Ladle Backing Layer Castables,Ladle Castable

Ladle Backing Layer Castables

Large ladle mostly uses magnesia-carbon brick and alumina-magnesia-carbon brick. There is also a layer of 90-110mm castable that is backing layer castable.

Casting of Backing Layer for Ladle Bottom (Construction Time: 1 Day)

Casting of Backing Layer for Ladle Bottom (Construction Time: 1 Day)

    Firstly, fix Permeable Brick and Ladle Nozzle Well Block, and then plug the inner hole with some resilient staff.

    Secoendly, weld some anchoring nails in the middle area of ladle bottom between one well block and another, the vertical and horizontal distances between every two anchoring nails are 25mm and 30mm.

    Thirdly, mix backing layer castable for ladle with about 5% of water, and then stir it for about 20 minutes till smooth.

    At last, pave the mixed backing layer castable at the bottom of ladle, and then vibrate it to 100mm in thickness by flat vibrator.

Casting of Backing Layer for Ladle wall (Construction Time: 1 Day)

    After maintenance of bottom permanent layer, stick a layer of high alumina fiber mat which is 10mm in thickness with the ladle shell. Then place the mould right in the middle, flat, no deviation. The mould surface should be clean, smooth and greased for easy demould.

    Lay the mould properly to ensure that the gaps between mould and sidewall are the same, then pour the mixed backing layer castable into the gaps, vibrate it by vibration bar till no bubble emerges(If mould is unavailable, cast working layer first and then permanent backing layer). The bottom of permanent backing layer is 100mm in height; vibrate 300-400mm per time, and its 90-100mm in thickness, then one circle by one circle till to the top.

    After vibration of permanent backing layer, lift the ladle to an area at higher temperature, so that it is convenient for water evaporation and drying of cast body. The time of demould should be more than 12 hours, usually 24 hours, specific time depends on lining harden situation.

How to Build a Solid Arch Ceramic Kiln with Castable Refractory

How to Build a Solid Arch Ceramic Kiln with Castable Refractory

       Kilns can be built out of many things and castable refractory is one of the materials we rarely consider. Perhaps it should be considered more since the castable is reasonably priced, easy to mix, and easy to use.

      As John Britt explains in today’s post, if you are comfortable with casting plaster and making molds, you can handle building a solid arch kiln with castable refractory. – Jennifer Harnetty, editor.

Casting an Arch

     Determine the size of your arch and cut enough expanded polystyrene arch pieces to form the entire arch. Set it on four-inch “legs,” which can be dropped out after casting. Make the exterior wooden mold form by cutting two identical arch pieces out of 3⁄4-inch plywood that are longer than the foam arch by the thickness of the kiln wall. Establish the length of the kiln and cut three 2×4s to that length, attaching two to the bottom sides of the plywood arch forms and one at the top (the top 2×4 is visible in image #1). Fill this form with the polystyrene arches.

      Mix the castable, paying specific attention to the manufacturer’s instructions. You can use a commerical castable, Pryor-Giggey Phlocast 30 Low cement, and added Rib-Tec 400 1-inch stainless steel pins. Use approximately four pounds of steel pins per 100 pounds of castablerefractory. When mixing, wear a respirator and use thick gloves—the castable is caustic and the pins are sharp.

    Pour the castable in 4-inch-high sections made from 3⁄4-inch plywood strips so the castable refractory don’t bow, being sure to pack down and smooth out each section. Form a V-shaped groove at the top of each section and let the castable refractory harden. Separate each section with plastic wrap before repeating—the plastic creates an expansion joint. After the castable castablehas cured for 24 hours, take the outer plywood off and drop the legs out from underneath, allowing the interior expanded polystyrene forms to drop out.

Above ways just for your reference.

Castasble,Refractory Castable,Ladle Castable,Tundish Castable at en1.chinaelong.com

Refractory castables

　Castable is simple production technology and energy production, use agile for cement kiln system, the characteristic is within the complex structure in the preheater system is becoming popular in the application. Applicable to the cement kiln of castable mainly includes the jade castable, just high aluminum pouring material, alkali pouring material and light pouring material, etc.

Types, Technical Properties and Application of Refractory Castable

Types of refractory castable
    Refractory castable mainly distinguished according to apparent porosity, anchoring agent, and types of aggregate. Besides that, refractory castable also classified according to applied temperate and functional characteristics when used. According to apparent porosity, it can be divided into compact refractory castable and adiabatic refractory castable whose apparent porosity is not less than 45%; according to anchoring agent, it can be divided to hydraulicity refractory castable, chemical constitution refractor castable and union refractor castable. The hydralicity refractory castable can harden in normal atmospheric temperature or by hydration, which mainly include portland cement, ordinary Calcium aluminate cement, pure Calcium aluminate cement and elect rometrical pure Calcium aluminate cement. The chemical constitution usually harden by adding curing agent to lead to chemical reaction in the normal atmospheric temperature, which mainly includes sodium silicate refractory castable, aluminum sulfate refractory castable and phosphate refractory castable. The union refractor castable turns to hard by sintering in the process of calcination, which mainly include Clay castable. According to refractory aggregate, there are clay aggregate (Al2O3 30%～45%),high aluminum aggregate (Al2O3%26ge;45%), silicon aggregate (SiO2%26ge;85%、Al2O3%26lt;10%), alkalin-ous aggregate (magnesite clinker and dolomite ) , special aggregate (carbon, carbide, spinel, zircon and nitride ) and adiabatic aggregate (pearlstone, vermiculite, ceramicite, floater, light brick sand, Porous clinker, and alumina hollow sphere). In the process of construction, it is available to use some mixture aggregate according to construction necessaries. Technical performances and applications of refractory castable
    Refractory castable as the main sort of unshaped refractory material, which can be used without fritting, besides that, among all he unshaped materials it with simple produce craft ship, needs no equipments, with high level of mechanization, easy to construct and with high coefficient of utilization. What’s more, refractory castable often have high intensity and can be made into fabricated material that used by furnace, for example, continuous casting weir plate preform which is pans available refractory castable.
     Refractory castable mainly used in casting industrial stoves, and also widely applied in fossil oil, chemical industry, electric power, mechanical industrial stoves, and thermal equipment.