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Product Attribute
| Product Name | Dry Permeation-Resistant Castable | Compressive Strength | 80(Mpa) | Specifications | Content55-80(mm) | |
| Refractory Temperature | 1500(ºC) | Is it a Hazardous Chemical? | NO | Thermal Conductivity | 0.1(ºC) | |
| Condition | State | Al2O3 | 75% | Packaging | Woven bags | |
Dry Permeation-Resistant Material for Aluminum Electrolytic Cells
After years of research and development, it has been established that the production of aluminum metal generally uses the cryolite-alumina molten salt electrolysis method, with aluminum electrolytic cells as the main equipment. The lining of these cells is made from materials such as carbon bricks, refractory bricks, and insulating bricks. During the electrolysis process, the cell lining is subjected to erosion by cryolite, the steam of Na and NaF, and the molten aluminum, which permeates through the gaps in the carbon bricks into the sidewall refractory bricks and insulating bricks. It then infiltrates the insulation layer through the carbon cathode at the cell bottom, leading to a reduced lifespan of the aluminum electrolytic cell. To address this issue, dry permeation-resistant materials have been developed for both the sidewalls and the cell bottom.
The design and material selection for electrolytic cells should ensure that the temperature inside the carbon cathode material remains above 850°C. This is because NaF crystallizes below 850°C, causing expansion in the carbon cathode and bricks, which reduces their service life. The solution is to use high-quality insulating bricks as the insulation layer, and to use permeation-resistant material as a barrier layer between the carbon bricks and insulation layer to prevent the penetration of harmful substances such as NaF. The principle for selecting permeation-resistant materials is to ensure that the ratio of m(AL2O3)/m(SiO2) is greater than 0.9, which can suppress the penetration of Na and NaF. The penetrating Na and NaF can react with AL2O3-SiO2 refractory materials to form nepheline (Na2O•AL2O3•2SiO2), thereby blocking the pores and preventing further penetration.
The permeation-resistant castable uses clay clinker as the refractory aggregate, with tertiary bauxite clinker as the refractory powder, added with ultra-fine powder, CA-50 cement as the binder, and dispersants and silica or feldspar-based permeation agents. Key properties of this material include: AL2O3 44%, SiO2 49%, bulk density ≥2.23g/cm³, compressive strength after firing at 110°C and 1000°C being 40MPa and 70MPa, respectively, linear change after firing at 1000°C being < -0.3%, and thermal conductivity at 350°C being about 0.55W/(m•K). This material is used between the carbon bricks of the aluminum electrolytic cell sidewall and the insulation layer, blocking the penetration of substances like Na and NaF, and protecting the insulation layer. The dry permeation-resistant material has a critical particle size of 3mm, with a bone powder material mass ratio of about 6:4, and is directly laid on the insulation layer at the cell bottom.
Gongyi Qianxiang Refractory Materials Co., Ltd. produces dry permeation-resistant materials according to customer usage conditions. The company uses various grades of clinker as refractory aggregates and bauxite clinker as refractory powders, adding ultra-fine powders, CA-50 cement as binders, and dispersants and silica or feldspar-based permeation agents. The dry permeation-resistant materials produced by our company can provide products suitable for various conditions with a refractory temperature range from 1000°C to 1700°C. High-strength permeation-resistant materials have excellent resistance to cryolite and molten aluminum erosion, high strength, good thermal shock stability, and are mainly used in the sidewalls of aluminum electrolytic cells.
Dry permeation-resistant materials laid at the bottom of the aluminum electrolytic cell form a nepheline layer at high temperatures, preventing the penetration of Na+, NaF vapor, and molten aluminum downward. Additionally, they have low thermal conductivity, resulting in significant energy-saving effects.
Refractory Dry Permeation-Resistant Material
| Item | Unit | Physicochemical Properties | ||||
| NH-45B | LN-55B | LN-65B | LN-75B | |||
| AL2O3 | % | ≥45 | ≥55 | ≥55 | ≥65 | |
| Refractory Temperature | ºC | ≥1730 | ≥1770 | ≥1790 | ≥1790 | |
| Powder Particle Size | ≥0.5mm | % | ≤1 | ≤1 | ≤1 | ≤1 |
| ≤0.0.76mm | % | ≥50 | ≥50 | ≥50 | ≥50 | |
| Mud Flexural Strength | 110ºCX24h ? | MPa | ≥2.0 | ≥2.0 | ≥2.0 | ≥2.0 |
| 1400ºCX3h ? | MPa | (1200ºCX3h)≥6.0 | ≥6.0 | ≥6.0 | ≥6.0 | |
| Softening Start Temperature under 2.0 MPa Load | ºC | ≥1200 | ≥1300 | ≥1400 | ≥1400 | |
| 1400ºCX3hLinear Change Rate after Firing at 1400°C for 3 hours | % | (1300ºCX3h)+1~-5 | +1~-5 | +1~-5 | +1~-5 | |
| Bonding Time | min | 1-3 | 1-3 | 1-3 | 1-3 | |
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