SPECIALIST EQUIPMENT
contributing to downtime and cost increases. In the past, the available wear products could withstand one or two of these harsh conditions but not all of them. For example, alumina tiles and basalt have excellent wear and abrasion properties but cannot withstand high temperatures. In some instances, process conditions often create different vapours that creep into and penetrate the joints in the refractory lining, resulting in the lining detaching causing blockages and damage to mechanical parts. Refraline has now developed a wear-
W
resistant product range of castables in different grades with a triple bonding system to withstand both hot and cold process wear conditions. With the above challenges and continuous research and development, Refraline has formulated the Ceratuff product range, installed by casting or trowelling and designed to mitigate the above problems. One key characteristic of the material is its thermal shock resistance. Termal shock is caused by a rapid change in temperature at a certain point. It can also be extended to the case of a thermal gradient, where different areas of a lining expand at different rate. Refraline’s material (tested according to ASTM C1171-16) is able to withstand 94 thermal cycles in air. It can be heated to 1,200°C in its cast shape and then be immersed into a drum of cold water without developing a crack from the rapid temperature shock. Wear resistance is another characteristic. Wear is a process of friction between surfaces that causes the deformation or removal of material on the surfaces due to the effect of mechanical action between the sliding surfaces. Te matrix of the lining is crucial as this forms the binding system for the aggregate in the material. If the material has a weak matrix the wear rate will be vey high. Te company’s triple bonding system has the strongest matrix resulting in its excellent wear properties.
LOW POROSITY Having a wear resistant material with a low porosity is key. A material with low porosity will have very high strength.
ear, abrasion and thermal shock cause many operational problems within the different furnace environments,
There are many different mining applications for the Ceratuff material
MATERIAL MATTERS
Manfred Rösch discusses a monolithic wear-resistant lining material that’s proving to be a popular choice in the mining industry
Refraline’s material has low porosity due to the low water requirement and the high-density value of the material. High compressive strength is another consideration here. A material with a very high compressive strength will have the ability to withstand very harsh wear and abrasion conditions. Silicon carbide is one of the mix components that adds to
the strength characteristics of the material because of its hardness. Te monolithic product should have a cold crushing strength of 145-160 MPA at 1,200° C
TRIPLE BONDING SYSTEM Te strength of a refractory material is determined by its matrix and bonding system. Te Ceratuff material has a
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