Electric Furnace Non-Basic Gunning Mix
Electric Furnace Non-Basic Gunning Mix is a category of refractory patching materials formulated with acidic or neutral aggregates (primarily alumina and silica) designed for hot repair applications. This mix is specifically used for maintaining the refractory lining in electric furnaces or sections of furnaces that utilize acidic or neutral slags, such as AOD converters, certain parts of coreless induction furnaces, or specialized EAF linings.
Its primary use is to efficiently repair worn zones, preventing further erosion and extending the campaign life of the lining without requiring a full cool-down and reline.
Main Function and Characteristics
The primary function is Neutral or Acidic Hot Repair. The composition is engineered to be chemically compatible with acidic refractory linings (like silica or alumina) and neutral slags, providing rapid adhesion and high resistance to thermal shock.
| Characteristic | Value Range | Primary Refractory Function |
|---|---|---|
| Material Base | Alumina / Silica / Mullite | Acidic/Neutral chemistry compatible with specific furnace environments |
| Application Method | Gunning (Pneumatic) | Allows for fast, remote application onto hot surfaces, minimizing downtime |
| Hot Setting Mechanism | Phosphate or Clay/Silicate Bond | Ensures strong, quick bond formation at elevated temperatures |
Classification
- Material Focus: Monolithic Refractory
- Primary Application Focus: Neutral/Acidic Patching Compound → Acidic/Neutral Induction Furnaces, AOD/VOD converter mouths, and specialized EAF sectors
Key Performance Metrics
- Adhesion to Acidic Substrate: EXCELLENT — Superior bonding with silica or alumina-based refractories
- Thermal Shock Resistance: HIGH — Withstands temperature gradients inherent in hot repair
- Refractoriness: GOOD — Service temperature up to ~1700°C for non-basic applications
Electric Furnace Non-Basic Gunning Mix
1. Chemical Compatibility in Furnace Linings
Refractory linings are classified as either Basic (MgO, CaO) or Non-Basic (Al₂O₃, SiO₂). A non-basic gunning mix is used when the existing lining and/or slag chemistry are not basic:
- Acidic Furnaces: Traditional acid-lined furnaces (e.g., some coreless induction furnaces) use silica or fireclay linings. Repairing these with a basic mix would cause destructive chemical reactions, hence the need for a silica-rich (acidic) gunning mix.
- Neutral Linings: Linings made of high-alumina, mullite, or chromite are chemically neutral. These are best patched with an alumina-based (neutral) gunning mix to ensure full chemical compatibility and maximum bond strength, particularly in critical areas like the mouths of AOD (Argon Oxygen Decarburization) or VOD (Vacuum Oxygen Decarburization) converters.
2. Composition and Bonding
The formulation relies on high-purity, non-basic aggregates optimized for pneumatic application:
- Aggregates: High-purity alumina, fused silica, or calcined mullite provide refractoriness and excellent thermal shock properties.
- Gunning Process: Typically applied in dry form through a gunite machine. Water or chemical binder is added at the nozzle, initiating hydraulic or chemical set.
- Setting Agents: Binder systems ensure adhesion and rapid strength development. Common non-basic binders include silicate gels, alumina cement, or phosphate binders (especially effective for rapid hot setting on alumina).
3. Applications
- Coreless Induction Furnaces: Patching silica or alumina linings used for melting specialized non-ferrous metals or specific iron grades
- AOD/VOD Converters: Rapid maintenance of mouth rings and upper barrels to extend vessel campaign life
- Ladle Linings (Acid/Neutral): Patching slag lines or sidewalls of ladles for acid steel grades or aluminum holding
- General Maintenance: Repairing hot spots and mechanical damage in industrial furnaces with neutral or acidic refractory linings
✨ Customization Services
We offer product customization services, allowing you to tailor the appearance, dimensions, or specific markings of items like refractory shapes or bricks. This includes options for incorporating specific geometric requirements to ensure seamless integration into your process systems.
🔬 Sampling for Testing & Validation
Free product samples are available for thorough testing and validation. This allows you to confirm the quality, compatibility, and performance of our materials—such as specific bricks, castables, or raw materials—before committing to a full order.
💡 Expertise in Refractory Solutions
Leverage our deep expertise to receive detailed, application-specific refractory solutions. We move beyond just selling products by providing comprehensive plans that encompass material selection, installation guidance, and performance optimization to maximize the lifespan and efficiency of your high-temperature processes.
Rabatec products are exclusively manufactured in facilities that have achieved rigorous ISO certifications across Quality (ISO 9001), Environmental Management, and Occupational Health & Safety. This commitment ensures every product, from refractory bricks to specialized equipment, meets the highest global benchmarks for performance, sustainability, and workplace safety.
📦 Logistics Excellence: Shipping, Packaging, and Marking
Minimizing Risk: We manage all logistics to minimize handling touchpoints and transit shock. Our carriers are pre-vetted for their experience in transporting heavy, fragile, and sensitive industrial materials.
Traceability: Every shipment includes comprehensive documentation and tracking information, providing end-to-end visibility and ensuring precise delivery coordination for your site.
Protection is Paramount: Our packaging strictly follows industry standards to prevent damage, corner chipping, and moisture absorption—especially critical for materials like Basic Refractory Bricks and Refractory Mortars & Mixes.
Robust Palletization: Products are secured on fumigated, high-strength export pallets (e.g., 1100x950mm or similar sturdy dimensions) using heavy-duty strapping and durable protective wrapping (polyethylene sheeting, cardboard, etc.) to withstand long-distance travel and multiple loadings.
Moisture Control: Sensitive materials are protected with appropriate sealing and, where necessary, desiccants or moisture-vapor proof enclosures to maintain the product's integrity until installation.
Clear Identification: All outer packaging is clearly marked on multiple sides with large, legible text for immediate identification and safe handling.
Full Traceability: Markings include all essential data points: Product Name, Quality Grade, Batch Number, Quantity, Net/Gross Weight, Order Number, and the Final Destination/Construction Area. This ensures every pallet can be accounted for and correctly staged upon arrival.
Safety & Compliance: We adhere to all regulatory requirements for marking, labeling, and placarding—especially for any items classified as Dangerous Goods—to ensure full compliance with international and domestic transport regulations.
❓ Frequently Asked Questions (FAQ)
Question | Elaborated Answer |
Q: What is the Refractoriness Under Load (RUL) of your refractories? | A: Refractoriness Under Load (RUL) is a critical property that defines the maximum temperature our materials can withstand while under compressive stress before deforming (softening). Since we offer a wide range of materials—from Alumina-Silicate Bricks to high-performance Silicon Carbide Bricks—the RUL varies significantly. For specific product data, please refer to the product data sheet or submit a quote request for the material you are interested in. |
Q: Where are the Rabatec refractories and materials produced? | A: Our products are primarily sourced from specialized manufacturing plants in China. Crucially, these facilities have all undergone rigorous audits and achieved comprehensive ISO certifications (Quality, Environment, and Safety), ensuring that production adheres to the highest global standards for consistency and performance. |
Q: What refractory materials does the company offer? | A: We supply a comprehensive portfolio of advanced refractory solutions, including: Shaped Products: Alumina & Silica Bricks, Basic & Specialized Bricks (e.g., Magnesia), SiC & Structural Ceramics, and Precast Shapes. Monolithic Products: Refractory Castables, Mixes & Mortars. Insulation: Insulation Fibre and High-Performance Insulation Products. |
Q: How should I choose the appropriate refractory material for my application? | A: Selecting the correct refractory is paramount to process efficiency. The choice depends on three key factors: 1. Operating Environment: Maximum process temperature and thermal cycling (shock). 2. Chemical Attack: Type of slag, molten metal, or corrosive gas being handled (acidic, neutral, or basic). 3. Mechanical Stress: Abrasion, erosion, and static load requirements. We recommend utilizing our detailed refractory solutions service to consult with our engineers for an optimized, application-specific recommendation. |
Q: Which monolithic material should I choose when patching an existing lining? | A: For patching and minor repairs, the ideal monolithic material depends on the parent lining material, the patching depth, and the need for a rapid return to service. Common choices include: Refractory Mortars & Mixes (for minor joints/surfaces) or Plastic Refractories (for areas requiring physical compaction). Always choose a patch material chemically compatible with the existing lining to ensure proper bonding and service life. |
Q: Can I receive product samples before placing a major order? | A: Yes. We gladly provide product samples for your internal testing and validation purposes. This ensures you can confirm the quality, composition, and fit of the material—such as our Refractory Castables or Alumina-Silicate Bricks—in your specific operational environment before committing to a bulk purchase. |
Q: Do you provide certifications to verify material quality? | A: Absolutely. We provide product-related inspection certificates and quality assurance documentation upon request. This verifies that your order has passed all internal quality control checks and meets the required material specifications and industry standards. |
Q: What measures are taken for product protection during transport? | A: We ensure quick, reliable transport by using robust, industrial packaging that strictly follows industry standards. This includes high-strength palletization, heavy-duty strapping, and weather-resistant wrapping to protect fragile items like bricks and mixes from corner chipping, mechanical damage, and moisture during transit. |
