The problem of kiln mouth explosion is the most common and troublesome technical pain point in high-temperature industrial kilns. Once a kiln mouth burst occurs, it may cause thermal system disorder and decrease in output, or cause the kiln lining to peel off, the cylinder to deform, or even cause a kiln shutdown accident. According to our statistics, the direct repair cost of a serious kiln mouth burst problem can reach hundreds of thousands of yuan. Including the loss of production suspension, it can easily reach millions of yuan. More importantly, frequent bursts will shorten the service life of the kiln body, causing enterprises to fall into a vicious cycle of 'repair cracks, then repair cracks.' As a source manufacturer of refractory insulation materials, we have been focusing on special rectification of kiln mouth explosion problems all year round, and have accumulated a lot of mature experience. In view of the common pain point in the industry that kiln mouths burst repeatedly and break after repair, we abandoned the traditional inefficient model of repeated repairs and mainly promoted the gradient composite anti-crack lining technology. Before construction, an exclusive material ratio and anchoring arrangement plan were customized based on the kiln mouth diameter, working temperature, and material erosion intensity; during construction, the curing time and oven temperature rise curve were strictly controlled to avoid water vapor explosion and stress accumulation problems. At present, this process has been applied in hundreds of production lines such as cement and metallurgy. The modified kiln mouth lining can operate stably for more than one year without bursting or falling off, significantly reducing the frequency of furnace shutdowns for maintenance and effectively reducing enterprise operation and maintenance costs and energy consumption.

1. Drastic changes in temperature cause refractory castables to be damaged too quickly. The thermal shock stability of refractory castables is relatively poor, and severe temperature changes can easily damage them. For example, the cooling zone of the rotary kiln is not only subject to the erosion of clinker, but also constantly receives the effect of secondary high-temperature clinker. The kiln lining material is sometimes buried under high-temperature materials, and sometimes exposed to flames, causing the surface temperature of the lining material to change with the rotation of the kiln, with a temperature difference of more than 200 degrees Celsius. If it is a cold cellar. This temperature change will be more severe, which are factors that cause damage to refractory castables. 2. The falling anchors form pieces of refractory castables. During the use of refractory castables, the falling anchors play a role in tightly sticking to the container wall, maintaining the integrity of the castables and resisting bending of the castables. In the places where the refractory castables fell in pieces, inspection found that many places had fallen off by their roots, leaving only traces of some solder joints. 3

1. Production process of steel fiber castables The steel fibers used in refractory castables generally have a diameter of 0.4-0.5mm and a length of 25mm. The shape and cross-section of the steel fibers are crescent-shaped. The amount of steel fiber added to the castable is 1~5% (weight), and the length and amount of steel fiber should be appropriate. Generally, water is added to the mixture first and then the steel fibers are added for full mixing. This not only enables the mixture to be stirred evenly, but also saves 1/3 of the mixing time compared to stirring the steel fibers in dry materials. The molding can be vibrated externally, or a vibrating rod can be used to vibrate inside the mixture, and dense products can also be obtained. The maintenance and drying of steel fiber castables are the same as those of ordinary castables.

Features of refractory prefabricated parts: 1. Can meet the needs of high-temperature industrial kilns. The parts to be constructed cannot be constructed with refractory bricks and castables, and prefabricated parts can be used. 2. When refractory bricks cannot be made due to factors such as weight, volume, size, etc. of the construction site, refractory prefabricated parts can be used. 3. The refractory prefabricated parts are integrally cast with refractory castables specially formulated according to customer requirements. They have the advantages of high temperature resistance, corrosion resistance, wear resistance, high strength, and good thermal shock stability. They can fully meet the use environment and conditions required by customers.

Construction should be carried out indoors during rainy days. All materials, transport, work sites and masonry must be protected from rain. Unfinished projects must be roofed, holes and leaks plugged, the upper opening of the completed furnace must be closed, and the completed floor prefabricated parts must be raised and covered, and immersion in water is strictly prohibited. When the ambient temperature is greater than 30℃, summer construction can be considered. During construction in summer, the water temperature and material temperature should be controlled below 30°C. Materials exposed to the scorching sun should be cooled down before use. When constructing castables in summer, try to arrange it in the morning or evening. After pouring, it should be covered with a curtain in time, and water should be sprinkled to cool down. The reasons for the following problems after the construction of refractory castables: 1. Peeling: generally caused by the formwork being too dry or the surface slag cleaning being incomplete. 2. Pockmarked noodles: caused by uneven mixing or improper treatment of the template surface. 3. Honeycomb: caused by poor vibration or uneven dryness and wetness of the material. 4. Holes: caused by leakage vibration. 5. Too much water in small micropores:

Refractory castables are attracting more and more attention from customers, but they are often affected by the ambient temperature during use and undergo drastic changes. The thermal shock resistance of the castables reflects its value. Its thermal shock resistance is an important indicator for measuring the breakage resistance of the castables. It is the ability to counteract the loss caused by rapid changes in temperature during the use of the castables.