Ultra Low Cement Castables


Salient Features

•  Low CaO content ensures high refractoriness.

•  Excellent ho: strength and MOR all temperature.

•  Lower apparent porosity after firing offers better corrosion resistance.

•  High abrasion and spalling resistance.

•  High Volume Stability.

 

 

UC 45

UC 95

Physical Properties

Max Service Temparature 0C

1550

1750

Density gm /cc (min)

Dried at 110 0 C

2.35

3.05

Water required for casting % by weight of castable

5.3 - 5.7

4.0 - 4.7

Cold Crushing Strength kg/cm 2 (min.)

110 o C/24 hrs

800°C/3 hrs

1100°C/3 hrs

1450°C/3 hrs

1550°C/3 hrs

 

375

800

825

825

900

 

450

1150

1200

1300

1450

Modulus of Rupture k/ cm 2 (min)

1100 C/24 hrs

800°C/3 hrs

1100°C/3 hrs

1450°C/3 hrs

1550°C/3 hrs

 

80

125

130

130

140

 

85

160

200

225

250

P. L. C.% (max)

800°C/3 hrs

1100°C/3 hrs

1450°C/3 hrs

1550°C/3 hrs

 

Nil

0.2

0.3

0.7

 

Nil

Nil

0.4

0.6

Thermal conductivity

k cal/m/hr/ ° C (min) (hot face)

400°C

600°C

800°C

1000°C

1200°C

 

 

1.0

1.1

1.2

1.3

1.4

 

 

1.8

1.9

2.0

2.1

2.2

Chemical Anayalasis

Al 2 O 3 (%) max

43

90

SiO 2 (%) max

50

68

Fe 2 O 3 (%) max

0.7

1.3

CaO (%) max

0.7-0.8

0.3 0.5

 

 

UC9S

Physical Properties

Water required for casting

3.8-404

Bulk Density gm/cc (min)

2.9

Modulus of Rupture kg/cm 2 (min)

110 o C/24 Hrs

800 o C/3 Hrs

110 o C/3 Hrs

1550 o C/3 Hrs

 

80

150

200

250

Cold Crusting Strength kg/cm 2 (min)

110 o C/24 Hrs

800 o C/3 Hrs

1100 o C/3 Hrs

1550 o C/3 Hrs

 

0.2

0.5

1.0

P.L.C. % (max)

800 o C/3 Hrs

1100 o C/3 Hrs

1550oC/3 Hrs

 

0.2

0.5

1.0

Thermal Conductivity

K cal/m/hr/ o C(max)(hot face)

800 o C

 

 

2.0

Chemical Analysis

Al 2 O 3 (%) max

92.0

Fe 2 O 3 (%) max

0.5

SiO 2 (%) max

7.0

CaO (%) max

0.5

 

 

 

UC 40

UC 90

Physical Properties

Max Service Temparature 0C

1500

1700

Density gm /cc (min)
Dried at 110 0 C

2.25

2.95

Water required for casting % by weight of castable

5.5 - 6.0

3.8 - 4.0

Cold Crushing Strength kg/cm 2 (min.)

110 o C/24 hrs

800°C/3 hrs

1100°C/3 hrs

1450°C/3 hrs

1550°C/3 hrs

 

450

740

900

900

950

 

450

1150

1200

1300

1450

Modulus of Rupture k/ cm 2 (min)

1100 C/24 hrs

800°C/3 hrs

1100°C/3 hrs

1450°C/3 hrs

1550°C/3 hrs

 

70

100

100

100

110

 

75

325

350

360

430

P. L. C.% (max)

800°C/3 hrs

1100°C/3 hrs

1450°C/3 hrs

1550°C/3 hrs

 

Nil

0.3

0.4

0.7

 

0.2

0.2

0.4

0.6

Thermal conductivity

k cal/m/hr/ o C (min) (hot face)

400°C.

600°C.

800°C.

1000°C

1200°C

 

 

1.0

1.1

1.2

1.3

1.4

 

 

1.8

1.9

2.0

2.1

2.2

Chemical Anayalasis

Al 2 O 3 (%) max

40.0

90.0

SiO 2 (%) max

50.0

5.0

Fe 2 O 3 (%) max

0.7

1.5

CaO (%) max

Nil

Nil

 

Note: Data represents average physical properties and do not constitute a specification

 

 

ACCMON

ACC has pioneered a series of refractories and castables, developed indigenously by the company's R & D division. ACCMON is another pioneering, in-house development. Regarded as a revolutionary ad­vance, Compared with the conventional range of similar products, ACCMON is designed to break new ground in castable applications.

Low lime content
Less cement means less lime content which also means reduced fear of linings weakening under pressures of high temperatures.

Low porosity
Less cement also means less water is required when using ACCMON castables. This, in turn, reduces porosity by almost 50% - against conventional varieties. This results in products with high density and low porosity.

High Strength
Less cement/lime ensures that aggregates are in direct contact with the surface of the lining. This results in extraordinary strength for ACCMON castables.

Decreased cost
Replacing the conventional range of refractory products with ACCMON reduces installation and material costs- a direct consequence of longer lining life with ACCMON castables.

ACCMON is offered in three varieties: Low Cement, Ultra low Cement No Cement castables each for a specific use.

Application
The utility of monolithic refractories is now well established. With the excellent properties and maturity of ACCMON castables, more and more application for monolithic refractories are envisaged.

 

PROPERTIES

ACCMON
LC-45

ACCMON
LC-60

ACCMON
LC-70

ACCMON
LC-80

ACCMON
LC-90

ACCMON
LC-95

Refractoriness Orlon/ o C

32(1717)

36(1804)

36(1804)

+36(+1804)

37(1820)

+40(1900)

Maximum Service Temperature °C

1550

1600

1600

1650

1700

+1800

Chemical Analysis %

Al 2 O 3 (%) min

Fe 2 O 3 (%) max

 

45.0

0.8-1.0

 

60.0

1.5

 

70.0

1.5

 

80.0

1.8

 

90.0

0.8-1.0

 

94.0

0.3

Dry Density (gm/cc) min 110 o C

2.3

2.6

2.7

2.85

3.0

3.1

Cold Crushing Strength (kg/cm 2 )

at 110 o C

at 800 o C

at 1100 o C

at 1500 o C

at 1550 o C

 

750

800

900

1000

-

 

750

800

900

1000

-

 

750

800

900

1000

-

 

800

900

1000

-

1200

 

950

1000

1150

-

1200

 

1000

1050

1100

-

1250

P.L.C%(Max)

at 800 o C

at 1100 o C

at 1500 o C

at 1550 o C

 

+/-0.2

+/-0.3

+/-1.0

-

 

+/-0.2

+/-0.3

-

-

 

+/-0.2

+/-0.3

-

+/-0.8

 

+/-0.2

+/-0.3

-

+/-0.6

 

+/-0.2

+/-0.3

-

+/-0.5

 

+/-0.2

+/-0.3

-

+/-0.5

% Water Required for casting

6-6.5

6.5

6.5

5.0-5.5

4.5-5.0

4.0-4.5

Maximum Grain size(mm)

6

6

6

6

6

6

Note: -Data represents typical average properties and do not constitute a specification.

 

 

WHYTHEAT CASTABLES

Classification

WHYTHEAT castables are product at present in 3 grades, desig­nated as WHYTHEAT A, WHYTHEAT K, and WHYTHEAT C, All contain the special high-purity, high alumina refractory binder CAL-AL-75. Typical properties of WHYTHEAT A, WHYTHEAT K and WHYHEAT C, including data on strength, conductivity and chemical composition are given below Each grade of WHYTHEAT castables is used for a specific service temperature and environment.

 

WHYTHEAT A

WHYTHEAT A is a high purity, high alumina castable of exceptional Quality with an AIE03 content of over 90% arid with very low silica and iron contents. Hence, it is used for service temperatures upto 1750°C and can resist attack from process gas atmospheres containing carbon monoxide and hydrogen.

 

WHYTHEAT K

WHYTHEAT K, which has alumina content of 60%, can be used for service temperatures upto 1600°C. This castable also has a low iron content and can resist carbon monoxide attack.

 

WHYTHEAT C

WHYTHEAT C is a castable with about 50% alumina and serves as a general purpose high temperature testable castable required for service temperatures upto 1500°C

Beside, Whytheat has castables are offered in higher strength and with special properties and applications.

WHYTHEAT K' & C' High strength for withstanding better SPECIAL abrasion attack WHYTHEAT 'A' (FH) Facilitates quick startup, slashes downtime in critical shutdowns & minimises production loss.

WHYTHEAT M' Highly cost effective castable for oxidizing atmosphere for services temperature upto 1700°C.

 

WHYTHEAT - A

WHYTHEAT - K

WHYTHEAT - C

Recommended Service Temp.°C(max)

1750

1600

1500

Refractoriness °C(min)

1800

1680

1650

Dry Density Kg/M 3 (Min)

2800

2200

2100

Linear Change % (max)

±1.5

1550°C

3hrs

±1.5

1550°C

3hrs

±1.0

1500°C

3hrs

CCS Kg/Cm 2 (min) 110 o C

550

350

350

Chemical Analysis %

Al 2 O 3 (%) min

Fe 2 O 3 (%) max

 

90

0.8

 

60

1.0

 

50

1.5

Maximum Grain Size (mm)

5

5

5

 

Note: CCS and linear change values are on 4 x 4 x 16 cm prisms.

Above are average test data subject to reasonable variations.

 

FIRECRETES

Fire creates are scientifically designed ready mixed castables made from ACC's CALUNDUM - a medium purity calcium aluminate binder and selected refractory grog. These retractory castables are hydraulic-setting, and can be cast or moulded to any shape and also used for gunning of furnace linings.  

Classification

Firecrete castable are produced at present in three standard grades designated as Firecrete, Firecrete Special & Firecrete Super.

Tailor-made grades to customer's specifications are also produced

 

FIRECRETE

Firecrete is a refractory castable with 45% Al2O3 and will have a Fe2O3 Content of 4% (max). It can be used in oxidising atmosphere for service upto temperatures of 1400°C.

 

FIRECRETE SPECIAL

Firecrete Special is a refractory castable with 45% Al2O3 and Fe2O3 of 4% (max). This castable develops high strengths for abrasion resis­tance applications and withstands service temperatures upto 1350°C in oxidising atmospheres.

 

FIRECRETE SUPER

Firecrete Super is a superior refractory castable of medium purity having Al2O3 content of 70% and Fe2O3 content ol 5% (max). This can withstand service temperatures of 1450°C in oxidising atmospheres.

 

 

FIRECRETE

FIRECRETE SUPER

FIRECRETE SPECIAL

LT CASTABLE

Recommended Service Temp.°C(max)

1400

1450

1350

500

Refractoriness °C(min)

1580

1680

1450

-

Dry Density Kg/M 3 (Min)

2100

2500

2250

2200

Linear Change % (max)

±1.0

1400°C/2hrs

±1.0

1400°C/3hrs

±0.8

1500°C/3hrs

 

-

CCS Kg/Cm 2

(min) 110 o C

1350 o C

1450 o C

 

250

225

-

 

350

-

450

 

400

300

-

 

400

500(200 o C)

400(400 o C)

Chemical Analysis %

Al 2 O 3 (%) min

Fe 2 O 3 (%) max

 

45

4

 

70

5

 

45

4

 

-

-

Maximum Grain Size (mm)

5

5

5

5

 

Note: Above are average test data subject to reasonable variations.

*Coarse grading can be supplied on request.

Note: -Data represents typical average properties and do not constitute a specification.

 

 

INSULYTE CASTABLES LOW IRON

PROPERTIES

INSULYTE
7

INSULYTE
9

INSULYTE 9HS

INSULYTE
11

INSULYTE
13

INSULYTE
15

Recommended Service Temp.
( ° C )

1100

1100

1100

1350

1350

1350

Dry Density (Kg/M 3 )

750 - 850

900 - 1000

900 - 1000

1100 - 1250

1300 - 1450

1500 - 1600

Thermal Conductivity
(K Cal/m/hr/ ° C)

0.14

0.28

0.28

0.31

0.33

0.44

CCS(Kg/Cm 2 )

110 ° C

800 ° C

1100 ° C

1300 ° C

 

12 - 14

4 -6

6 - 8

-

 

15 - 20

6 - 8

10 -14

-

 

20 - 25

8 - 10

15 - 20

-

 

50 - 60

30 - 40

30 - 40

50 - 70

 

90 - 100

60 - 70

60 70

70 - 90

 

90 100

60 70

60 70

70 - 90

PLC (%)

 

110 ° C

500 ° C

800 ° C

1100 ° C

1300 ° C

 

 

-

-

+/-1.0

+/-1.6

-

 

 

-

+/-0.2

+/-0.6

+/-1.0

-

 

 

-

-

-

+/-1.5

-

 

 

-

-

-

+/-0.2

+/-1.0

 

 

-

-

-

+/-0.2

+/-0.6

 

 

-

-

-

+/-0.2

+/-0.6

Fe 2 O 3 (%) max

8.5

6

3

3.5

3.5

3.2

Note: CCS and PLC values are on 4 x 4 x 16 cm prisms. Thermal Conductivity prefired hot face 500 ° C.

 

INSULYTES CASTABLES LOW IRON

PROPERTIES

INSULYTE
11 LI

INSULYTE
11 LI(z)

INSULYTE
11-SPL

INSULYTE
13 LI

INSULYTE
15 LI

Recommended Service Temp. ( ° C)

1350

1300

1350

1350

1350

Dry Density (Kg/M 3 )

1100 - 1250

900 - 1000

1080 - 1100

1300 - 1450

1500 - 1600

Thermal Conductivity
(K Cal/m/hr/ ° C)

0.34

0.22

0.30

0.40

0.44

CCS(Kg/Cm 2 )

110 ° C

800 ° C

1100 ° C

1300 ° C

 

45 - 55

30- 35

30 - 40

50 - 60

 

10 - 15

5 - 7

6 - 10

15 - 25

 

30 - 40

25 - 30

25 - 30

35 - 40

 

80 - 100

40 - 50

40- 50

40 - 50

 

130 - 50

75 - 80

75 - 80

90 - 100

PLC (%)

110 ° C

500 ° C

800 ° C

1100 ° C

1300 ° C

 

-

-

-

+/-0.2

+/-1.0

 

-

-

-

+/-1.0

+/-1.5

 

-

-

-

+/-0.2

+/-1.0

 

-

-

-

+/-0.2

+/-0.6

 

-

-

+/-0.2

+/-0.5

+/-1.0

Fe 2 O 3 (%) max

1.5

1.2

1.5

1.5

1.5

Note: CCS and PLC values are on 4 x 4 x 16 cm prisms. Thermal Conductivity - pre-fired hot face 500 ° C.

Note: - Data represents typical average properties and do not constitute a specification.

 

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