“ ” ULTRA-ZCOAT

ULTRA-ZCOAT

is the family name for a series of refractory coatings designed to protect the bricks, monolithics, castables, ceramic fibres and steel shells in furnaces, boilers and various high temperature vessels. refractories are characterised by a very high content of zirconia and other special ceramics which imparts

ULTRA-ZCOAT

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Wearresist Technologies Private Limited

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extremely high resistance to the aggressive environments typically encountered at temperatures up to 1900°C. has better adhesion than most conventional zirconia based refractories.

1. Finish: Matt, buff coloured, non-vitreous. 2. Temperature Range: Up to 1,900°C

o1. Finish: Vitreous, highly glazed. 2. Temperature Range: Up to 1250 C

oTemperature Range: Up to 1250 C

is the versatile, general purpose product. is used as a slag resistant finish to in annealing furnaces, spouts and funnels.

A 3mm protective layer of can typically increase the working life of any underlying refractory by a factor of two to four times. is supplied in the form of a powder which is mixed with cold water to the consistency of a paste, cement or slurry prior to application by trowel, brush or spray

To reduce the effects of thermal shock.. To protect refractories against the aggressive effects of burning fuel oil, gas and solid fuels.. To produce a gas tight surface and minimise energy losses.. To reduce spalling.. To eliminate cracking.. To reduce slag adhesion.. Generally, to increase the working life of furnaces and reduce the costs of maintenance shut downs.

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ULTRA-ZCOAT

ULTRA-ZCOAT(N)

ULTRA-ZCOAT(H)

ULTRA-ZCOAT(F):- For Ceramic Fibre Coating1. Finish: Matt. 2.

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THE THREE MAIN ULTRA-ZCOAT TYPES

MAIN USES FOR ULTRA-ZCOAT

ULTRA-ZCOAT Is Used Regularly In The Following Industries And Processes:

Fertilizer Plants Hospital Incinerators.Stop spouts and channel slagging.Boilers in Industry, schools, hospitals, laundries etc.Boilers using Solid Fuels.Horizontal kiln showing stalactite formation. will prevent this.ULTRA-ZCOAT(N)Inside walls and lips of receivers will last longer with ULTRA-ZCOAT(N)

Electricity Generating Station using Fuels Oil, Gas, Coal or P.F. can benefit from this.

Catalytic Cracker and Heat Exchangers in Oil Refineries and Chemical Works.

Horizontal Kilns will benefit from a lining.ULTRA-ZCOAT(N)

Tankers and Ships using Steam Turbines.

For more information please contact info@processaids.in or visit www.processaids.in

Some Miscellaneous ApplicationsINCINERATOR / CREMATORIUMThe usual problems encountered are those of thermal shock and slag formation. A coatingof at 2 to 3 mm maximises the life of the refractory lining.ULTRA-ZCOAT(N)

stALUMINIUM MELTING / HOLDING FURNACE-1 APPLICATION The refractory lining is typically a high alumina castable which is subject to the destructive effects of high temperature and molten aluminium. The frequency of repairs is reduced by a lining of 3 to 6 mm ULTRA-ZCOAT(N).

NDALUMINIUM MELTING FURNACE - 2 APPLICATION3 mm of will seal the refractory against the leaching effects of moltenaluminum. 6mm is used to line the connecting channel.

ULTRA-ZCOAT(N)

NOSE ARCH IN FIELD ERECTED WATER TUBE BOILERSThis part of the boiler is subjected to both high temperatures and slag attack from theproducts of combustion. A coating of 2 to 3 mm of on therefractory surface will minimise the effects of spalling, slagging and abrasion.

ULTRA-ZCOAT(N)

SUSPENDED MONOLITHIC ROOF OF FIELD ERECTED BOILER USING BOTH OIL AND SOLID FUEL A coating of 2 to 3 mm applied to the refractory surface increases its resistance to the destructive effects of spalling, slagging, chemical attack and erosion.

ULTRA-ZCOAT(F)

INDUCTION FURNACEThe rammed lining is subjected to chemical attack by molten metal and to cracking and spallingfrom thermal shock, 1 - 3 mm of will reduce these effects, extend the lifeof the furnace and improve the quality of the processed metal.

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REHEATING FURNACEA thin coat of 1 to 2 mm reduces the adhesion of slags to the floorThe makes it easier to remove slag when cleaning.

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RECEIVERSA coating of 2 to 3 mm on the walls and lips of receivers will prolongthe life of the lining.

ULTRA-ZCOAT(N)

SMALL LADLESHand ladles lined with mouldable refractory can be coated with 2 to 3 mm

to increase the number of heats and increase production life.ULTRA-ZCOAT(N)

CRUCIBLE FURNACEFrequent repairs are necessary due to the damaging effects of high temperature and thermal shock. These conditions cause cracking of the refractory lining and heat losses.

coated at 2 to 3 mm, will eliminate or minimise the problem.ULTRA-

ZCOAT(N)

TUNNEL KILNSThermal shock and slag formation are common problems with high refractory wear around burner parts. Salt glazes are corrosive to conventional refractories. A coating of

t at 2 to 3 mm minimises the destructive effects of combustion, glazing and thermal shock. Slag removal is easier and reject rates reduced.

ULTRA-ZCOAT(N)

TUNDISH IN CONTINUOUS CASTINGFrequent repairs and shutdowns are encountered due to the effects of high temperature and thermal shock. A thin coat of 2 to 3 mm prolongs the life of the refractory lining.

ULTRA-ZCOAT(N)

SOAKING PITSHigh temperature and thermal shock lead to spalling of the refractory lining.These effects and hence the cost of maintenance can be reduced by application of 2 to 3 mm lining of .ULTRA-ZCOAT(N)

ELECTRIC ARC FURNACEThe centre section of the roof is made of either castable or plastic refractory. A coating of 2 to 3 mm of will minimise the destructive effect of high temperature and thermal shock, prolonging the life of the refractory.

ULTRA-ZCOAT(N) For more information please contact info@processaids.in or visit www.processaids.in

BAFFLES IN WATER TUBE BOILERSA thin coat of 1 to 2 mm of on the baffles prevents or minimises theeffects of spalling, reduces the adhesion of slag and ensures a gas tight surface.

ULTRA-ZCOAT(N)

WATERTUBE OIL FIRED POWER BOILERThe burner throat is subjected to intense wear and tear due to the effects of high temperature,slagging, chemical attack, erosion and thermal shock. A coating of 2 to 3 mm of

resists these combined effects on the refractory lining. A coating of 1 to 2 mm onthe walls and floors minimises the adhesion of slags and helps in prolonging the life of therefractory life.

ULTRA-ZCOAT(N)

FIRETUBE PACKAGE TYPE BOILERS FOR PROCESSINGHigh temperature, thermal shock, slags, chemical attack and erosion have a devastatingeffect on the parts exposed to heat, particularly the burner throat. A 2 to 3 mm coating of

on the burner throat and a 1 to 2 mm coating the rear and frontbaffles will extend the life of the refractory lining.ULTRA-ZCOAT(N)

GENERAL PROPERTIES:

PHYSICAL PROPERTIES:

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ULTRA-ZCOAT

grades are odourless, tasteless and non-toxic.

FORM : Dry powderDENSITY : 2.20PACKED: 5 Kg/25Kg plastic drums.CHEMICAL RESISTANCE: After firing, are unaffected by most acids and alkalis in liquid or gaseous form, being particularly resistant to vanadium pentoxide. A 3mm coating is gas tight at normal pressures.

become slightly elastic above 200°C thus providing outstanding resistance to thermal shock. Thermal expansion is approximately 1 % over the range 0°C-1900°C.

SHRINKAGE is less than 0.25%.EMISSIVITY VALUE : 0.7K VALUE : 3.5 at 500°C.RESISTANCE to powdering is excellent.

PREPARATION:

MIXING:

APPLICATION:

DRYING:

ULTRA-ZCOAT

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should only be applied to sound, clean surfaces. Old refractory surfaces must be thoroughly cleaned with a scraper or wire brush removing all loose pieces. Any glassy surfaces should be roughened with an abrasive disc. Cracks and holes should be cleaned out and then filled with a paste of

.

Mix with water to a smooth, creamy paste by adding 2 - 2.5 litre of water to 10kg powder. Adjust the consistency of the "mix to suit brushing or trowelling as required. Use less water for a repair mortar or plugging mix. For spray application, add more water to form a slurry and apply using cement spraying equipment. Allow to stand after mixing for approximately 1 hour minimum then re-mix briefly (preferably 3 to 4 hours).

Using a brush, trowel or spray, coat the furnace walls, hearth, ceiling, bridges etc. to a thickness of approximately 3mm. After an hour, further coats of or may be applied as required.

Allow to dry out thoroughly. Thin coatings (1-2mm) for a few hours; 24-72 hours for thicker coats. 7 days should be allowed when has been used as the mortar for building with new refractory bricks.

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FIRING:

COVERAGE:

ORaise firing temperature as slowly and evenly as possible, typically at 25 C per hour, until 125°C is reached. Thereafter, for , the furnace may be heated to its working temperature as usual. For

the first firing must attain at least 1200°C, thereafter, any temperature up to 1650°C can be used.

Approximately 2kg per square metre at 1mm thickness.

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HEALTH and SAFETY:Avoid inhalation of dust. Wear dust mask, gloves and goggles whilst mixing and applying . ULTRA-ZCOAT

749/9, G.I.D.C.,Makarpura, Vadodara 390 010, Gujarat, (INDIA)Ph: 0091-265-2651548, 2634734Fax: 0091-265-3042002Works: 861/4, G.I.D.C. Makarpura, Vadodara - 390 010E-mail: wearresist@wearresist.com, Visit Us at www.wearresist.com

Wearresist Technologies Private Limited

X`tralife to your wear prone components

A n I S O 9 0 0 1 : 2 0 0 0 C o m p a n y

ULTRA-ZCOAT

For more information please contact info@processaids.in or visit www.processaids.in