REFRACTORIES FOR MOLTEN IRON & STEEL...
Transcript of REFRACTORIES FOR MOLTEN IRON & STEEL...
SHARADAA
SHARADAA CERAMICS PVT LTD
MINISTEEL
REFRACTORIES FOR MOLTEN IRON & STEEL
SLIDE GATE REFRACTORIESLADLE INNER / COLLECTOR NOZZLESTUNDISH NOZZLESPOROUS PLUGWELL BLOCKS FOR LADLE / TUNDISH95%, 90%, 60% CASTABLES90K MORTORNOZZLE FILLING COMPOUND
TUNDISH BOARDSCASTING POWDERREHEAT FURNACE BRICKS / BLOCKSBURNER BLOCKSINDUCTION FURNACE TOP /BOTTOM BLOCKSI.F. RAMMING MASSESCOILKOTE
REFRACTORY MONOLITHIC & INSULATIONSFOUNDRIESFOUNDRY LADLE CASTABLES FOR HIGHER CAMPAIGN LIFENEUTRAL / BASIC / SILICA RAMMING MASS FOR INDUCTION FURNACESPRECAST SHAPES FOR INDUCTION FURNACE / LADLEPATCHING PLASTICS / PLASTER - IMPORT SUBSTITUTIONEXOTHERMIC / INSULATION SLEEVESMOULD COATINGSANTI SLAG COATINGS FOR LADLEREFRACTORIES FOR LONG CAMPAIGN CUPOLASCERAMIC FIBER SLEEVES FOR NON-FERROUS FOUNDRIES
2
LADLE AND TUNDISH NOZZLE
General Properties
Service Temperature °C (Max) 1650 1700 1700 1700 1700
Body Alumina Alumina Alumina Alumina Carbon Carbon Carbon Carbon
Insert ZiRCON 95 % - - - -
Physical Properties
Body
Bulk Density (gm/cc)
Dired at 200 C (Min) 2.8 2.8 2.8 3.2 3
AP % 10 10 10 8 10
Insert
Bulk Density (Min) 5.2 - - - -
AP % (Max) 5 - - - -
Chemical Properties
Al2O3(Min) 70 80 80 90 90
Fe2O3(Max) 1 0.5 0.5 0.3 0.2
SiO2(Max) 7 5 5 2 5
Fixed Carbon (Min) 7 5 5 5 -
Thermal Properties
Resistance to Metal Erosion Excellent Excellent Excellent Excellent Excellent
Application Area Tundish Ladle Bottom Ladle Bottom Ladle Bottom Ladle Bottom
PERTICULARS TUNDISH LADDLE COLLECTOR SLIDE GATE POROUS NOZZLE NOZZLE NOZZLE PLATE PLUG
Chemical Analysis (%)SiO2
Fe2O3
C Bulk Density (gm/cc)Cold Crushing Strength (kgf/cm2)Ignition Loss (%)Application Temperature°C
≥89≤12 to 3≥1.25205 to 6≥1650°C
≥90≤12 to 3≥1.4254 to 5≥1650°C
TUNDISH SEALING PACKING COMPOUND
Chemical Analysis (%)SiO2
Fe2O3
Al2O3
MgOCaOCAlkalis (%)Application Temp°C
≥ 85≤ 0.55 to 7
≤ 0.5
3 to 5≥1650°C
≥ 85≤ 0.55 to 7≤ 1.0≤ 2.04 to 7--≥ 1650°C
PARTICULARS
TUNDISH BOARD AND CONE
TUNDISH IMPACT PAD
PARTICULARS
Tundish Sealing and Packing Compound
Tundish Board, Cone and Impact Pad
Vacuum Formed Products and Mixes for Tundishes
Chemical Analysis (%) Cr2O3 >23 % >10 %SiO2 40 ~ 50 % 70 ~ 80 %Fe2O3 <30 % <30 %Al2O3 <5 % <5 %MgO <10 % <10 %Moisture Nil NilPhysical Properties Shape Semi round Semi roundGrain size 0 - 1 mm 0 - 1 mmDensity (gm/cc) 1.6 - 2.0 1.4 - 1.6
Nozzle Filling Compound for Ladle & Tundish - Mini Steel PlantPARTICULARS SPECIAL STEEL CARBON STEEL
FOR STEEL /MINISTEEL
Slide Gate Refractory for Steel / Ministeel
SHARADAA 95SLR SHARADAA A SHARADAA K
Particulars
General Properties
Service Temp°C (max) 1800 1750 1600
Grain size mm (max) 5 5 5
Water Required to Mix
For Ramming 8-10 8-10 8-10
For Casting 10-12 10-12 10-12
Physical Properties
Bd Dried at 110C 2.8 2.75 2.2
Cold Crushing Strength
after Fired at 1550°C 500 650 400
Mor after Fired at 1550°C 100 110 90
Thermal Properties
Permanent Linear Change
after Fired at 1550°C -0.5 -0.8 -1.20
Al203+Spinel (min) 92 90 60
Fe203 (max) 0.8 0.8 1.5
Resistance to Slag Corrosion Excellent Good Good
Resistance to Metal Erosion Excellent Good Good
Application Area Ladle Bottom Repair Ladle Bottom Repair Ladle Side Wall & Lunder
Installation Essential Padle Mixer Padle Mixer Padle Mixer
18°C ICE Water 18°C ICE Water 18°C ICE Water
Store at Cool Dry Place Store at Cool Dry Place Store at Cool Dry Place
Steel Ladle Slag Resistance Castable
PARTICULARS SHARADAA 90KTypes of Setting HEATService Temp°C (max) 1800Refractories (Min.) 37 - 38Grain Size mm (max.) 0 - 0.25Chemical Properties Al203+Spinel (min) 90Fe203 (max) 1Resistance to Slag Corrosion ExcellentResistance to Metal Erosion ExcellentApplication Area Nozzle Fixing at Ladle and TundishInstallation Essential Padle Mixer / 18°C ICE Water Store at Cool Dry Place
Refractory Mortor for Ministeel
3
• Brick Lined
• Fully Monolithic Lined ladles are preferred over the brick lining due to following benefits; - Longer Life / Lower Downtime - Jointless lining minimising metal / slag penetration - Lesser Wear pattern - Lower Shell temperature / Energy Saving - Zero Refractory Inclusion - Labour Cost Reduction
High Alumina Castables / Plastics are generally used as an original refractory lining and also used as a topup material to repair the wornout lining. The ladle lining can be broadly classified as follows:
For smaller ladles precast prefired shapes are preferred. The extended heats are achieved by usage of appropriate patching castables.
Foundry Needs
Sleeves & Coatings• Exothermic Sleeves• Insulating Sleeves• Coating Materials a. ZIRCON (Alcohol & Water Based) b. GRAPHITE (Alcohol & Water Based) c. ALUMINO SILICATE (Water Based)• Filters a. SIC Foam Filter b. Mullite Based Ceramic Filter
Induction Furnace• Ramming Mass - Silica / Basic / Neutral• Precast Shoulder / Top Blocks• Coil Coating Materials
Foundry Ladle• Iron Foundries - Velcast SF204 - Ladle Ram with Ladle Coat• Steel Foundries - Velcast 90 SPL
• We offer Debricking / Castable Laying / Heat Curing at our factory of Ladles
• Converters to save space, labour / power costs at your works
LADLE / CONVERTER IN FERROUS / NON-FERROUS /STEEL FOUNDRIES
REFRACTORY MONOLITHIC SOLUTIONS FOR
Ladle Cover
Ceramic Fibre Paper
Converter
Slag Cup Test
Refractory Castablesfor Grey Iron / SG Iron / Steel Casting
Ceramic Fibre Paper 6mm
Installation Options: Trowelling / Vibrocasting / Free Flow / Ramming / Ready Made Plastics
Anti Slag Coating
SLEEVESEXOTHERMIC SLEEVES / INSULATION SLEEVES / CERAMIC FIBRE SLEEVES / DIRECT POUR SYSTEM
BENEFITS AS COMPARED TO CONVENTIONAL REFRACTORY SHAPES
• Small in size but more effective than large sand risers
• Extend the solidification time for the risers
• Improve the yield by reducing the require- ment of riser metal by 70%
• Increase the number of moulds poured per hour
• Eliminate shrinkage defects in casting at riser junctions
• Reduce cutting and fettling costs due to lesser contact area with the castings
• Improve casting contour and casting finish (Supplements the use of breaker cores)
• Consistent perfor- mance of the sleeves results in consistent quality castings
CERAMIC FIBRE SLEEVES FOR
INDUCTION FURNACESNON-FERROUSSILICA / BASIC / NEUTRAL RAMMING MASS FOR
4
5
LONG CAMPAIGN COST EFFECTIVE INCLUSIONFREE LINING FROM SHARADAA
REFRACTORY SOLUTIONS FOR FOUNDRIES LADLES
REFRACTORY CASTABLES FOR IRON LADLE
Parameters Existing Practice Sharadaa Solution
Refractory Used 90% Coventional Castable Velcrete SF-204Backup Insulation Not used 6mm Mica PaperShell Temperature 140-160C 130-150CLife 30 Days 90 DaysRefractory Inclusion High LowCost / Lining 3.30 Lacs 1.90 LacsCost / Heat 138 80Cost / MT 27 16Other Advantages Slag Buildup Very High Very Less Repair Every 5 Days Once in all the area Every 30 Days Once Only in Slag Zone Area Lining Safety Very Bad Very GoodInclusion in Casting Often Present Eliminated
Parameters Existing Practice Sharadaa Solution
Refractory Used 40% Refractory Mass Velcast-90 SPLBackup Insulation Not used 3 mm Asbestos SheetLife 12 Tappings 400 TappingsRefractory Inclusion High LowCost / Lining Rs. 3,000 Rs. 20,000Cost/ Tapping Rs. 250 Rs. 50Cost / MT Rs. 500 Rs. 100Other Advantages Slag Buildup Very High Very Less Lining Safety Very Bad Very GoodInclusion in Casting Often Present Eliminated
REFRACTORY CASTABLES FOR STEEL LADLE
Parameters Existing Practice Sharadaa Solution
Refractory Used Alumina Carbon Nanobond-630 Ramming MassBackup Insulation Nil NilShell Temperature 80-100C 80-100CLife 15 Days 50 DaysRefractory Inclusion High LowCost / Lining 5.4 Lacs 7 LacsCost / MT 180 70Other Advantages Slag Generation Very High Very Less Lining Safety Very Bad Very Good
REFRACTORY CASTABLES FOR WATER COOLED CUPOLA
6
Parameters Existing Practice Sharadaa Solution
Refractory Used Alumina Carbon Plastic Velplast-1030 SCBackup Insulation 60% Alumina Castable 60% Alumina CastableShell Temperature Life 24 Hrs. 24 HrsRefractory Inclusion Low LowCost / Lining 0.20 Lacs 0.15 LacsCost / Tapping Rs. 333 Rs. 250Cost / MT Rs. 333 Rs. 250
REFRACTORY PLASTER FOR IRON LADLE
Parameters Existing Practice Sharadaa Solution
Refractory Used Ramming Mass LadleRam with LadleCoatBackup Insulation Nil NilShell Temperature 130 - 160 C 130-160 CLife (Tapping) 300 400Refractory Inclusion High LowCost / Lining 0.5 Lacs 0.4 LacsCost / MT 175 106Other Advantages - Slag Chipping (Removal) Hard Easy- Slag Penetration High Low
LADLERAM WITH LADLECOAT FOR IRON LADLE
LONG CAMPAIGN COST EFFECTIVE INCLUSION FREE LINING
Zircon Coating :Baume :Solids :Application Area :
Applying Method :
Water Base100-12070%Steel Castings, High DutyIrons & Ingot MouldsBrushing
ZIRCOAT (W)
Graphite Coating :Solids :Application Area :Applying Method :
Water Base60%Grey Iron, Non-FerrousBrushing
GRAPHCOAT (W)
Alumina Silicate Coating :Solids :Application Area :
Applying Method :
Water Base60%Grey & Ductile IronComponentsSwabbing, Dipping, Brushing
ALUCOAT (W)
• Excellent surface cast finish• Reduces the fettling process• Reduces the casting defects
- Metal Penetration- Poor casting strip- Mould erosion- Sand inclusion defects
Advantages
• High Refractory Properties• Good Adhesion to the Substrate• Good Suspension Properties
Coating Characteristics
Zircon Coating :Baume :Solids :Application Area :
Applying Method :
Spirit Base55-6265%Steel Castings, Grey & Malleable IronBrushing, Spraying, Swabbing
ZIRCOAT (S)
Graphite coating :Solids :Application Area :Applying Method :
Spirit Base35%Cast Iron, Grey IronBrushing, Spraying
GRAPHCOAT (S)
REFRACTORY COATINGS FOR FOUNDRIES
7
FOUNDRY LADLES
LADLE COAT - CIF
General PropertiesType of Material Ready mix mortarNature of bond HeatInstallation Method Hand Patching / BrushingMaximum Service Temperature (°C) 1650
Typical Physical PropertiesAppearance Dark grey mortarSpecific Gravity 1.80 - 2.00
LADLE COAT
LADLE RAM
FOR IRON FOUNDRIES / STEEL FOUNDRIES
PROPERTIES VELCAST SF 204 VELCAST 90 SPLLADLE RAM - CIF
Product CharecteristicsBond Ultra Fine Phospate Ultra FineAggregate Cal. Bauxite Cal. Bauxite Fused AluminaType of Setting Ceramic Hardening Phospate Hardening HydraulicService Temp °C (Max) 1700 1650 1750Grain Size (mm) 6 3 6Chemical Properties Al2O3 80 60 88 Fe2O3 1.2 3.5 0.8
Physical PropertiesBulk Density After Drying at 110°C (gm/cc) 2.90 2.50 3.0Cold Crushing Strength (Kg/cm2) 110°C 500 150 1000 1100°C 900 300 1500°C 1200 600 1200Cold MOR (Kg/cm2) 110°C 90 65 180 1100°C 160 135 1500°C 200 300 200
Thermal PropertiesThermal Conductivity at 600°C HF (Kcal/hr/m/°C ) 1.4 -- 1.8Hot MOR at 1400°C (Kg/cm2) 100 -- Thermal Expansion at 1100°C (%) 0.9 -- 1.2Permanent Linear Change at 1500°C(%)(Max) ±1.0 ±0.5 ±1.0Thermal Shock Resistance at 1100°C + 50 Cycles -- + 40 CyclesApparent Porosity at 1500°C (Max) 16 -- 18
CUPOLA TYPE FURNACES
PROPERTIES VELCRETE SF-20 SC NANOBOND-630 VELCRETE SF-203
HIGH PERFORMANCE CASTABLE & PRECAST SHAPES
Product CharecteristicsType of Cupola Gas Fired Coal Fired Coal & Gas Fired Application area Below Tuyers Below Tuyers Above TuyersAggregate BFA+SIC WTA+SIC CAL.BAUXITEBond Ultra fine Nano Bond Ultra fineType of Setting Ceramic Hardening Hydraulic Ceramic HardeningService Temp °C (Max) 1700 1700 1700Refractorieness °C (Min) 1800 1800 1800Grain Size (mm) 6 6 6Chemical Properties Al2O3 60 40 60SiC+C 30 50 Fe2O3 1 0.6 1.5Physical Properties Bulk Density at 110°C (Min) 2.9 2.8 2.5Cold Crushing Strength (Kgs/cm2) 110°C 400 700 4001100°C 1000 1200 9001500°C 1000 1800 1000Thermal Properties Thermal Conductivity at 600°C Hot face (Kcal/hr/m/ °C ) 3.2 3.8 1.2Thermal Expansion at 1100°C (%) 1.2 1.5 0.6Permanent Linear Change at 1500°C (%) +1.5 +1.5 +0.5Apparent Porosity at 1500°C (Max) 16 16 16Material Required per M3 (Kg) 2900 2800 2500Form demoulding time 8 8 8Temperature of mix 20 - 25 20 - 25 20 - 25Slag Resistance Excellent Excellent
Melting ZoneCastable : Velcrete SiC 42Maintenance : Backups PCF 704
1
Well ZoneCastable : Velcrete SF20SiCMaintenance : Plascrete 80D
2
StackCastable: Super Patch 1700ºC
3
HearthCastable : Velcrete SiC 20Maintenance : Super Patch 1700ºC
4
RunnerCastable : Velcrete 504Maintenance : Superpatch 1700
5
MONOLITHIC SOLUTIONS FOR HOT BLAST CUPOLAS
1
2
4
5
3
LONG CAMPAIGN CUPOLAS
387, 388 SIDCO Industrial Estate, Ambattur, Chennai-600098Tel : +91 44 26254365 / 26254366Fax : +91 44 42189355Mobile : +91 9600095559 / 9600095574 / 8754530681Email : [email protected] www.sharadaceramics.com
SHARADAAC E R A M I C S P V T. LT D.