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Refractory Monolithic & Castables

Refractory Monolithic

Refractory Monolithic is composed of dry aggregate (alumina based/Alumino-silicate based/ Silica based etc.) and a refractory binder (high alumina cement/ Non calcareous binder) which can be mixed with water with desired consistency and then applied to the desired area of application either by casting with extensive vibration/ ramming/ gunning/pouring etc. These are under the following classification.

Conventional Castable

Conventional castable, coming under the dense castable category, contains a high amount of refractory high alumina cement. The choice of aggregate is alumina based (Tabular alumina, fused alumina, calcined bauxite etc.) or alumino-silicate based (calcined clay, mullite etc.). The water requirement for casting is relatively high. Placing of conventional castable requires extensive vibration and ramming.

Low cement castable

Low cement castable, from its name, contains low amount of cement. The choice of aggregate here is also same as conventional castable. Further it contains superfine material (Micro-silica, reactive alumina) and deflocculant system which provides better placing property and very good intermediate temperature strength. The advantage of low cement castable over conventional castable is, it provides low porosity and high HMOR. Here the water requirement for casting is low and it requires extensive vibration for placing.

Refractory Mortar

Refractory mortar composed of low grain sized refractory material and a het resistant bonding system. Refractory mortars are of two types

• Air setting: In this case the mortar hardens at room temperature

• Heat setting: In this case the mortar requires temperature to develop the bonding.

• Refractory mortars are normally applied for laying refractory bricks.

Basic ramming mass

Basic ramming mass are by name contains basic refractory aggregate (Sintered MgO, DBM etc.). Placing of ramming mass requires extensive ramming by pneumatic rammer. These are of two types depending on their application types

• Dry ramming mass: Placing of dry ramming mass does not require water. Special additive exhibits strength at high temperature.

• Wet ramming mass: Placing of wet basic ramming mass requires water. The bonding here developed is a type of heat setting bond.

Insulating Castable

Insulating castable comes in the category of low density castable. The choice of aggregate here are alumino-silicate (Perlite, Vermicullite, Insulating brick grog etc.). This category of castable contains a high amount of refractory cement. The water requirement for casting is high. This category of castable has low density, low thermal conductivity for which they are applied in the back up lining. Placing of insulating castable requires tamping or pouring.

Carbon Injection grouting mass

This is a specially formulated refractory material containing carbon. This material comes in the liquid form. The base material is resin. It is applied in the blast furnace hearth shell for repairing the hot spot. Hardening of the material occurs in presence of heat. Placing of this material requires pressure grouting.

Coating Mass

Coating mass comes under the separate category of refractory monolithic which is basically either a two component system or a single component slurry form. Placing of this material is done either by spraying or by brushing. This is basically application driven customized product.

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