Monolithic concept solutions for Aluminium
Innovative refractory concepts for the Aluminium Industry Our role in the Aluminium Industry is to bring the best valuein-use to our customers by continuous improvements of our prod-ucts. Based on this approach, we have started for a long time ago, research & development programs to improve not only the performance of our products, but also facilitate their placement and general properties. As a consequence, we enjoy successful activity and partnership with the Aluminium Industry worldwide for more than 50 years. Our offer includes a full range of commodity and speciality materials for new lining or maintenance of any equipment on the Aluminium Industry. Moreover, based on our long term and multinational experience we can suggest lining concepts and provide full service including installation. Our main product ranges: ALKON PHLOCAST BASACAST PLICAST SPRAYCAST BASAGUN PLIBRICO
Tank Melting and Holding Furnaces 1 BATH LINING melting PLICAST BL 80 B3 furnaces ALKON cast Optimum 204 SPRAYCAST BL 85 B3 (wall) holding ALKON cast Optimum 206 furnaces PLICAST HyMOR 80 AL high purity ALKON cast Super 208 aluminium 2 BATH SAFETY LAYER PLICAST FM 40 AT ALKON cast Classic 202 3 BATH INSULATION & SAFETY LINING ALKON cast iso 122 PLICAST 18 CG 4 ROOF & UPPER WALLS PLICAST HyMOR 2800 PHLOCAST M 28 SPRAYCAST FL 50 B6 5 INSULATION roof BASACAST iso 09-110 wall BASACAST iso 09-110 PLISTIX isogun 125 6 LINTEL & PILLARS GIBRAM PLICAST LX 58 PHLOCAST M 32 7 BURNER BLOCKS PLIBRICO 85 S KERPLAST P 85
Scrap Melting Furnaces 1 BATH LINING ALKON cast Optimum 204 PLICAST HyMOR 80 AL ALKON cast Maximum 209 SPRAYCAST BL 85 B3 (walls) 2 SAFETY LAYER PLICAST FM 40 AT ALKON cast Classic 202 3 BATH INSULATION & SAFETY LINING ALKON iso 135 PLICAST 18 CG 4 UPPER WALLS LINING PLICAST LX 58 PLIBRICO 85 S (plastic) SPRAYCAST FL 60 B3 ALKON cast Robust 203 5 UPPER WALL INSULATION BASACAST iso 13-135 PLICAST Strong-Lite Insulating bricks (if plastic) 6 LINTEL & PILLARS GIBRAM PLICAST LX 58 PHLOCAST M 32 7 ROOF LINING PLICAST HyMOR 2800 8 ROOF INSULATION BASACAST iso 09-110 PLICAST LW Mix 123 9 DOOR LINING PLICAST FM 40 AT ALKON cast Robust 203
Barrel Melting Furnaces 1 BATH LINING PLICAST BL 80 B3 ALKON cast Optimum 204 ALKON cast Maximum 207 2 SAFETY & INSULATION ALKON iso 122 (gun) PLISTIX isogun 125 3 ROOF LINING PLIGUN 75 AL ALKON gun Maximum 402 4 BURNER BLOCK LINING PLIBRICO 85 S KERPLAST P 85
Shaft Melting Furnace with Side Well 1 BATH LINING PLICAST HyMOR 80 AL 4 ROOF LINING ALKON cast Optimum 204 ALKON cast Maximum 207 PLIGUN 75 AL (holding chamber) ALKON gun Robust 401 ALKON cast Robust 203 2 BATH SAFETY & INSULATION 5 ROOF INSULATION ALKON iso 135 PLISTIX isogun 123 PLICAST 18 CG BASACAST iso 09-110 3 CHARGING SHAFT 6 BURNER BLOCKS PLICAST FM 50 PHLOCAST M 32 PHLOX 1560 PLIBRICO 85 S PLICAST 039 KK KERPLAST P 85
Bi-Chamber Shaft Melting Furnace 1 BATH LINING PLICAST HyMOR 80 AL ALKON cast Optimum 204 ALKON cast Maximum 207 (holding chamber) 2 BATH SAFETY & INSULATION ALKON iso 135 PLICAST 18 CG 3 TRANSITION VAULT PLICAST BL 80 B3 ALKON cast Maximum 209 GIBRAM 5 ROOF LINING PLIGUN 75 AL ALKON gun Robust 401 6 ROOF INSULATION PLISTIX isogun 123 BASACAST iso 09-110 7 MINERAL FIBRE 4 CHARGING SHAFT PLICAST FM 50 PHLOCAST M 32 8 BURNER BLOCKS PLIBRICO 85 S PLICAST 039 KK
Dosing (Holding) Furnace 1 BATH LINING ALKON cast Optimum 206 PLICAST HyMOR 80 AL SAFETY & INSULATION 2 INSULATING BRICKS 3 DENSE FIBRE BOARD 4 CALCIUM SILICATE 6 ROOF SCREEN CHARGING ZONE 5 MICROPOROUS PANELS PLICAST FM 40 AT ALKON cast Robust 203
Coreless Induction Furnaces 1 CRUCIBLE LINING ALKON dry Maximum 505 TV 200 PLIRAM 24 S pre-shaped ALKON cast Super 208 crucible 2 COIL PROTECTION Coil cement Mica sheet (M 40) 3 POURING SPOUT LINING PLICAST FM 40 AT ALKON cast Classic 202 4 UPPER RING LINING BASACAST iso 13-135 PLICAST Strong-Lite 5 COVER LINING ALKON iso 122 PLICAST XL-25
Channel Induction Melting Furnaces 1 BATH LINING PLICAST BL 80 B3 ALKON cast Optimum 204 ALKON cast Maximum 209 2 UPPER BATH LINING & METAL LINE PLICAST HyMOR SIC 85 ALKON cast Optimum 204 3 BOTTOM SAFETY LINING PLICAST 18 C/G ALKON iso 135 4 WALL SAFETY & INSULATION LINING PLICAST 18 C/G ALKON iso 135 (gun) 5 CALCIUM SILICATE
Channel Induction Holding Furnaces 1 BATH LINING PLICAST HyMOR 80 AL ALKON cast Super 206 4 INDUCTOR LINING 2 SAFETY & ALKON dry Maximum 504 INSULATION LINING ALKON ram Optimum 600 ALKON iso 122 (gun) PLIGUN XL-25 3 CALCIUM SILICATE 5 PLICAST AL 65 B3 (castable) INDUCTOR TOPPING RODAROX coat 953 PJ
Road Transport Ladles 1 MAIN WORKING LINING PLIFLOW AL 65 B3 ALKON flow Optimum 303 2 SAFETY & INSULATION PLIGUN XL-25 ALKON iso 122 3 INSULATION Microporous insulation panels 4 COVER LINING PLICAST Strong Mix AT ALKON cast Classic 202
Products Technical Information Product name Chemical analysis (%) Permanent Material Max grain size Main Mixing water linear CCS 800 C required (mm) component (l/100kg) change (MPa) Al 2O 3 Fe 2O 3 CaO (t/m 3 ) 800 C (%) Dense anti-wetting castables PLICAST BL 80 B3 10 Bauxite 81 1.1 2.2 3.08 4.4-4.8-0.2 150 ALKON cast Optimum 204 5 Bauxite 79.5 1.1 4.2 2.82 4.5-6.0-0.2 > 140 ALKON cast Optimum 206 6 Bauxite 81 1.1 3.6 3 7.0-7.5 0 60 PLICAST HyMOR 80 AL 6 Corundum 80 0.25 4.6 3.05 5.2-6.0-0.15 130 ALKON cast Super 208 6 Tabular alumina 90 0.1 3.4 3.1 5.5-6.0 0 80 ALKON cast Maximum 209 5 Corundum 92 0.2 2.2 3.15 4.0-5.0 0 140 ALKON cast Maximum 207 6 Corundum 87 0.2 3.6 3.2 5.5-6.0 0 95 ALKON flow Optimum 303 5 Bauxite 84.5 1 2.7 2.9 5.5-6.5-0.1 120 PLIFLOW AL 65 B3 6 Andalusite 65 0.5 2.4 2.69 6.0-6.4 0 95 ALKON cast Robust 203 6 Mullite 61 0.9 3 2.6 5.5-6 0 80 PLICAST FM 40 AT 6 Chamotte 40 2.4 3.1 2.12 8.8-9.6-0.3 60 ALKON cast Classic 202 5 Chamotte 44.6 1 4.2 2.25 6.0-7.5-0.25 90 PLICAST Strong-Mix AT 6 Chamotte 41 4.9 11 2 12-14 -0.1 45 Insulating anti-wetting castables ALKON iso 135 8 Light weight 40 3.1 14 1.3 25-35 -0.2 6 chamotte ALKON iso 122 4 Light weight 40 3.4 11.5 1.2 32-38 -0.3 6 chamotte Dry & Ramming Mixes ALKON dry Maximum 504 6 Corundum 90.5 0.4 5.7 2.9 dry mix, -0.2 30 heat setting ALKON dry Maximum 505 6 Corundum 92.4 0.2 1.1 3 dry mix, -0.1 40 heat setting TV 200 6 Chamotte 51 0.6 40 2.7 dry mix, -0.15 12 heat setting ALKON ram Optimum 600 6 Bauxite 84 0.9 3.02 phosphatic 0 45 (humid) PLIRAM 24 S 6 Chamotte 48 0.7 7.5 2.3 phosphatic -0.15 60 (humid) Plastics PLIBRICO 85 S 6 Bauxite 85 0.9 7.4 2.95 phosphatic, -0.85 90 ready to use KERPLAST P 85 6 Bauxite 82 1.3 7.5 3.1 phosphatic, -0.15 70 ready to use
Chemical analysis (%) Material Mixing Permanent Product name Max grain size Main linear CCS 800 C required water (mm) component change (MPa) Al 2O 3 Fe 2O 3 CaO (t/m 3 ) (l/100kg) 800 C (%) Gunning castables ALKON gun Maximum 402 6 Corundum 84 0.2 6.5 2.9 added at -0.2 40 the nozzle ALKON gun Robust 401 6 Chamotte 50 1 6.3 2.3 added at -0.1 40 the nozzle PLIGUN 75 AL 7 Corundum 84 0.2 6.5 2.85 added at -0.1 80 the nozzle PLIGUN 45 AL 6 Chamotte 48 0.7 7.5 2.3 added at -0.15 60 the nozzle Low cement dense gunning ALKON gun Optimum 404 6 Bauxite 74 1 4.1 2.9 5-6% added -0.2 100 at the nozzle SPRAYCAST (low cement wet gunning) SPRAYCAST BL 85 B3 6 Bauxite 85 0.9 1.8 2.93 5.2-6.0-0.1 70 SPRAYCAST FL 60 B3 6 Syntetic mullite 60 0.7 1.9 2.68 5.6-6.4-0.2 80 SPRAYCAST FL 50 B6 6 Chamotte 49 0.85 1.9 2.45 6.4-7.6-0.1 80 Patching & repair mixes (for gunning and trowelling) ALKON patch Classic 701 3 Chamotte 44 1.1 4.2 2 16-18 -0.3 15 ALKON patch Maximum 702 3 Corundum 80 0.9 4.7 2.6 11-13 -0.1 25 ALKON coat Super 900 6 Tabular alumina 82 0.1 1.5 ready to use patching paste (heat setting)
Product name Chemical analysis (%) Permanent Material Max grain size Main Mixing water linear CCS 800 C required (mm) component (l/100kg) change (MPa) Al 2O 3 Fe 2O 3 CaO (t/m 3 ) 800 C (%) Alternative castables for aluminium furnaces PLICAST 18 C/G 6 Chamotte 33 2.3 6.2 1.85 14-16 -0.1 25 PLICAST HyMOR 2800 6 Chamotte 50 0.75 4.2 2.33 6.4-7.6-0.2 135 PLICAST HyMOR SIC 85 3 Silicon Carbide 9.5 0.2 1.85 2.6 5.6-6.4-0.15 95 PLICAST 039 KK 6 Alumina 69 0.7 1.5 2.51 7.0-8.0-0.04 30 PHLOCAST M 28 5 Chamotte 45.5 1.3 3 2.2 6.0-7.5-0.25 90-0.3 110 PHLOCAST M 32 SR 5 Bauxite 77.7 1 2.65 6.5-8.5 (1200 C) (1200 C) +0.1 70 PHLOX 1560 5 Andalusite 59 1.1 2.2 2.5 6.0-8.0 (1200 C) (1200 C) PLICAST LX 58 6 Andalusite 57 1.1 2.3 2.53 5.6-6.0-0.04 100 GIBRAM 5 Bauxite 82.5 1.5 1.2 2.9 5.0-6.0-0.15 130 Alternative insulating castables BASACAST iso 13-135 (cast) 5 Light weight 41 3.1 9.6 1.3 25-30 -0.1 8 chamotte Light weight BASACAST iso 09-110 8 chamotte; 25 9 13 0.9 45-60 -0.3 2 Vermiculite PLICAST Strong-Lite 4 Light weight 40 5.5 13 1.43 22-24 -0.15 18 chamotte PLICAST XL-25 5 Light weight 45 0.9 16 0.63 52-56 -0.05 2 aggregates Light weight added at PLIGUN XL-25 5 43 0.9 15.2 0.98-0.15 5 chamotte the nozzle PLICAST LW-mix 123 4 Vermiculite 25 10.5 17.5 1.02 38-42 -0.25 4.5 Light weight added at BASACAST iso 13-135 (gun) 5 41 3.1 9.6 1.6-0.2 25 chamotte the nozzle Light weight added at PLISTIX isogun 125 4 chamotte; 36 4 9 1.35-0.4 5.5 the nozzle Vermiculite NOTES: CALDERYS does not warrant the accuracy, fi tness for purpose or update of any information disclosed herein. The recipient shall refer to instructions and advice provided under any technical documentation. This document and the information contained herein are the exclusive property of CALDERYS. Reproduction, alteration, copy, release, publication or distribution, in whole or in part, is not allowed. References, trademarks and specifi cations of the products may change according to the geographical area to be supplied. Please check the availability of the products with the sales area manager.