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Development of Unshaped Refractories for Thermal Power Plant Boilers

  • Categories:Industry news
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  • Time of issue:2020-02-16 20:26
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(Summary description)ThedevelopmentofamorphousrefractoriesinChinacanberoughlydividedinto3stages:  Beforethe1970s,thevarietiesweresingle,mainlyaluminacementcastable,phosphatecastable,waterglasscastableandasmallamountoframmingcastable.  Intheearly1970s,withtheintroductionofmanyprojectssuchasthe1.7-meterprojectofWISCO'smetallurgicalsystemandDagangandYuanbaoshanofthepowersystem,refractoryplasticsdevelopedrapidlyinChina.Thematerialhasmanyexcellentpropertiessuchasgoodthermalshockstability,andhasachievedGooduseeffect.Withtheexpansionofthescopeofapplication,theexistingproblemsarealsoveryprominent,whichcanbesummarizedasfollows:(1)Plasticcanbeintheformofcement,whichrequirestampingorrammingconstruction,longconstructionperiodandhighlaborintensity.(2)Plasticcanbemadeintovariousrequiredshapesintherefractoryplantafterbatching,mixing,anddegassing,andthensealedandpackagedfordirectuseonsite.Althoughtheon-sitemixingprocessisomitted,asthestoragetimeisprolonged,thewaterretentioncapacityisreduced,andthewaterisdispersedandhardened,whichbringsalotoftroubletotheproducersandusersaroundthestorageperiod.(3)Inordertoextendtheshelflife,manyproductionplantsoftenadoptthemethodofaddingextraclayandwater.Whendrying,theshrinkageislarge,severecrackingoccurs,andthestrengthafterdryingislow,whichaffectstheservicelifeandeffect.(4)Theamountofbinderislarge,andtherearemanylowmeltingmaterialswhenheatedathightemperature,andobviousshrinkageoccursabove1000℃.Ifnoexpansionagentisadded,afterheattreatmentat1350℃,thetotalshrinkagecanreach7%,thestrengthchangesgreatlywithtemperature,andtheresistancetospallingandcrackingispoor.  Inordertomakeupfortheabove-mentionedshortcomings,aclay-boundcastablewasdevelopedattheendofthe1970s,anditsperformanceisbasicallyequivalenttothatofrefractoryplastics.Itcanalsobepouredforconstruction,andtheshelflifeisgreatlyextended.Itquicklyreplacedrefractoryplastics,andwaswidelyusedinthermalequipmentsuchassoakingfurnaces,heatingfurnaces,andironditches.Sincetheconstructionqualitycanbeguaranteed,theuseeffectismoreexcellent.However,thestrengthatroomtemperatureistoolow,whichlimitsitsdevelopment.  Sincethe1980s,inordertoreduceresourcewaste,varioushigh-performancesyntheticrawmaterialshavebeenmanufacturedinlargequantities,especiallylow-cementcastables,ultra-low-cementcastables,cementlesscastables,andself-levelingrefractorypouring.Thesuccessfuldevelopmentofmaterialsreducestheharmcausedbylow-meltingsubstancesandharmfulgasesduringtheuseofcementcastablesandchemicallycombinedcastables,andthephysicalpropertiesofcastableshavebeensignificantlyimproved.Thesematerialshavebeenusedinindustrialfurnacesandtheirfurnacelifehasincreased3~5times.  Practicehasprovedthatthesematerialsareequallyapplicabletovariouspartsofboilersinthermalpowerplants.Theboilersinthermalpowerplantsshouldalsochooserefractorymaterialsfordifferentconditionsofuseandformaseriesofproductssuitableforpowerplantsinordertoachievethebestenergysavingandlonglife.

Development of Unshaped Refractories for Thermal Power Plant Boilers

(Summary description)ThedevelopmentofamorphousrefractoriesinChinacanberoughlydividedinto3stages:  Beforethe1970s,thevarietiesweresingle,mainlyaluminacementcastable,phosphatecastable,waterglasscastableandasmallamountoframmingcastable.  Intheearly1970s,withtheintroductionofmanyprojectssuchasthe1.7-meterprojectofWISCO'smetallurgicalsystemandDagangandYuanbaoshanofthepowersystem,refractoryplasticsdevelopedrapidlyinChina.Thematerialhasmanyexcellentpropertiessuchasgoodthermalshockstability,andhasachievedGooduseeffect.Withtheexpansionofthescopeofapplication,theexistingproblemsarealsoveryprominent,whichcanbesummarizedasfollows:(1)Plasticcanbeintheformofcement,whichrequirestampingorrammingconstruction,longconstructionperiodandhighlaborintensity.(2)Plasticcanbemadeintovariousrequiredshapesintherefractoryplantafterbatching,mixing,anddegassing,andthensealedandpackagedfordirectuseonsite.Althoughtheon-sitemixingprocessisomitted,asthestoragetimeisprolonged,thewaterretentioncapacityisreduced,andthewaterisdispersedandhardened,whichbringsalotoftroubletotheproducersandusersaroundthestorageperiod.(3)Inordertoextendtheshelflife,manyproductionplantsoftenadoptthemethodofaddingextraclayandwater.Whendrying,theshrinkageislarge,severecrackingoccurs,andthestrengthafterdryingislow,whichaffectstheservicelifeandeffect.(4)Theamountofbinderislarge,andtherearemanylowmeltingmaterialswhenheatedathightemperature,andobviousshrinkageoccursabove1000℃.Ifnoexpansionagentisadded,afterheattreatmentat1350℃,thetotalshrinkagecanreach7%,thestrengthchangesgreatlywithtemperature,andtheresistancetospallingandcrackingispoor.  Inordertomakeupfortheabove-mentionedshortcomings,aclay-boundcastablewasdevelopedattheendofthe1970s,anditsperformanceisbasicallyequivalenttothatofrefractoryplastics.Itcanalsobepouredforconstruction,andtheshelflifeisgreatlyextended.Itquicklyreplacedrefractoryplastics,andwaswidelyusedinthermalequipmentsuchassoakingfurnaces,heatingfurnaces,andironditches.Sincetheconstructionqualitycanbeguaranteed,theuseeffectismoreexcellent.However,thestrengthatroomtemperatureistoolow,whichlimitsitsdevelopment.  Sincethe1980s,inordertoreduceresourcewaste,varioushigh-performancesyntheticrawmaterialshavebeenmanufacturedinlargequantities,especiallylow-cementcastables,ultra-low-cementcastables,cementlesscastables,andself-levelingrefractorypouring.Thesuccessfuldevelopmentofmaterialsreducestheharmcausedbylow-meltingsubstancesandharmfulgasesduringtheuseofcementcastablesandchemicallycombinedcastables,andthephysicalpropertiesofcastableshavebeensignificantlyimproved.Thesematerialshavebeenusedinindustrialfurnacesandtheirfurnacelifehasincreased3~5times.  Practicehasprovedthatthesematerialsareequallyapplicabletovariouspartsofboilersinthermalpowerplants.Theboilersinthermalpowerplantsshouldalsochooserefractorymaterialsfordifferentconditionsofuseandformaseriesofproductssuitableforpowerplantsinordertoachievethebestenergysavingandlonglife.

  • Categories:Industry news
  • Author:
  • Origin:
  • Time of issue:2020-02-16 20:26
  • Views:
Information

  The development of amorphous refractories in China can be roughly divided into 3 stages:

  Before the 1970s, the varieties were single, mainly alumina cement castable, phosphate castable, water glass castable and a small amount of ramming castable.

  In the early 1970s, with the introduction of many projects such as the 1.7-meter project of WISCO's metallurgical system and Dagang and Yuanbaoshan of the power system, refractory plastics developed rapidly in China. The material has many excellent properties such as good thermal shock stability, and has achieved Good use effect. With the expansion of the scope of application, the existing problems are also very prominent, which can be summarized as follows: (1) Plastic can be in the form of cement, which requires tamping or ramming construction, long construction period and high labor intensity. (2) Plastic can be made into various required shapes in the refractory plant after batching, mixing, and degassing, and then sealed and packaged for direct use on site. Although the on-site mixing process is omitted, as the storage time is prolonged, the water retention capacity is reduced, and the water is dispersed and hardened, which brings a lot of trouble to the producers and users around the storage period. (3) In order to extend the shelf life, many production plants often adopt the method of adding extra clay and water. When drying, the shrinkage is large, severe cracking occurs, and the strength after drying is low, which affects the service life and effect. (4) The amount of binder is large, and there are many low melting materials when heated at high temperature, and obvious shrinkage occurs above 1000 ℃. If no expansion agent is added, after heat treatment at 1350 ℃, the total shrinkage can reach 7%, the strength changes greatly with temperature, and the resistance to spalling and cracking is poor.

  In order to make up for the above-mentioned shortcomings, a clay-bound castable was developed at the end of the 1970s, and its performance is basically equivalent to that of refractory plastics. It can also be poured for construction, and the shelf life is greatly extended. It quickly replaced refractory plastics, and was widely used in thermal equipment such as soaking furnaces, heating furnaces, and iron ditches. Since the construction quality can be guaranteed, the use effect is more excellent. However, the strength at room temperature is too low, which limits its development.

  Since the 1980s, in order to reduce resource waste, various high-performance synthetic raw materials have been manufactured in large quantities, especially low-cement castables, ultra-low-cement castables, cementless castables, and self-leveling refractory pouring. The successful development of materials reduces the harm caused by low-melting substances and harmful gases during the use of cement castables and chemically combined castables, and the physical properties of castables have been significantly improved. These materials have been used in industrial furnaces and their furnace life has increased 3 ~ 5 times.

  Practice has proved that these materials are equally applicable to various parts of boilers in thermal power plants. The boilers in thermal power plants should also choose refractory materials for different conditions of use and form a series of products suitable for power plants in order to achieve the best energy saving and long life.

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