Construction and installation skills of refractory materials
2025-01-16 13:51:54
Refractory materials are widely used in high-temperature environments. They have good fire resistance, high temperature resistance, corrosion resistance and thermal shock resistance. Therefore, they play an important role in high-temperature furnaces, reactors, pipelines and other equipment in metallurgy, chemical industry, power industry and other industries. Correct construction and installation can not only ensure the best performance of refractory materials, but also effectively extend their service life. This article will introduce the construction and installation skills of refractory materials in detail.
1. Construction preparation of refractory materials
Construction environment preparation
Before construction, the construction environment should be kept clean and tidy, especially the debris around the construction site should be cleaned up to avoid adverse effects on construction. The construction area should be well ventilated to avoid high temperature and humid weather affecting the construction quality.
Material inspection
Before construction, the refractory materials should be inspected first to ensure that they meet the design and specification requirements. The inspection content includes the appearance quality, specifications, performance data, etc. of the refractory materials, and confirm that the materials are not damaged or deteriorated.
Tool preparation
According to different construction methods, prepare the tools and equipment required for construction, such as refractory masonry tools, mixers, spraying equipment, protective gloves, special protective glasses, etc. Construction workers should also wear appropriate protective equipment, such as high-temperature resistant gloves, dust masks, etc.
2. Construction methods of refractory materials
The construction methods of refractory materials vary according to the type of material and the environment in which they are used. Common construction methods include masonry, spraying, pouring, etc. The following is an introduction to several common methods.
Masonry method
Masonry is the most common method of refractory construction, usually used for the installation of refractory bricks. The following points should be noted when laying:
Brick joint treatment: Bricks should be screened before laying to ensure that the size and shape of the bricks meet the requirements. Brick joints usually need to be controlled at around 10mm. In order to ensure that the brick joints are tight, refractory cement or refractory slurry is needed to fill the brick joints.
Brick arrangement: When laying, the design drawings should be followed, and the principle of staggered brick joints should be followed to avoid linear gaps, prevent thermal stress concentration, and cause brick cracking.
Construction sequence: Usually start laying from the bottom and proceed gradually upward. For the laying of equipment such as blast furnaces, it is necessary to pay attention to layer by layer, and pay attention to the docking of each layer of bricks.
Spraying method
The spraying method is to evenly apply the refractory coating to the construction surface through the spraying equipment. It is suitable for steel structures, furnace walls and other surfaces. Things to pay attention to when using the spraying method:
Surface treatment: The construction surface should be clean, oil-free and rust-free to ensure the adhesion of the coating.
Spraying process: Select appropriate spraying equipment according to the size of the construction surface and the type of refractory material. The thickness should be kept uniform during spraying, and it is generally not too thin or too thick.
Construction environment control: Spraying operations should avoid high temperature and humid weather, and it is best to be carried out at room temperature. The coating after spraying should be cured within the specified time.
Pouring method
The pouring method is suitable for the installation of refractory castables, and is usually used for the lining of equipment with complex shapes. Things to pay attention to during construction:
Stirring evenly: Before pouring, the refractory castable should be mixed and stirred evenly with water or other additives according to the formula requirements to avoid stratification or solidification of the material.
Pouring operation: The mixed castable is quickly and evenly poured to the required construction location through special pouring equipment to avoid bubbles or gaps.
Vibration compaction: During the pouring process, vibration equipment should be used to vibrate the material to ensure that the material is fully compacted and avoid voids or unevenness.
Prefabrication method
For some high-temperature structural parts, it may be necessary to use the prefabrication method for the construction of refractory materials. The prefabrication method is usually used to manufacture large refractory components or bricks. During construction, the following are required:
Mold design: According to the design requirements, select a suitable mold to ensure the accurate size of the component.
Material filling: Fill the refractory material into the mold to ensure uniform filling and vibration compaction.
3. Precautions in the construction of refractory materials
Control construction temperature and humidity
High temperature weather or overly humid environment may have a negative impact on the construction quality of refractory materials, so it is necessary to reasonably adjust the construction plan according to climatic conditions. Avoid construction under extreme weather conditions.
Ensure construction quality
The construction of refractory materials must be delicate, and quality inspection should be carried out after each layer of construction to ensure that there are no defects such as cracks and voids. At the same time, collisions and damage to materials should be avoided as much as possible during construction.
Curing and maintenance
For materials with high humidity such as castables, proper maintenance should be carried out after construction. The curing time of refractory materials varies depending on the type of material, and maintenance should be carried out according to specific requirements to ensure the strength and fire resistance of the material.
Safe operation
The construction process of refractory materials involves high temperature, dust and other environments. Construction workers should wear appropriate protective equipment, such as high temperature gloves, goggles, masks, etc., to avoid burns or inhalation of harmful substances.
IV. Inspection and maintenance of refractory materials after construction
After the construction is completed, a comprehensive inspection must be carried out to ensure that the refractory materials are firmly installed, the surface is flat, and it meets the design requirements. If defective or unqualified parts are found, they should be repaired in time. The installed refractory materials need regular inspection and maintenance to ensure their long-term stable operation.
In short, the construction and installation of refractory materials is a highly technical process, requiring construction workers to have certain professional knowledge and skills. Through reasonable construction methods and strict quality control, it can ensure the good performance of refractory materials in high temperature environments and improve the operating efficiency and safety of industrial equipment.