Cyclone Separators and Refractory Selection

Common Types of Refractories

1. High-Alumina Refractories

   Refractory bricks or castables with high Al₂O₃ content (e.g., high-alumina bricks, mullite bricks) feature high refractoriness (up to 1500-1700℃) and excellent thermal shock resistance, making them suitable for medium-to-high temperature environments. They are often used for the inner walls of cyclone separators or areas in direct contact with high-temperature gases. High-alumina castables or precast components are recommended for their convenient construction and good wear resistance.
2. Silica-Alumina Refractories

   With aluminosilicate as the main component, these refractories offer high cost-effectiveness and a refractoriness range of 1300-1500℃, making them ideal for medium-temperature and abrasion environments. They are applicable to low-temperature sections of cyclone separators or used as transition layer materials.
3. Silicon Carbide (SiC) Refractories

   Characterized by high wear resistance, excellent thermal shock resistance, high refractoriness, and strong chemical corrosion resistance, these refractories are suitable for high-abrasion and high-corrosion conditions. They are commonly used for the inner walls, cone sections, or high-abrasion areas of cyclone separators. Silicon carbide bricks or castables are recommended.
4. Corundum Refractories

   With alumina (Al₂O₃) as the primary component, these refractories have extremely high refractoriness (above 1800℃) and outstanding chemical corrosion resistance and wear resistance, though they come at a relatively high cost. They are suitable for high-temperature and strong-corrosion environments, such as high-temperature cyclone separators or equipment operating in aggressive chemical atmospheres. Corundum bricks or corundum-mullite composite materials are recommended.
5. Refractory Castables and Wear-Resistant Coatings

   Refractory castables (e.g., high-alumina castables, silicon carbide castables) allow flexible construction and can be customized according to the shape of cyclone separators. Wear-resistant coatings can enhance the surface wear resistance of equipment. They are suitable for complex-shaped parts or areas requiring frequent maintenance. Phosphate-bonded wear-resistant castables or wear-resistant ceramic coatings are recommended.
6. Zirconia Refractories

   Zirconia (ZrO₂)-containing materials possess ultra-high refractoriness (up to 2000℃), excellent thermal shock resistance, and good corrosion resistance, but they are expensive. They are suitable for high-temperature or strong alkaline corrosion environments.

Key Considerations for Material Selection

• Operating Temperature: High-alumina materials are suitable for temperatures below 1400℃; corundum or silicon carbide materials are recommended for temperatures above 1500℃.
• Abrasion Intensity: The wear resistance grade is determined by the concentration, velocity, hardness, and particle size of the particulates. The inlet, cone section, and central cylinder are high-abrasion areas. Silicon carbide or wear-resistant castables are preferred for such regions.
• Chemical Environment: Zirconia or corundum materials are the top choices if strong acid or alkali corrosion is present.
• Thermal Shock Stability: During startup, shutdown, or operating condition fluctuations, the equipment undergoes drastic temperature changes, and the selected materials must be able to withstand the resulting thermal stress.
• Construction and Cost: Castables and precast components enable convenient construction and are suitable for complex structures.