REFRACTORIES FOR MOLTEN IRON & STEEL

Transcription

1 SHARADAA REFRACTORIES FOR MOLTEN IRON & STEEL MINISTEEL SLIDE GATE REFRACTORIES LADLE INNER / COLLECTOR NOZZLES TUNDISH NOZZLES POROUS PLUG WELL BLOCKS FOR LADLE / TUNDISH 95%, 90%, 60% CASTABLES 90K MORTOR NOZZLE FILLING COMPOUND TUNDISH BOARDS CASTING POWDER REHEAT FURNACE BRICKS / BLOCKS BURNER BLOCKS INDUCTION FURNACE TOP / BOTTOM BLOCKS I.F. RAMMING MASSES COILKOTE FOUNDRIES REFRACTORY MONOLITHIC & INSULATIONS FOUNDRY LADLE CASTABLES FOR HIGHER CAMPAIGN LIFE NEUTRAL / BASIC / SILICA RAMMING MASS FOR INDUCTION FURNACES PRECAST SHAPES FOR INDUCTION FURNACE / LADLE PATCHING PLASTICS / PLASTER - IMPORT SUBSTITUTION EXOTHERMIC / INSULATION SLEEVES MOULD COATINGS ANTI SLAG COATINGS FOR LADLE REFRACTORIES FOR LONG CAMPAIGN CUPOLAS CERAMIC FIBER SLEEVES FOR NON-FERROUS FOUNDRIES SHARADAA CERAMICS PVT LTD

2 LADLE AND TUNDISH NOZZLE FOR STEEL /MINISTEEL Slide Gate Refractory for Steel / Ministeel PERTICULARS TUNDISH LADDLE COLLECTOR SLIDE GATE POROUS NOZZLE NOZZLE NOZZLE PLATE PLUG General Properties Service Temperature C (Max) Body Alumina Alumina Alumina Alumina Carbon Carbon Carbon Carbon Insert ZiRCON 95 % Body Bulk Density (gm/cc) Dired at 200 C (Min) AP % Insert Bulk Density (Min) AP % (Max) Chemical Properties (Min) (Max) SiO 2 (Max) Fixed Carbon (Min) Thermal Properties Resistance to Metal Erosion Excellent Excellent Excellent Excellent Excellent Application Area Tundish Ladle Bottom Ladle Bottom Ladle Bottom Ladle Bottom Steel Ladle Slag Resistance Castable SHARADAA 95SLR SHARADAA A SHARADAA K Particulars General Properties Service Temp C (max) Grain size mm (max) Water Required to Mix For Ramming For Casting Bd Dried at 110C Cold Crushing Strength after Fired at 1550 C Mor after Fired at 1550 C Thermal Properties Permanent Linear Change after Fired at 1550 C Spinel (min) (max) 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 2 Nozzle Filling Compound for Ladle & Tundish - Mini Steel Plant PARTICULARS SPECIAL STEEL CARBON STEEL Chemical Analysis (%) Cr 2 >23 % >10 % SiO 2 40 ~ 50 % 70 ~ 80 % <30 % <30 % <5 % <5 % MgO <10 % <10 % Moisture Nil Nil Shape Semi round Semi round Grain size 0-1 mm 0-1 mm Density (gm/cc) Vacuum Formed Products and Mixes for Tundishes Tundish Board, Cone and Impact Pad PARTICULARS Chemical Analysis (%) SiO 2 C Bulk Density (gm/cc) Cold Crushing Strength (kgf/cm 2 ) Ignition Loss (%) Application Temperature C PARTICULARS Chemical Analysis (%) SiO 2 MgO CaO C Alkalis (%) Application Temp C to to C TUNDISH SEALING to to C TUNDISH BOARD AND CONE Tundish Sealing and Packing Compound to to C PACKING COMPOUND to to C Refractory Mortor for Ministeel TUNDISH IMPACT PAD PARTICULARS SHARADAA 90K Types of Setting HEAT Service Temp C (max) 1800 Refractories (Min.) Grain Size mm (max.) Chemical Properties 0 3 +Spinel (min) (max) 1 Resistance to Slag Corrosion Excellent Resistance to Metal Erosion Excellent Application Area Nozzle Fixing at Ladle and Tundish Installation Essential Padle Mixer / 18 C ICE Water Store at Cool Dry Place

3 REFRACTORY MONOLITHIC SOLUTIONS FOR LADLE / CONVERTER IN FERROUS / NON-FERROUS / STEEL FOUNDRIES Refractory Castables for Grey Iron / SG Iron / Steel Casting Ladle Cover Converter Ceramic Fibre Paper 6mm Anti Slag Coating Ceramic Fibre Paper Slag Cup Test Installation Options: Trowelling / Vibrocasting / Free Flow / Ramming / Ready Made Plastics 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: 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 For smaller ladles precast prefired shapes are preferred. The extended heats are achieved by usage of appropriate patching castables. Foundry Needs 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 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 We offer Debricking / Castable Laying / Heat Curing at our factory of Ladles Converters to save space, labour / power costs at your works 3

4 SLEEVES EXOTHERMIC 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 requirement 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 performance of the sleeves results in consistent quality castings CERAMIC FIBRE SLEEVES FOR NON-FERROUS SILICA / BASIC / NEUTRAL RAMMING MASS FOR INDUCTION FURNACES 4

5 REFRACTORY SOLUTIONS FOR FOUNDRIES LADLES LONG CAMPAIGN COST EFFECTIVE INCLUSION FREE LINING FROM SHARADAA REFRACTORY CASTABLES FOR IRON LADLE Refractory Used 90% Coventional Castable Velcrete SF-204 Backup Insulation Not used 6mm Mica Paper Shell Temperature C C Life 30 Days 90 Days Refractory Inclusion High Low Cost / Lining 3.30 Lacs 1.90 Lacs Cost / Heat Cost / MT Other 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 Good Inclusion in Casting Often Present Eliminated REFRACTORY CASTABLES FOR STEEL LADLE Refractory Used 40% Refractory Mass Velcast-90 SPL Backup Insulation Not used 3 mm Asbestos Sheet Life 12 Tappings 400 Tappings Refractory Inclusion High Low Cost / Lining Rs. 3,000 Rs. 20,000 Cost/ Tapping Rs. 250 Rs. 50 Cost / MT Rs. 500 Rs. 100 Other Advantages Slag Buildup Very High Very Less Lining Safety Very Bad Very Good Inclusion in Casting Often Present Eliminated REFRACTORY CASTABLES FOR WATER COOLED CUPOLA Refractory Used Alumina Carbon Nanobond-630 Ramming Mass Backup Insulation Nil Nil Shell Temperature C C Life 15 Days 50 Days Refractory Inclusion High Low Cost / Lining 5.4 Lacs 7 Lacs Cost / MT Other Advantages Slag Generation Very High Very Less Lining Safety Very Bad Very Good 5

6 LONG CAMPAIGN COST EFFECTIVE INCLUSION FREE LINING REFRACTORY PLASTER FOR IRON LADLE Refractory Used Alumina Carbon Plastic Velplast-1030 SC Backup Insulation 60% Alumina Castable 60% Alumina Castable Shell Temperature Life 24 Hrs. 24 Hrs Refractory Inclusion Low Low Cost / Lining 0.20 Lacs 0.15 Lacs Cost / Tapping Rs. 333 Rs. 250 Cost / MT Rs. 333 Rs. 250 LADLERAM WITH LADLECOAT FOR IRON LADLE Refractory Used Ramming Mass LadleRam with LadleCoat Backup Insulation Nil Nil Shell Temperature C C Life (Tapping) Refractory Inclusion High Low Cost / Lining 0.5 Lacs 0.4 Lacs Cost / MT Other Advantages - Slag Chipping (Removal) Hard Easy - Slag Penetration High Low REFRACTORY COATINGS Advantages Excellent surface cast finish Reduces the fettling process Reduces the casting defects - Metal Penetration - Poor casting strip - Mould erosion - Sand inclusion defects Coating Characteristics High Refractory Properties Good Adhesion to the Substrate Good Suspension Properties FOR FOUNDRIES ALUCOAT (W) Alumina Silicate Coating : Water Base Solids : 60% Application Area : Grey & Ductile Iron Applying Method : Components Swabbing, Dipping, Brushing GRAPHCOAT (W) Graphite Coating : Water Base Solids : 60% Application Area : Grey Iron, Non-Ferrous Applying Method : Brushing GRAPHCOAT (S) Graphite coating : Spirit Base Solids : 35% Application Area : Cast Iron, Grey Iron Applying Method : Brushing, Spraying ZIRCOAT (S) Zircon Coating : Baume : Solids : Application Area : Applying Method : ZIRCOAT (W) Zircon Coating : Baume : Solids : Application Area : Applying Method : Spirit Base % Steel Castings, Grey & Malleable Iron Brushing, Spraying, Swabbing Water Base % Steel Castings, High Duty Irons & Ingot Moulds Brushing 6

7 FOUNDRY LADLES FOR IRON FOUNDRIES / STEEL FOUNDRIES PROPERTIES VELCAST SF 204 LADLE RAM - CIF VELCAST 90 SPL Product Charecteristics Bond Ultra Fine Phospate Ultra Fine Aggregate Cal. Bauxite Cal. Bauxite Fused Alumina Type of Setting Ceramic Hardening Phospate Hardening Hydraulic Service Temp C (Max) Grain Size (mm) Chemical Properties Bulk Density After Drying at 110 C (gm/cc) Cold Crushing Strength (Kg/cm 2 ) 110 C C C Cold MOR (Kg/cm 2 ) 110 C C C Thermal Properties Thermal Conductivity at 600 C HF (Kcal/hr/m/ C ) Hot MOR at 1400 C (Kg/cm 2 ) Thermal Expansion at 1100 C (%) Permanent Linear Change at 1500 C(%)(Max) ±1.0 ±0.5 ±1.0 Thermal Shock Resistance at 1100 C + 50 Cycles Cycles Apparent Porosity at 1500 C (Max) LADLE COAT - CIF General Properties Type of Material Ready mix mortar Nature of bond Heat Installation Method Hand Patching / Brushing Maximum Service Temperature ( C) 1650 Typical Appearance Dark grey mortar Specific Gravity LADLE COAT LADLE RAM 7

8 LONG CAMPAIGN CUPOLAS MONOLITHIC SOLUTIONS FOR HOT BLAST CUPOLAS 1 2 Melting Zone Castable : Velcrete SiC 42 Maintenance : Backups PCF 704 Well Zone Castable : Velcrete SF20SiC Maintenance : Plascrete 80D 4 5 Hearth Castable : Velcrete SiC 20 Maintenance : Super Patch 1700ºC Runner Castable : Velcrete 504 Maintenance : Superpatch Stack Castable: Super Patch 1700ºC 5 CUPOLA TYPE FURNACES HIGH PERFORMANCE CASTABLE & PRECAST SHAPES 2 4 PROPERTIES VELCRETE SF-20 SC NANOBOND-630 VELCRETE SF-203 Product Charecteristics Type of Cupola Gas Fired Coal Fired Coal & Gas Fired Application area Below Tuyers Below Tuyers Above Tuyers Aggregate BFA+SIC WTA+SIC CAL.BAUXITE Bond Ultra fine Nano Bond Ultra fine Type of Setting Ceramic Hardening Hydraulic Ceramic Hardening Service Temp C (Max) Refractorieness C (Min) Grain Size (mm) Chemical Properties SiC+C Bulk Density at 110 C (Min) Cold Crushing Strength (Kgs/cm 2 ) 110 C C C Thermal Properties Thermal Conductivity at 600 C Hot face (Kcal/hr/m/ C ) Thermal Expansion at 1100 C (%) Permanent Linear Change at 1500 C (%) Apparent Porosity at 1500 C (Max) Material Required per M3 (Kg) Form demoulding time Temperature of mix Slag Resistance Excellent Excellent SHARADAA CERAMICS PVT. LTD. 387, 388 SIDCO Industrial Estate, Ambattur, Chennai Tel : / Fax : Mobile : / / admin@sharadaamonolithic.com