In China, the new dry cement process is developing rapidly, and the lining design and brick shape of PC and SP kilns are also very complicated. In order to adapt to this situation, practice has proved that it is more suitable to use in the parts of complex structure and deformation of kiln body. It is also suitable for coolers, preheaters, decomposition furnaces, kiln door covers, secondary air ducts and other parts requiring heat insulation. Its varieties include alkali resistant castable, high aluminum and corundum castable, heat insulation castable, steel fiber reinforced refractory castable and so on. The application of these castables has been successful, and its dosage has accounted for 25% to 35% of the total fire-resistant refractories in PC kilns.

1. Alkali-resistant castable

The test shows that the alkali castings have better alkali resistance than ordinary clay or high alumina castings. Ordinary and low-cement alkali-resistant castables have been successfully used in double-layer structural linings of preheater heads, cones, and tertiary ducts where shaped bricks are not suitable. Low cement type alkali resistant casting material can also be used in the rear kiln, cooling machine and kiln door cover and other parts.

2, high aluminum and corundum castable

The high alumina and corundum castable used in cement kiln includes low cement castable and ultra low cement castable, high strength corundum castable and so on. In castable, calcined bauxite and cut jade are used as aggregate. Low cement and ultra low cement type high aluminum castables can be used for front and rear kiln openings, chain belts, kiln door covers and side walls of coolers.

3, insulation pouring department

The castables for cement kiln include ordinary castables, high strength castables, ordinary and low cement castables with alkali resistance. High alumina cement is usually used as a binder in castable. Expanded perlite, expanded vermiculite and waste lightweight brick are used as aggregate for ordinary thermal insulation castable. The high strength heat insulation castable is made of refractory clay ceramisite, pulverized coal ash ceramisite, shale ceramisite, etc. Alkali resistant heat insulation castable is made of alkali resistant lightweight aggregate. Ordinary castable and its prefabricated blocks can be used as insulation in the double-layer structural lining of coolers, preheaters, calciners, kiln door covers and tertiary air ducts. The high strength insulated castable and its prefabricated blocks can be used as a single layer lining in the neck and decomposition zones of traditional kilns. Ordinary type and low cement type alkali resistant insulation castables can be applied to preheaters in small and medium kilns and other parts requiring alkali resistant insulation.

4, steel fiber reinforced refractory castable

The addition of steel fiber can increase the demolition strength of castable, and greatly improve the thermal shock resistance, impact resistance and wear resistance of castable.