Castables

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

ACCMON

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.

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.

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.