中工耐铬刚玉捣打料：高温工业耐材领域的技术突破与应用SIR Chromium-Resistant Corundum Ramming Mixture: Technological Breakthroughs and Applications in the Field of High-Temperature Industrial Refractory Materials

高温工业炉窑的耐材革命

A Refractory Revolution in High-Temperature Industrial Furnaces

在高温工业领域，炉窑内衬的耐用性直接决定了生产效率与成本控制。2023年，某大型钢铁企业的球团带式焙烧机燃烧室因传统铬刚玉捣打料频繁开裂，全年停炉检修达12次，直接经济损失超800万元。这一痛点在行业内并非个例——传统铬刚玉材料普遍存在Cr₂O₃含量超30%导致的高脆性问题，同时施工需困料16小时以上，严重制约生产连续性。

In high-temperature industrial applications, the durability of furnace linings directly determines production efficiency and cost control. In 2023, a large steel company experienced frequent cracking of the combustion chamber in its pellet belt roasting machine due to the use of traditional chromium corundum ramming mix, resulting in 12 shutdowns for maintenance throughout the year and direct economic losses exceeding 8 million yuan. This problem is not unique in the industry—traditional chromium corundum materials generally suffer from high brittleness due to Cr₂O₃ content exceeding 30%, and require over 16 hours of material confinement during construction, severely restricting production continuity.

河南中工耐有限公司历时五年研发的低铬环保铬刚玉捣打料彻底改变了这一局面。该产品凭借Cr₂O₃含量≤7.5% 的创新配方（技术号：ZL202310503911.8），在2024年安徽省无为华塑矿业547万元的石灰回转窑项目中，实现燃烧室连续运行5年无大修，较传统材料寿命提升35%，年节约维护成本200万元。这一技术突破不仅解决了行业痛点，更推动高温耐材向"低碳高寿"方向迈进。

Henan Sino Industrial  Refractories  New Material Co., Ltd.'s low-chromium, environmentally friendly chromium corundum ramming mix, developed over five years, has completely changed this situation. This product, with its innovative formula (technology number: ZL202310503911.8) containing ≤7.5% Cr₂O₃, achieved continuous operation of the combustion chamber for five years without major repairs in the 5.47 million RMB lime rotary kiln project of Anhui Wuwei Huasheng Mining in 2024. This represents a 35% increase in lifespan compared to traditional materials, saving 2 million RMB in annual maintenance costs. This technological breakthrough not only solves a pain point in the industry but also propels high-temperature refractory materials towards a "low-carbon, long-life" direction.

2 核心技术：低铬配方与复合结合剂的双重突破

Core technologies: a dual breakthrough in low-chromium formulation and composite binders

颠覆行业的低铬环保解决方案

Revolutionary Low-Chromium Environmental Solutions

传统铬刚玉捣打料为追求高温强度，Cr₂O₃含量普遍高达30%以上，不仅导致材料脆性增加，更因六价铬溶出造成水体污染。中工耐研发团队通过原位生成Cr₂O₃技术，在电熔高铬砂表面形成富Cr₂O₃保护层，使整体Cr₂O₃含量降至7.5%以下，达到GB 28664-2012《炼钢工业大气污染物排放标准》要求，同时通过四级颗粒级配设计（板状刚玉15.5-18.5mm、白刚玉5-8mm、棕刚玉1-3mm、电熔高铬砂0-1mm），构建"孤岛支撑结构"，热震稳定性提升至50次（1100℃水冷循环），远超行业平均的30次标准。

Traditional chromium corundum ramming mixes, in pursuit of high-temperature strength, typically have a Cr₂O₃ content exceeding 30%, which not only increases material brittleness but also causes water pollution due to the leaching of hexavalent chromium. The Zhonggong Nai R&D team has developed an in-situ Cr₂O₃ generation technology, forming a Cr₂O₃-rich protective layer on the surface of fused high-chromium sand, reducing the overall Cr₂O₃ content to below 7.5%, meeting the requirements of GB 28664-2012 "Emission Standard of Air Pollutants for Steelmaking Industry". Simultaneously, through a four-stage particle size distribution design (15.5-18.5mm for tabular corundum, 5-8mm for white corundum, 1-3mm for brown corundum, and 0-1mm for fused high-chromium sand), an "island support structure" is constructed, improving thermal shock resistance to 50 cycles (1100℃ water cooling cycle), far exceeding the industry average of 30 cycles.

复合结合剂的强度密码

The strength code of composite binders

产品核心竞争力源于自主研发的复合结合剂体系，由苏州土、活性SiO₂微粉、镁砂细粉等12种原料复配而成。其中：

阳离子淀粉（0.5-1wt%）促进微粉均匀分散，使烧结温度降低至1050℃

聚合氯化铝铁与镁砂反应生成镁铝尖晶石晶须，常温耐压强度突破80MPa

铬酸钙在1350℃原位分解，使骨料与基质结合强度提升8.5MPa

第三方检测显示，该材料1550℃烧后抗压强度达120MPa，耐磨性是普通高铝捣打料的2.3倍，在河南某铝业公司的电解槽应用中，槽龄从180天延长至280天，吨铝耐材消耗降低42%。

The product's core competitiveness stems from its independently developed composite binder system, composed of 12 raw materials including Suzhou clay, activated SiO₂ micro powder, and magnesia fine powder. Specifically:

Cationic starch (0.5-1wt%) promotes uniform dispersion of the micro powder, lowering the sintering temperature to 1050℃.

Polyaluminum ferric chloride reacts with magnesia to form magnesium aluminum spinel whiskers, achieving a room-temperature compressive strength exceeding 80MPa.

Calcium chromate decomposes in situ at 1350℃, increasing the bond strength between the aggregate and matrix by 8.5MPa.

Third-party testing shows that the material achieves a compressive strength of 120MPa after firing at 1550℃, and its wear resistance is 2.3 times that of ordinary high-alumina ramming mixes. In an electrolytic cell application at an aluminum company in Henan, the cell life was extended from 180 days to 280 days, and refractory material consumption per ton of aluminum was reduced by 42%.

技术参数与性能优势

Technical parameters and performance advantages

关键指标对比 comparion of Key technical Data

环保与施工优势Environmental and construction advantages

该材料通过ISO 14001环境管理体系认证，六价铬溶出量<0.05mg/L，达到饮用标准。创新的无困料施工工艺将传统16小时困料时间压缩至零，配合氧化铝短纤维三维增强筋骨（长度21.2-24.5mm占比20%），施工体致密度达98%以上。在山东某碳素企业的10m³焙烧炉应用中，单日施工效率提升3倍，烘炉周期从7天缩短至3天，提前投产创造效益超50万元。

This material is ISO 14001 environmental management system certified, with a hexavalent chromium leaching amount of <0.05mg/L, meeting drinking water standards. The innovative no-trapping construction process reduces the traditional 16-hour trapping time to zero. Combined with three-dimensional reinforcement of alumina short fibers (21.2-24.5mm in length, accounting for 20%), the density of the constructed volume reaches over 98%. In a 10m³ calcining furnace application at a carbon company in Shandong, daily construction efficiency increased threefold, the furnace drying cycle was shortened from 7 days to 3 days, and production was brought forward, generating over 500,000 yuan in benefits.

应用案例与行业验证 Application Cases and Industry Validation

钢铁冶金领域的标杆应用 Benchmark applications in the iron and steel metallurgy industry

2024年，中工耐为河北某钢铁集团220㎡烧结机燃烧室提供一整套耐材解决方案，采用低铬铬刚玉捣打料作为内衬保护层。通过对比传统材料：

热风温度从1150℃稳定提升至1250℃，烧结矿产量增加8%

年减少停炉次数从8次降至3次，维护成本节约240万元

烟气中NOx排放浓度从85mg/m³降至25mg/m³，超额完成环保指标

In 2024, Zhonggong Refractories provided a complete refractory material solution for the combustion chamber of a 220㎡ sintering machine for a steel group in Hebei Province, using low-chromium corundum ramming mix as the inner lining protective layer. Compared with traditional materials:

Hot air temperature steadily increased from 1150℃ to 1250℃, sinter production increased by 8%.

Annual furnace shutdown frequency decreased from 8 times to 3 times, saving 2.4 million yuan in maintenance costs.

NOx emission concentration in flue gas decreased from 85mg/m³ to 25mg/m³, exceeding environmental protection targets.

企业实力与资质认证Enterprise strength and qualification certification

技术研发与生产能力Technology research and development and production capabilities

河南中工耐作为我国认证企业，拥有河南省功能不定形耐火材料工程技术研究中心，累计获得技术130项，其中发明技术9项。公司占地66000㎡的智能化生产线（https://s.coze.cn/image/aH0Jz9s4SGI/）配备全自动配料系统和窑炉健康监测平台，年产能达10万吨，产品通过ISO 9001质量管理体系认证和欧盟CE认证，出口至德国、韩国等20余个我国。

核心资质与荣誉

我国专精特新"小巨人"企业（2023年）

冶金工程施工总承包二级资质

2023年度河南省建材行业技术革新一等奖

无为华塑矿业547万元耐材采购项目中标单位

施工工艺与服务保障

标准化施工流程

中工耐自有的三步施工法确保材料性能优化：

干混预处理：骨料与复合结合剂在强制式搅拌机中干混3分钟，确保均匀度

分层捣打：每层厚度控制在150mm，采用2.2kW风动捣固机（风压0.6MPa）

梯度烘炉：从常温至1050℃分8个阶段升温，关键节点保温2小时

Henan Zhonggong Refractory, a certified enterprise in my country, possesses the Henan Provincial Engineering Technology Research Center for Functional Unshaped Refractory Materials and has accumulated 130 technical patents, including 9 invention patents. The company's 66,000㎡ intelligent production line (https://s.coze.cn/image/aH0Jz9s4SGI/) is equipped with a fully automated batching system and a kiln health monitoring platform, with an annual production capacity of 100,000 tons. Its products have passed ISO 9001 quality management system certification and EU CE certification, and are exported to more than 20 countries including Germany and South Korea.

Core Qualifications and Honors

National Specialized, Refined, and Innovative "Little Giant" Enterprise (2023)

Class II Qualification for General Contracting of Metallurgical Engineering Construction

First Prize for Technological Innovation in Henan Province's Building Materials Industry in 2023

Winning Bid for Wuwei Huasheng Mining's 5.47 Million Yuan Refractory Material Procurement Project

Construction Technology and Service Guarantee

Standardized Construction Process

Zhonggong Refractory's proprietary three-step construction method ensures optimized material performance:

Dry Mixing Pretreatment: Aggregates and composite binders are dry-mixed in a forced mixer for 3 minutes to ensure uniformity.

Layered Compaction: Each layer thickness is controlled at 150mm, using a 2.2kW pneumatic tamping machine (0.6MPa air pressure).

Gradient Furnace Drying: Heating is performed in 8 stages from room temperature to 1050℃, with key nodes held at the same temperature for 2 hours.

全生命周期服务

公司提供从炉型设计-材料供应-施工指导-寿命评估的全链条服务，在全国设立6个技术服务中心，承诺24小时内响应现场问题。2024年为山西某煤化工企业提供的"耐材+运维"打包服务，使气化炉运行周期突破8000小时，创行业纪录。

行业价值与未来展望

在"双碳"目标推动下，宏达低铬铬刚玉捣打料通过热导率降低15%（常温导热系数1.2W/m·K）和再生料利用率30% 的技术创新，助力客户实现单位产品能耗下降12%。随着第三代纳米复合结合剂的研发成功，材料高温强度有望再提升20%，届时将完全替代进口产品，推动高温耐材行业的国产化进程。

作为高温工业的"隐形基石"，河南中工耐正以技术创新重新定义耐材标准，其铬刚玉捣打料不仅是一种材料，更是一套完整的高温解决方案，为冶金、化工、环保等行业的绿色转型提供坚实支撑。

Full Lifecycle Services

The company provides a complete service chain, from furnace design and material supply to construction guidance and life assessment. It has established six technical service centers nationwide and promises to respond to on-site issues within 24 hours. In 2024, the "refractory materials + operation and maintenance" package service provided to a coal chemical company in Shanxi enabled the gasifier's operating cycle to exceed 8,000 hours, setting an industry record.

Industry Value and Future Outlook

Driven by the "dual carbon" target, Hongda's low-chromium corundum ramming mix, through technological innovations such as a 15% reduction in thermal conductivity (room temperature thermal conductivity 1.2W/m·K) and a 30% recycling rate, helps customers achieve a 12% reduction in unit product energy consumption. With the successful development of the third-generation nanocomposite binder, the material's high-temperature strength is expected to increase by another 20%, at which point it will completely replace imported products, promoting the localization process of the high-temperature refractory materials industry.

As the "invisible cornerstone" of high-temperature industry, Henan Zhonggong Refractories is redefining refractory standards through technological innovation. Its chromium corundum ramming mix is ​​not only a material, but also a complete high-temperature solution, providing solid support for the green transformation of industries such as metallurgy, chemical industry, and environmental protection.