The Round Steel Flattening Anchors for Steel Mill Kilns are innovative anchoring solutions designed to address the unique stress dynamics of rotary kilns and stationary furnaces, where cylindrical anchors often fail due to rotational movement and uneven stress distribution.
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Their flattened profile (ovalized cross-section, 20mm×30mm) increases contact area with refractory by 50% compared to round anchors, while rolled threads enhance grip strength, reducing refractory cracking by 35% in kiln transition zones. Constructed from 310S stainless steel (25% Cr, 20% Ni), these anchors resist creep deformation at 1150°C and chemical attack from cement clinker (CaO-rich), making them indispensable for cement and steel mill kilns operating in extreme thermal and chemical environments.
Parameter | Value |
Material | 310S Stainless Steel (25% Cr, 20% Ni) |
Temperature Range | -40°C to 1150°C |
Tensile Strength | 600MPa (ambient); 360MPa at 1150°C |
Design | Ovalized (20mm×30mm) with rolled threads (M12-M24) |
Length | 150mm-400mm (customizable) |
Installation | Welded (TIG with ER310 filler) or bolted to kiln shell |
Surface Finish | Polished (Ra 0.8μm) for enhanced refractory adhesion |
Certifications | ASTM A276, EN 10216-5, ISO 15156-1 |
High-Temperature Strength: The 310S alloy’s high chromium and nickel content forms a stable austenitic microstructure that retains 60% of its tensile strength at 1150°C (360MPa vs. 600MPa at 20°C). This ensures integrity in kiln burning zones with 1450°C peak temperatures, where low-alloy steels would melt or deform.
Stress Distribution: The ovalized design reduces bending stress by 25% in kiln shells with 3mm/hour ovalization during operation. FEA simulations confirm uniform stress distribution across the refractory interface, minimizing spalling in high-gradient areas.
Corrosion Resistance: 310S stainless steel resists alkali attack from cement clinker (CaO + SiO₂) and sulfuric acid (H₂SO₄) in flue gases, with corrosion rates <0.1mm/year in environments with 1000ppm SO₂. This extends service life by 5 years compared to 304 stainless steel anchors.
Efficient Installation: The bolted design with high-temperature locknuts allows for 30-minute replacement of individual anchors during kiln maintenance, reducing shutdown duration by 40% compared to welded-only systems that require refractory removal.
Cement Kilns: Secures refractory linings in the burning zone, withstanding 1200°C continuous operation and 20kPa gas pressure from clinker formation. The oval profile prevents anchor rotation during kiln rotation (3-5rpm).
Lime Kilns: Anchors refractory bricks in vertical shaft kilns, resisting 1100°C temperatures and CO₂-rich atmospheres (20% CO₂) that cause carbonation in standard steel anchors.
Steel Reheating Furnaces: Stabilizes refractory walls in pusher-type furnaces, handling 1200°C billet temperatures and 50-ton/day throughput without loosening, even during rapid temperature changes (200°C/hour).
Waste Incinerators: Used in refractory-lined combustion chambers, resisting HCl corrosion (1000ppm HCl) and 1000°C heat during municipal solid waste burning, outperforming carbon steel by 8x in service life.
Q: What is the maximum load capacity of these anchors?
A: The 310S variant supports 15kN in tension (1.5 tons) and 8kN in shear (0.8 tons), suitable for heavy refractory linings (150-300mm thickness) in kiln walls.
Q: Can they be used in reducing atmospheres?
A: Yes, the 25% chromium content of 310S forms a protective oxide layer that resists sulfidation in coke oven gas environments (5% H₂S), preventing embrittlement that affects low-chromium steels.
Q: How do I prevent anchor loosening?
A: Use high-temp locknuts (Inconel 600, rated to 1200°C) with a 0.5mm copper washer to maintain preload, and apply nickel-based antiseize compound (rated to 1100°C) during installation to prevent galling.
Q: Are non-stainless options available?
A: Yes, nickel-based alloys (Inconel 601) are offered for 1250°C applications. With 23% Cr and 60% Ni, they resist oxidation up to 1250°C but cost 40% more than 310S, making them ideal for ultra-high-temperature zones.
Their flattened profile (ovalized cross-section, 20mm×30mm) increases contact area with refractory by 50% compared to round anchors, while rolled threads enhance grip strength, reducing refractory cracking by 35% in kiln transition zones. Constructed from 310S stainless steel (25% Cr, 20% Ni), these anchors resist creep deformation at 1150°C and chemical attack from cement clinker (CaO-rich), making them indispensable for cement and steel mill kilns operating in extreme thermal and chemical environments.
Parameter | Value |
Material | 310S Stainless Steel (25% Cr, 20% Ni) |
Temperature Range | -40°C to 1150°C |
Tensile Strength | 600MPa (ambient); 360MPa at 1150°C |
Design | Ovalized (20mm×30mm) with rolled threads (M12-M24) |
Length | 150mm-400mm (customizable) |
Installation | Welded (TIG with ER310 filler) or bolted to kiln shell |
Surface Finish | Polished (Ra 0.8μm) for enhanced refractory adhesion |
Certifications | ASTM A276, EN 10216-5, ISO 15156-1 |
High-Temperature Strength: The 310S alloy’s high chromium and nickel content forms a stable austenitic microstructure that retains 60% of its tensile strength at 1150°C (360MPa vs. 600MPa at 20°C). This ensures integrity in kiln burning zones with 1450°C peak temperatures, where low-alloy steels would melt or deform.
Stress Distribution: The ovalized design reduces bending stress by 25% in kiln shells with 3mm/hour ovalization during operation. FEA simulations confirm uniform stress distribution across the refractory interface, minimizing spalling in high-gradient areas.
Corrosion Resistance: 310S stainless steel resists alkali attack from cement clinker (CaO + SiO₂) and sulfuric acid (H₂SO₄) in flue gases, with corrosion rates <0.1mm/year in environments with 1000ppm SO₂. This extends service life by 5 years compared to 304 stainless steel anchors.
Efficient Installation: The bolted design with high-temperature locknuts allows for 30-minute replacement of individual anchors during kiln maintenance, reducing shutdown duration by 40% compared to welded-only systems that require refractory removal.
Cement Kilns: Secures refractory linings in the burning zone, withstanding 1200°C continuous operation and 20kPa gas pressure from clinker formation. The oval profile prevents anchor rotation during kiln rotation (3-5rpm).
Lime Kilns: Anchors refractory bricks in vertical shaft kilns, resisting 1100°C temperatures and CO₂-rich atmospheres (20% CO₂) that cause carbonation in standard steel anchors.
Steel Reheating Furnaces: Stabilizes refractory walls in pusher-type furnaces, handling 1200°C billet temperatures and 50-ton/day throughput without loosening, even during rapid temperature changes (200°C/hour).
Waste Incinerators: Used in refractory-lined combustion chambers, resisting HCl corrosion (1000ppm HCl) and 1000°C heat during municipal solid waste burning, outperforming carbon steel by 8x in service life.
Q: What is the maximum load capacity of these anchors?
A: The 310S variant supports 15kN in tension (1.5 tons) and 8kN in shear (0.8 tons), suitable for heavy refractory linings (150-300mm thickness) in kiln walls.
Q: Can they be used in reducing atmospheres?
A: Yes, the 25% chromium content of 310S forms a protective oxide layer that resists sulfidation in coke oven gas environments (5% H₂S), preventing embrittlement that affects low-chromium steels.
Q: How do I prevent anchor loosening?
A: Use high-temp locknuts (Inconel 600, rated to 1200°C) with a 0.5mm copper washer to maintain preload, and apply nickel-based antiseize compound (rated to 1100°C) during installation to prevent galling.
Q: Are non-stainless options available?
A: Yes, nickel-based alloys (Inconel 601) are offered for 1250°C applications. With 23% Cr and 60% Ni, they resist oxidation up to 1250°C but cost 40% more than 310S, making them ideal for ultra-high-temperature zones.
