Uniceram Advanced Materials, Inc.uniceramusa.com/Catalogues/Uniceram Refractory Products for...

$: Uniceram Advanced Materials, Inc.uniceramusa.com/Catalogues/Uniceram Refractory Products for Cement...alumina spinel bricks, high alumina bricks, insulation bricks, conventional and$
Uniceram Advanced Materials, Inc. ………..A provider of quality ceramic products………….

3883 Rogers Bridge Road, Suite 304B Duluth, GA 30097

Tel: 678 957 0896 / 678 957 0893 / 973 941 7427 Fax: 678-475-1823

Email: [email protected]

Product Catalogue: Refractory Products for Cement Roller Kilns

3883 Rogers Bridge Road, Suite 304B, Duluth, Georgia 30097 Tel: 678 957 0896 / 973 941 7427 Fax: 678 475 1823 E-mail: [email protected]

Uniceram Advanced Materials, Inc.

Company Introduction

Allow us to introduce our company, Uniceram Advanced Materials, Inc. a provider of quality ceramic

products.

We have a wide array of products that serve a broad spectrum of industrial applications. Our products,

typically, may be classified to four categories on basis of their end use:

• Insulators • Wear Resistant Parts • Porous Filters • Refractory Products

Our core ability is the ability to customize and innovate. With the backing of the solid experience of our

product development team, we are in a position to manufacture products as per our customer’s pricing

and technical requirements. For us, component geometry is not a restriction. As we say, if you can draw

it, we CAN make it.

Uniceram Advanced Materials has dedicated manufacturing units at two locations around the world. Both

these locations are ISO 9001 certified. Our expertise in supply chain management enables us to have the

optimum quality at the optimum price.

We have been in this field for more than 35 years and have developed the technology indigenously, so

have total mastery over managing the efficiency of the applications. We believe in adding competitive

advantage to the client by enhancing the operational effectiveness of their processes.

Uniceram Advanced Materials is a quality conscious organization: All our vendors are ISO9001 Certified

for their quality assurance in design, development, production and delivery. This shows our commitment

to quality. We believe in setting very high standards to exceed the expectations of our customers.

If you have any queries about our products or need more information, feel free to contact us.

We look forward to having a long and a mutually beneficial business relationship with you. Count on us

to deliver the best, always!

Thanks,

The Uniceram Team



Our Product Range:

Wear Resistant Parts-

o Textile and Wire Drawing guides

o Mechanical and Chemical Seals

o Alumina Grinding Media

o Yttria Stabilized Zirconia Microgrinding Media and Structural Ceramics

o Ceramic Coatings

Insulators-

o Resistor Casing

o Fuse Bodies

o Ignitors

o Heat Resistant Interlocking Beads

Porous Filters-

o Honey Comb Filters

o Acid Filters

o Vaporization wicks

Refractory Materials-

o Crucibles

o Ferrules

o Thermocouple Sheeths and other labware.

o Coil Supports

o Infra-Red Heaters

o Assay Testing Ceramics

o Ceramic Rollers for Tile Industry

o Refractory products for Steel, Iron, Glass and Cement Industry

o Water Ground Mica



Refractory Solution for the Cement Industry Uniceram offers products and technical services for suspension preheater / precalciner and the cement rotary kiln. The product range for cement includes magnesia chrome / magnesia alumina spinel bricks, high alumina bricks, insulation bricks, conventional and low cement castables, gunning mixes and insulating castables. These products are designed to combat dynamic wear mechanisms encountered in cement manufacture. Wear linings based on these products are distinguished by their abrasion, impact and alkali resistance. To ensure highest possible life in service, we believe in designing customized products for unique kiln operating condition and clinker chemistry. This is preceded by a comprehensive study of the kiln operation under optimal thermal load and analysis of the clinker using such modern tools as XRF and XRD. We also provide support during application of the refractories and monitor the same on a continuous basis. Post performance analysis of worn out refractories is done to ensure that product performance is further optimized in the future. Preheater / PreCalciner: See the vertical figure on the side . PRODUCT BRAND

. Insulating castable UACLITE 9 / 11

. Insulating castable UACLITE 13

. Low cement castable UACVIB 60 / 70

. Low cement castable UACVIB 45

. Conventional castable UACRETE / UACRETE SUPER

Cement Kiln:

. AREA PRODUCT BRAND

. Feed cone Low cement castable UAC VIB45 / UAC VIB60

. Preheating zone High Alumina UAM 60B / UAM 60K

. Calcination zone High Alumina UAM 70BD / 80BD

. Upper transition zone Magnesia Alumina UAM MGAL I / MGAL II Direct bonded Magchrome UAM DBMC IV

. Sintering zone Magnesia Alumina UAM MGAL I / MGAL II Direct bonded Magchrome UAM DBMC A / DBMC IV

. Lower transition zone Magnesia Alumina UAM MGAL I / MGAL II Direct bonded Magchrome UAM DBMC A / DBMC IV

. Discharge Low Cement Castable UAC VIB60 High Alumina UAM 70B

Preheater Please see further for description and specifications.



General Description of the Refractory Types mentioned above:

Basic Refractories:

Magnesite This range of fired and chemically bonded magnesite bricks is suitable for use in backup applications of EAF, LD converter, steel ladle and can be supplied with or without steel cladding. Dense Magnesite Dense fired magnesite bricks containing up to 92% MgO are supplied for utilities such as EAF sub hearth and working lining, hot metal mixer wear out lining and converter back up.

Low Iron Magnesite With the increased focus on fuel efficiency in glassmaking and increase in furnace life necessitated by economy, the use of high purity magnesite bricks in glass regenerator has become universal. Uniceram offers the MGIS range of low iron high purity Magnesite bricks manufactured with high grade Sea water and sintered natural magnesia. These refractories are distinguished by their high density and resistance to alkali, sulfur, silica carry over and fume attack. Refractory solutions based on this range can be customized depending on the cost economics, capacity and the life expectancy of the glass furnace. Magnesite Chrome Conventional and dense fired conventional Magnesia chrome bricks are offered for utilities such as steel ladle, LRF, AOD, VOD, EAF/EOF for back up and working lining applications. Chrome Magnesite In this range Uniceram offers general purpose varieties for back up application, reheating furnace and other non ferrous industries. Direct Bonded Magnesite Chrome The DBMC range is based on high grade magnesite chrome co-sintering and firing at a very high temperature. These are very good corrosion, erosion and thermal shock resistant bricks suitable for non-ferrous applications and AOD working lining. For the cement rotary kiln burning zone, a superior product, UAM DBMCA has been developed. Magnesia Alumina Spinel The MGAL range is specifically designed for chrome free rotary cement kiln application. These are manufactured from very high grade sintered magnesia and electrofused spinel and are capable of a high coatability in service.



Insulation Refractories: Conventional Insulations: These bricks are manufactured by the sawdust process using selected grades of china clay and kyanite for hot face as well as back up applications. Particularly notable is the HFK brick, which is one of the most economical insulations in its classification temperature. Uniceram also manufactures high CCS insulation tiles, UAM HSI for glass melter bottom and can supply the same in any size. Vibro-cast Insulations: This range of bricks has been entirely developed through indigenous research. The bricks are formed by the vibro-casting method. Vibro-casting ensures extremely low thermal conductivity and proportionately high strength. These bricks are engineered for cold face as well as hot face applications and can withstand temperatures of upto 1500°C. Customized solutions for kilns and furnaces based on vibro-cast bricks can be developed along with the cost benefit analysis in terms of energy savings.

High Alumina insulations: This range of insulation bricks have alumina content extending upto 95% alumina and are mostly use for applications starting from 1500°C.These products are distinguished by their pure chemistry, high hot strength and excellent volume stability in service. Especially notable are bubble alumina based bricks, UAM BA90AL which are manufactured by vibrocasting and can withstand continuous hot face temperatures of upto 1800°c. These bricks have always given valuable returns in terms of durability and fuel savings.



Castables:

General purpose castables: The UAC CRETE range of conventional castables is suitable for moderate and high heat duty applications. These are calcium aluminate bonded refractory concrete for application for temperatures upto 1400° c. These can be either vibration cast or poured. The grading of these products is formulated such that they can be gunned if required. High alumina High purity Conventional Castables: The UACHEAT range of high alumina conventional castables is made with aluminous aggregate and high purity high alumina refractory cement. These are suitable for use in critical applications upto 1800°C. They exhibit high volume stability, good thermal shock resistance and excellent hot strength. These castables are installed by both vibration and hand placement.

Low Cement Castables: The UACVIB range of low cement castable is available in 45% to 90% Al2O3 content. They are made with aluminous and mullite aggregates and high purity high alumina cement. These are suitable for extreme service conditions and have application temperatures upto 1800° c. These products are distinguished by their high volume stability, low porosity, better corrosion and erosion resistance, good thermal shock resistance and excellent hot strength. Installation of these castables is by vibration only.

Large aggregate Low cement castables: Uniceram also manufactures large aggregate (upto 10mm) based low cement castables. They exhibit excellent volume stability, spalling resistance and high temperature mechanical properties. Application of these castables is recommended in severe service conditions where the thickness exceeds 75mm. The castables are most suitably installed by vibration casting. Self flow castables: The UACFLOW range is a set of customized self flow castables. Depending on the end use, these could be either silicate bonded or alumina bonded. This range is available in a wide range of alumina content. Their installation is recommended by pouring against the form work. Extreme purity of the bond system and easy placement make them highly acceptable for various applications. Insulating castables: The UACLITE range of insulating castables is based on high purity insulating grog manufactured in-house. The service temperature goes upto 1800°C for bubble alumina based 95% Al2O3 castable and bulk densities achieved are as low as 500 gms/dm3. This prolific range of castables find use as both hot face and backup refractory lining.



General Specifications of the Refractory Types mentioned above:

INSULATING CASTABLE

UAC LITE 4 UAC LITE 7 UAC LITE 9 UAC LITE 11 UAC LITE 13 UAC LITE 15

General Properties

Maximum Service Temp. °C

1000 1100 1100 1350 1350 1350

Maximum Grain Size (mm) 6 6 6 6 6 6

Water addition on site %

100-110 70-80 55-60 35-40 30-35 30-35

Reversible Thermal Expansion % at 1000°C.

0.55 0.57 0.57 0.57 0.60 0.60

Physical Properties

Refractoriness (°C) / Orton min

- 1337/12 1398/14 1398/14 1398/14 1530/15

Dry Density (Kg/m3) min at 110° C

500 850 1000 1250 1450 1600

Cold Crushing Strength (Kg/cm2) min at 110°C /24 hrs 800°C / 3 hrs 1000°C / 3 hrs 1300°C / 3 hrs

2 1 - -

12 4 6 -

15 6

10 -

35 25 25 40

50 30 30 50

90 60 60 70

Thermal Conductivity ( KCal/m/hr/°C) 500°C Hot Face

0.10

0.14

0.28

0.31

0.33

0.44

P.L.C. % max. at 500°C / 3 hrs 800°C / 3 hrs 1100°C / 3 hrs 1300°C / 3 hrs

-

±0.50 - -

-

±1.00 ±1.60

-

±0.20 ±0.60 ±1.00

-

- -

±0.20 ±1.00

- -

±0.20 ±0.60

- -

±0.20 ±0.60

Chemical Analysis

Al2O3 (%) min.

30.00 33.00 33.00 34.00 39.00 40.00

Fe2O3 (%) max 11.00 8.50 6.00 3.50 3.50 3.20 The above values are from test samples and should be only used for guidance. We can also provide highly customized products, made to the end-user’s specifications or application. Nature of Bond : Hydraulic Installation : Rodding / Tamping Storage Life : 6 Months Delivery State : Dry



LOW CEMENT CASTABLE

The above values are from test samples and should be only used for guidance. We can also provide highly customized products, made to the end-user’s specifications or application. Nature of Bond : Hydraulic Installation : Vibrating Storage Life : 3 Months Delivery State : Dry

UAC VIB - 45 UAC VIB - 60 UAC VIB -70 UAC VIB - 80 UAC VIB - 90

General Properties

Maximum Service Temp. °C 1550 1600 1600 1700 1700

Maximum Grain Size (mm) 6 6 6 6 6

Water addition on site % 5-6 5-6 4.5-5.0 4.5-4.8 4.2-4.5


0.55 0.66 0.65 0.75 0.85

Physical Properties

Refractoriness (°C) / Orton min 32 (1717) 36 (1804) 36 (1804) 37 (1820) 37 (1820)

Dry Density (Kg/m3) min at 110° C 2300 2600 2700 2900 3050

Cold Crushing Strength (Kg/cm2) at 110°C /24 hrs 800°C / 3 hrs 1100°C / 3 hrs 1500°C / 3 hrs 1550°C / 3 hrs

700 800 900

1000 -

750 800 900

1000 -

750 800 900

- 1000

800 900

1000 -

1200

950 1000 1150

- 1200

P.L.C. % (max.) at 800°C / 3 hrs 1100°C / 3 hrs 1500°C / 3 hrs 1550°C / 3 hrs

± 0.2 ± 0.3 ± 1.0

-

± 0.2 ± 0.3 ± 1.0

-

± 0.2 ± 0.3

- ± 1.0

± 0.2 ± 0.3

- ± 0.8

± 0.2 ± 0.3

- ± 0.6

Chemical Analysis

Al2O3 (%) min. 45.0 60.0 70.0 80.0 90.0

Fe2O3 (%) max 1.0 1.5 1.5 1.5 1.0



CONVENTIONAL CASTABLE

UAC HEAT 94 T

UAC HEAT 97 T

UAC CRETE LT

LOW TEMPERATURE CASTABLE LTC

General Properties

Maximum Service Temp. °C

1800 1850 800 500

Maximum Grain Size (mm) 5 5 5 5

Water addition on site %

9.0-10.0 9.0-10.0 11.0-12.0 12.0-13.0


0.90 0.90 0.55 0.55

Physical Properties

Refractoriness (°C) / Orton min.

38(1835) 38(1835) - -

Dry Density (Kg/m3) min at 110° C

2500 2600 1900 2200

Cold Crushing Strength (Kg/cm2) min at 110°C /24 hrs 800°C / 3 hrs 1100°C / 3 hrs 1550°C / 3 hrs

900 550 450 550

400 280 280 380

250 200

- -

400

- - -

Modules Of Rupture (Kg/cm2) min. at 110°C /24 hrs 800°C / 3 hrs 1100°C / 3 hrs 1550°C / 3 hrs

100 65 55

110

80 45 60

130

- - - -

- - - -

Thermal Conductivity ( KCal/m/hr/°C)500°C Hot Face

1.50

1.70

-

-

P.L.C. % max. at 500°C / 3 hrs 800°C / 3 hrs 1100°C / 3 hrs 1550°C / 3 hrs

Nil

±0.10 ±0.20 ±0.40

- -

±0.25 ±0.80

-

±1.00 - -

0.50

- - -

Chemical Analysis

Al2O3 (%) min.

94.50 96.00 30.00 32.00

SiO2 (%) max 0.30 0.30 - - Fe2O3 (%) max 0.30 0.30 4.00 2.50 CaO max 5.00 2.80 - -

The above values are from test samples and should be only used for guidance. We can also provide highly customized products, made to the end-user’s specifications or application. Nature of Bond : Hydraulic Installation : Pouring / Casting Storage Life : 6 Months Delivery State : Dry



HIGH ALUMINA BRICKS

BRAND Al2O3 %

Fe2O3 %

PCE Orton

AP %

BD gm/cc

CCS Kg/cm2

RUL ta °C

PLC at °C/hrs %

UAM HA 99 98.5 0.2 42 18 3.1 600 1700 1600/2/± 0.1 UAM COR 94 94 0.3 41 18 3.0 800 1700 1600/2/± 0.2 UAM COR 90 90 0.3 40 18 2.9 800 1700 1600/2/± 0.2 UAM MULCOR 85 85 0.3 39 18 2.8 800 1680 1600/2/± 0.3 UAM HAH ** 88 1.5 38 18 3.0 1000 1500 1500/2/± 0.5 UAM 80S 80 1.5 37 18 2.8 600 1550 1600/2/± 1.0 UAM 80 SD 80 0.5 38 18 2.8 600 1600 1600/2/± 0.2 UAM 85 SDP 85 1.0 38 17 2.85 800 1550 1500/2/± 0.5 UAM 80 B 80 2.8 38 23 2.7 500 1500 1600/2/+ 1.5 UAM 80 BD 80 2.0 38 21 2.75 600 1520 1600/2/± 1.5 UAM MULL 72 0.5 38 20 2.55 600 1650 1600/2/± 0.2 UAM MULL D 72 0.3 38 18.0 2.65 700 1700 1600/2/± 0.3 UAM HA70 70 4.0 36 23 2.55 500 1430 1600/2/± 3.0 UAM 70 B 70 2.8 36 23 2.65 600 1470 1600/2/+ 3.0 UAM 70 BD 70 2.0 37 22 2.65 800 1500 1600/2/+ 2.5 UAM 70 BDS 75 1.5 37 21 2.70 800 1550 1600/2/+ 2.5 UAM 70 D 70 1.2 37 20 2.60 600 1600 1600/2/± 1 UAM 62 62 1.5 36 22 2.4 400 1520 1500/2/± 0.5 UAM 62 D 62 1.0 36 15 2.5 600 1500 1600/2/± 0.5 at 4 kg/Cm2 UAM 62 SD 62 0.8 37 15 2.55 800 1600 1600/2/± 0.3 UAM 60 K 60 1.0 36 18 2.4 500 1540 1500/2/± 0.5 UAM 60 B 60 3.0 35 23 2.5 400 1500/2/± 2.0 UAM SILL 56 1.2 36 23 2.3 450 1500 1500/2/± 0.8 UAM SILL DENSE 58 1.0 36 16 2.4 500 1550 1500/2/± 0.5 UAM 50 K 50 1.5 34 23 2.25 400 1500 1450/2/± 0.5 UAM 50 B 50 2.5 34 23 2.35 400 1500/2/+ 2.0

The above values are from test samples and should be only used for guidance. ** ABRASION RESISTANCE MORGAN MARSHAL 20-30 Remarks: The above data relates to standard size pressed bricks. These are subject to variation for bigger pressed and hand molded shapes. Standard Tolerance on Size: ± 1.5% or ±2 mm whichever is greater.



SPECIAL BASIC REFRACTORIES

BRAND MgO %

min

Cr2O3

% min

SiO2

% max

Fe2O3 %

max

CaO %

max

A.P. %

B.D. Gm/Cc

min

C.C.S. Kg/Cm2

min

RUL ta °C min

Direct Bonded Magnesite Chrome For Copper, Zinc in Non Ferrous and VOD, AOD in Steel and Cement Industry UAM-DBMC-I 68 12 3.0 ⎯ ⎯ 18 2.95 350 1650 UAM-DBMC-II 70 10 2.5 ⎯ ⎯ 18 3.00 400 1700 UAM-DBMC-III 75 8 2.0 4 ⎯ 18 3.05 400 1700 UAM-DBMC-SPL 65 18 1.0 ⎯ ⎯ 18 3.10 400 1700 UAM-DBCM-SPL 50 28 1.0 ⎯ 0.6 17 3.15 400 1700 The above values are from test samples and should be only used for guidance.

MAGNESITE ALUMINA

BRAND MgO

% min

Al2O3

% min

SiO2

% max

Fe2O3 %

max

CaO %

max

A.P. %

max

B.D. Gm/cc

Min

C.C.S. Kg/Cm2

min

RUL ta °C min

General Basic Refractory

UAM-MGAL-I 80 8 1 1 2 21 2.90 450 1700 UAM- MGAL -II 74 20 1 1 2 20 2.90 450 1700

The above values are from test samples and should be only used for guidance.

Remarks: The above data for Special Refractories and Magnesite Alumina relates to standard size pressed bricks. These are subject to variation for bigger pressed and hand molded shapes. Standard Tolerance on Size: ± 1.5% or ±2 mm whichever is greater. For further details contact us at [email protected]

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