the so-called places of wear, i.e. Finally, another sprayable ceramic fiber insulation system marketed under the trademark FIBERBRAX®, a trademark of the Sohio Engineered Materials Company (CARBORUNDUM) is a sprayable system which is rated to a maximum temperature of 2100° F. While suited for its intended application, the system is limited in temperature application and is also a silica based binder material which is subject to debonding at the substrate interface as with the clay and phosphate binders. The main difference of Refractory coating in comparison with other monolithic refractories is the mixing granular particle, trace additives and water content. A 2'×2' area was sprayed with the 65% binder solution and a medium length refractory fiber to a desired thickness of 4 inches. 2,093,014 and 2,093,015. This blend can be applied in a wide range of thicknesses, typically 50mm~250mm. The oxides of aluminium (), silicon and magnesium are the most important materials used … Carbon lined wallscan be cooled by spray coolers. KC2000 can be also be hand painted with a stiff brush. Aremco’s refractory coatings offer the ultimate protection of high temperature components used in the processing of ceramics, glass, metals, and plastics. Still another spraying method is disclosed in U.K. Patent application Nos. Refractory is used on all steam-generating boilers. Granted Application number GB8034571A Other versions GB2057301B (en Current Assignee (The listed assignees may be inaccurate. 4 is a side sectional view of the refractor material applied to the brick substrate in one layer. This method is faster and more effective than brushing and also more effective than spraying. Refractory Lining is a layer of material which can resist high heat temperature in the kiln or furnace. Finally, the 1:2 binder-water solution was sprayed over the binder-fiber layer. Refractory walls of a furnace interior with burner blocks (BEE, 2005) Some of the important properties of refractories are: Melting point: Pure substances melt instantly at a specific temperature. Advantages of such a method include reduced costs and reduced down time for a furnace or the like. Its maximum service temperature is of 1750°C / 3180°F. 20-21. curing said coated fibers on said substrate so as to produce an alpha alumina (Corundum) crystal bond between at least some of said fibers and said substrate. Click for automatic bibliography (3) Combustion chamber lining: high temperature parts are made of silica bricks, light high alumina bricks, light clay bricks, refractory spray paint, etc. Continuous casting of steel is a widely used process and an important step in the production of steel. That is, the bond between the fiber-binder layer and the substrate is strong enough to withstand the repeated differential thermal expansion and contraction encountered as a result of the thermal cycling. However, a greater concentration of aluminum chloride binder to water may be utilized with pumps which can spray higher viscosity liquid. The experimental procedure is described below: Panel A: This panel was pre-wetted with a 65% by volume aluminum phosphate and water solution. Panel B: This panel was pre-wetted with a 50% by volume aluminum chloride and water solution. For an economic, hot or cold refractory repair of degassing tubes inside and also outside of vacuum vessels in steel production. This continued for two cycles, after which the panels were removed to reveal that the Panel A insulation layer had completely and cleanly delaminated from the brick substrate while Panel B remained firmly bonded to the brick.
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