Introduction
Dry ramming mass is composed of high-iron, high-calcium synthetic magnesia and fused magnesia as aggregates, with synthetic magnesia and fused magnesia also used as fine powders. The critical particle size ranges between 5 and 6 mm. Calcium diferrite (C₂F) derived from synthetic magnesia serves as a sintering aid, and no additional binders are required. The material is prepared using a multi-stage batching process.
Through intensive ramming during application, high density is achieved, and the material can be sintered into a solid mass at appropriate temperatures. Its lifespan is several times longer than that of previous ramming or bricklaying methods.
Typically, dry ramming mass can last for over 300 cycles per use. With hot repairs, this can be extended to 500–600 cycles. This approach not only reduces the frequency of furnace shutdowns but also significantly lowers refractory material consumption per ton of steel.
major components
Aggregate (60%–80%): Typically composed of high-melting-point minerals (e.g., magnesia, corundum, silicon carbide, graphite), aggregates provide structural strength and corrosion resistance.
Fine Powder: Fills the voids between aggregates to improve density. Commonly used materials include refractory clay and silica micro powder.
Binder (<5%): Used in small amounts, typically dry or hydraulic binders (e.g., cement, phosphate, asphalt), which are solid at room temperature and form chemical bonds or promote sintering when heated.
feature
Construction Method
Dry Application: No need to add large amounts of water. The dry material is directly rammed into shape, avoiding cracking or strength loss caused by moisture.
Flexible Molding: Can be rammed manually or mechanically (e.g., with a pneumatic tamper), making it adaptable to complex geometries (e.g., furnace bottoms, hearths, pipe bends) without the need for molds.
Performance Advantages
High Temperature Resistance: Depending on the type of aggregate, the service temperature can range from 1000°C to 1800°C (e.g., magnesia ramming materials for steelmaking furnaces; silicon carbide ramming materials for non-ferrous metal smelting).
Erosion Resistance: High-purity aggregates and a dense structure resist erosion from molten slag, metal, or gases.
Wear Resistance: The dense structure can withstand mechanical wear, making it suitable for high-impact areas such as furnace bottoms, submerged arc furnaces, and blast furnace tap holes.
Comparison with other refractory materials
| Characteristics | Dry Rammed Material | Refractory Castable | Refractory Plastic |
|---|---|---|---|
| Binder State | Dry | Liquid (water/solution) | Plastic (mud-like, with binder) |
| Construction Method | Rammed molding | Casting/vibration molding | Ramming/extrusion molding |
| Requires Baking? | Must (sintering or chemical bonding) | Requires curing/baking | Natural curing or low-temperature baking |
| Applicable Temperature | Medium-high (1000~1800℃) | Medium-high (800~1600℃) | Medium-low (≤1300℃) |
| Typical Scenarios | Thick structures like furnace bottoms/hearths | Complex shapes, load-bearing parts | Repairs, special-shaped components |
Physical and Chemical Specifications
|
Material |
MgO |
Al2O3 |
CaO |
SiO2 |
Bulk Density |
Particle Size |
Max Working Temperature |
|
Quartz |
– |
– |
– |
98 |
1.9~2.2 |
0~6 |
1650 |
|
Magnesia |
≥96 |
＜1.5 |
– |
＜2 |
2.85~2.9 |
0~10 |
1800 |
|
Alumina Magnesia Spinel |
11~32 |
65~88 |
1 |
1 |
2.95~3.15 |
0~6 |
1800 |
|
Corundum |
– |
90 |
– |
– |
2.95~3.15 |
0~6 |
1800 |
|
Mullite |
– |
＞80 |
– |
＜16 |
2.6 |
0~6 |
1400 |
|
Magnesia Alumina Spinel |
75 |
22 |
– |
– |
3.05 |
0~6 |
1800 |
Application
| Industry | Application Parts | Common Materials | Key Requirements |
|---|---|---|---|
| Metallurgical | Blast furnace bottom, hearth, taphole | Magnesia, corundum-silicon carbide | Resistance to hot metal erosion, wear resistance |
| Nonferrous Metals | Linings of copper/aluminum smelting furnaces, bottom of electrolytic cells | Silicon carbide, graphite | Resistance to melt corrosion, electrical and thermal conductivity |
| Chemical/Energy | Linings of gas generators, incinerators | High-alumina, mullite | Resistance to high-temperature gases and slag erosion |
| Glass Industry | Bottom of glass furnaces, flow liquid holes | Zircon, corundum | Resistance to glass melt erosion, high-temperature resistance |
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