Introduction
Magnesium-based refractory gunning material is a spray-applied refractory composed primarily of magnesium oxide (MgO, typically ≥85% content), combined with binders, additives, and aggregates. It exhibits excellent resistance to alkaline slag corrosion, making it suitable for high-temperature alkaline environments. With refractoriness usually ranging from 1500°C to 1700°C, it is widely used in areas exposed to alkaline atmospheres, such as cement kilns and glass kiln regenerators.
Advantage
High refractoriness: With a melting point up to 2800°C, it can be used long-term in high-temperature environments exceeding 1700°C.
Strong alkali resistance: Exhibits excellent resistance to erosion from alkaline slags containing CaO, FeO, and other components.
Efficient construction: Quickly adheres to furnace lining surfaces via spraying equipment, making it ideal for emergency repairs or the construction of complex structures.
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Main Categories and Compositions
|
Type |
Typical Components |
Characteristics and Applications |
|
Magnesia gunning material |
MgO (85%-95%), aluminate binder |
Basic-type product, used in general alkaline environments (e.g., decomposition zone of cement kilns). |
|
Magnesia-carbon gunning material |
MgO + graphite (5%-20%), resin binder |
Outstanding thermal shock resistance, suitable for converter barrel and bottom in areas with abrupt temperature changes to prevent slag penetration. |
|
Magnesia-alumina spinel gunning material |
MgO + MgAl₂O₄ spinel (10%-30%) |
Balanced thermal shock and erosion resistance, commonly used in blast furnace taphole trenches and ladle slag lines. |
|
Low-cement magnesia gunning material |
MgO + low-cement (CaO≤5%), micro-powders (SiO₂/Al₂O₃) |
High density and strength, suitable for high-temperature load areas (e.g., regenerators of glass kilns). |
Physical and Chemical Specifications
Magnesia gunning material:
|
Item |
MgO(%) |
CaO(%) |
Al2O3(%) |
Fe2O3(%) |
BD(g/cm³) |
CCS (Mpa) |
|
HX-TM1 |
≥70 |
≤10 |
≥3 |
≤3.3 |
≥2.4 |
≥6 |
|
HX-TM2 |
≥82 |
/ |
≥4 |
≤1.7 |
≥2.5 |
≥4 |
|
HX-TM3 |
≥85 |
/ |
≥3 |
≤1.5 |
≥2.55 |
≥12 |
Process
Raw material crushing and screening → batching and mixing (magnesia sand + binders + additives) → dry granulation → finished product packaging.
Application
Iron and Steel Metallurgy
Converters and electric furnaces: Used to repair furnace bodies and bottoms, resisting scouring by 1600–1700°C molten steel and alkaline slags.
Steel ladles: Spraying the slag line area extends service life to over 100 heats (compared to about 60 heats for traditional brick linings).
Cement and Building Materials Industry
Cement kiln firing zones: Withstands CaO-based clinker slag erosion at 1450–1600°C, replacing magnesia-chromite bricks and reducing chromium pollution.
Glass kiln regenerators: Prevents penetration of glass melt vapors and maintains heat exchange efficiency.
Non-Ferrous Metal Smelting
Nickel and copper smelting furnaces: Sprayed linings resist erosion from high-nickel slags, matte, and other strongly alkaline melts.
Construction Methods
1. Pre-spraying Preparation
Thoroughly clean the surface to be sprayed by removing oil, rust, dust, and other impurities to ensure good adhesion between the gunning material and substrate. Methods such as sandblasting, grinding, and air blowing can be used.
Inspect spraying equipment (spray gun, feed hose, air compressor, etc.) to ensure proper operation. Adjust parameters such as spraying pressure and airflow. Air compressor pressure is typically set at 0.4–0.6 MPa, depending on the gunning material type and required spraying thickness.
Pre-mix the gunning material to ensure uniform distribution of raw materials. Powdered materials should be sieved to remove lumps, and liquid binders should be measured accurately according to the formulation. Mixing time should generally be no less than 15 minutes to ensure quality.
2. Spraying Operation
Hold the spray gun at a suitable angle to the surface, typically between 70° and 90°, maintaining a distance of 0.5 to 1.5 meters. Adjust in real time based on the rebound of the gunning material. For corundum gunning material, maintain about 1 meter distance and an angle close to vertical to ensure a uniform, dense coating.
Control the thickness of each layer at 20–30 mm. Apply the next layer after the previous one is slightly dry (no obvious indentation when pressed with a finger) to prevent sagging or cracking due to self-weight. Total coating thickness depends on design requirements-for example, large industrial furnace linings may require a total thickness of 100–200 mm.
3. Post-spraying Treatment
After spraying, allow the coating to dry naturally for 24–72 hours, depending on the binder type and ambient temperature. Avoid collisions or vibrations during this period.
For kilns with special requirements (e.g., high-temperature kilns), bake the coating after drying. Follow a predetermined heating curve for slow warming to remove moisture and promote further binder curing. The heating rate is typically 10–20°C/h initially, increasing to 30–50°C/h later. The maximum baking temperature should reach or slightly exceed the service temperature.
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01/Delivery cycle and logistics
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We recognize that pricing is a critical factor in our customers' purchasing decisions. Leveraging our proximity to abundant mineral resources and advanced manufacturing technologies, we offer competitive pricing without compromising on quality. Our strategic location minimizes raw material costs, while economies of scale achieved through state-of-the-art processes further reduce unit production expenses.
It is worth noting that while price is an important factor, it should not be the sole determinant of your purchasing decision. When buying refractory bricks from ZINFON, quality, reliability, and technical support are equally important considerations.
By choosing ZINFON as your supplier, you can access high-quality refractory bricks, a wide range of other refractory materials, and comprehensive support. Contact ZINFON Refractories immediately to discuss your specific requirements and obtain customized solutions!
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