Monolithic Refractory Castables

By Author: Vivek Singh
Total Articles: 2
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Refractories are non-metallic materials that have chemical and physical properties that can withstand high temperature without changing their physical and chemical properties. Due to their high resistance to heat and thermal shock, this can be used as a lining material inside the kilns and furnaces which will prevent the damages to the steel structures and reduce the heat loss from the furnace / kiln, Refractories are mainly used in Iron & Steel, Cement, Power, Aluminium, petroleum and other high temperature process industries. Refractory materials are pivotal to this energy-saving process due to their inherent low heat conductivity as well as advantages derived from ease of placement and the strength of the materials.

Calderys is a globally leading manufacturer of refractory that provides customized refractory solutions such as Shaped & unshaped refractory of both dense and insulation, Precast Prefired blocks, high alumina cement, isostatically pressed continuous casting refractories and many similar products to widely diversified industries which include Iron & Steel making, Cement, Petrochemicals, ...
... Boilers & Incinerators, Foundry, Aluminium, DRI etc.
To make the shopping experience more convenient Calderys have developed 'Caldezone', their very own online portal with all their products so the clients can check their specifications, get the best price and buy refractory products online according to their requirement.

Usage of Monolithic Refractory Castables In The Aluminium Industry
Rotary Furnace: - Rotary furnaces are batch furnaces that generally use oxy-fuel burners and restrict the volume of off-gases. A rotary furnace can be controlled with a charge high in metallics and scrap lead, dust drosses, battery paste refinery drosses and any combination thereof.
Calderys product for rotary furnaces: - ACCMON 80 AL is a non-wetting castable having excellent thermo-mechanical properties. The product is made from high-grade raw materials. It helps in lowering the maintenance cost of the furnace and is best suitable for rotary furnaces.
Cast House Furnace: - Melting & Holding Furnaces are created to supply casting machines with metal that is at the appropriate casting specification on a continuously recurring basis. A door is designed to allow complete access to the furnace for loading and cleaning operations. Multi-fuel heating method (gas, oil or electrical).
Calderys product for case house furnace: - ACCPLAST 80 AL is ready to use refractory product which is a phosphate bonded monolithic product and hence doesn’t need any water addition and is best suitable for cast house furnace.
Metal Transfer Ladle:- Ladles are used in the aluminium and foundry industries to transfer molten metal between locations, generally from a melting furnace to a holding furnace. They are often used to grip metal while it is treated by degassing and/or fluxing.
Calderys product for metal transfer ladle:- ACCMON 80 AL is a non-wetting castable having excellent thermo-mechanical properties. The product is made from high-grade raw materials. It helps in lowering the maintenance cost of the furnace and is best suitable for metal transfer ladle.

Usage of Monolithic Refractory Castables In The Boiler & Incinerator Industry
Bubbling Fluidized Bed:- A bubbling fluidized bed (BFB) is a boiler that can also handle fuels that are tough to pulverize or less combustible. The fuel is introduced into a mixture of sand flowing at high temperatures, allowing the fuel to be optimally combusted.
Calderys product for (BFB):- BOILERCRETE is a specially carved cost economical medium cement castable that is easy on application and provides optimum performance and is best suitable for (BFB).

Circulating Fluidised Boiler: - A circulating fluidized bed (CFB) boiler features greater gas rapidness (superficial flow velocity) in the furnace (combustor) compared with a bubbling fluidized bed (BFB) boiler. The boiler activates a mix of particles and gas to improve combustion reaction.
Calderys product for (CFB):- ACCMON 90 is best suited for (CBF) because it is a Low cement, high-density castable created with carefully selected raw material with strict grain size distribution is a high alumina castable having a high packing density.
Grate Fired Boiler: - A Grate Fired Boiler is a type of boiler in which hot gases pass from a fire through multiple tubes running through a sealed container of water. The heat of the gases is conducted through the walls of the tubes by thermal conduction, heating the water and ultimately generating steam.
Calderys product for Grate fired boiler: - ACCMON 45 is Low cement, high-density castable created with choice raw materials with strict grain size distribution and it is best suitable for grate fired boiler.
Pulverized Coal Fired Boiler: - A pulverized coal-fired boiler is an industrial or utility boiler that creates thermal energy by burning pulverized coal (also known as powdered coal or coal dust since it is as fine as face powder in cosmetic makeup) that is blown into the firebox.
Calderys product for pulverized coal-fired boiler: - WHYTHEAT C is Hydraulic Bonded Alumina & High Purity Dense Castable installed by Vibration casting method. Suitable for Maximum Service Temperature up to 1500° C. It is suitable for Patching applications, best suitable for a pulverized coal-fired boiler.
Rotary Kiln Incinerator: - The rotary kiln incinerator is a rotary combustion chamber that keeps waste moving, thereby allowing it for easier burning.
Calderys product for rotary kiln incinerator: - AC INCAR is best suitable for rotary kiln incinerator because of its chemical inertness to the atmosphere inside the kiln. It is an excellent product to prevent heat loss and to reduce the fuel consumption of the furnace.

Usage of Monolithic Refractory Castables In The Cement Industry
Calciner: - A calciner performs all high-temperature processing in the area of 550 to 1,150°C within its restricted atmosphere. Alternative fuels are burnt in the calciners which makes the calciner one of the most critical vessels in the plant.
Calderys product for calciner: - ACCMON AFR is a low cement castable suitable for Alternative fuels, which is easy to install, has superior resistance to chemical attacks and gives extended service life and is best suitable for calciner.
Dampers: - Dampers are a plate-shaped device that opens or closes to circulate the amount of air that passes through the duct and vents. Cement manufacturing facilities require high-quality dampers to suit the complex operating equipment and also they have to tackle the extreme conditions of high temperatures, debris, and emissions generated.
Calderys product for dampsters:- ACCMON C is High Alumina Low cement castable having specialised high-density aggregates and Binders. Special additives addition is done to enhance the Chemical and Physical Properties of the product and is best suitable for dampers.
Usage of Monolithic Refractory Castables In The Ironmaking Industry
Coal Based Rotary Kiln: -The coal-based direct reduction rotary kiln process was developed for converting iron ore directly into metallic iron without the melting of the materials. The process has the advantage of low capital expenditure and no requirement of coking coal.
Calderys product for coal-based rotary kiln: - ACCMON DAR BC is a High Alumina Low Cement Castable installed through the Vibration casting method, suitable for Maximum Service Temperature up to 1400 Deg C.
Pellet Plant - Grate Kiln: -The Grate Kiln process is a unique process designed to evenly indurate pellets to increase their mechanical properties. This process employs a conventional 'Straight Grate' followed by a 'Rotary Kiln' designed to churn the pellets & thus increase even heating as well to avoid fragmentation in transportation.
Calderys product for pellet plant: -ACCMON 45 is a High Alumina Low Cement Castable installed through the Vibration casting method, suitable for Maximum Service Temperature up to 1550 Deg C.

Usage Monolithic Refractory Castables In The Foundry Industry
Channel Holding Furnaces:- Channel Holding Furnaces combine high productivity with cost-effective operation and provide a regular supply of ready-to-pour metal 24 hours a day. Channel Holding Furnaces are capable of holding large quantities of metal at low holding power levels for extended periods.
Calderys product for channel holding furnaces: - ACCMON 50 ASZ is Zirconia based on special low cement castable which Reduces heat loss & it is non-wetting and has excellent lining life.
Channel press pour Furnace - Iron Foundry:- Pouring furnaces are found in various sizes and configurations, especially where automated moulding lines are used for large scale production.
Calderys product for channel press pour furnace: - SiC bases low cement castable eliminates slag sticking has optimum thermal conductivity and longer campaign life perfectly suitable for channel press pour furnace.
Usage of Monolithic Refractory Castables In the Iron Making Industry
Blast furnaces: - Blast furnaces are used to produce pig iron from iron ore for subsequent processing into steel.
Calderys product for blast furnaces: - ACCGUN 62 BFSM & ACCSHOT 62 M are being used for robotic repair of the blast furnace stacks. ACCSHOT BF HS2 is being used for hearth repair by means of shotcrete technique.
ACCPLAST AI 550 is Alumina based anhydrous grouting with great flowability. It is injected either between the BF shell and the lining or into the interior of the furnace to rebuild the existing lining. An injection is done by using a pump that can push the product at a pressure of around 50 - 60 bars, perfectly suitable for blast furnaces.
Coke Oven: - Coke oven furnace is used for calcination of coal to make coke for iron making.
Calderys product for coke oven:- INSULYTE COD is a Hydraulic Bonded Moderate Density insulating Castable installed through the tamping method. Suitable for Maximum Service Temperature up to 1350° C best for a coke oven.

Usage of Monolithic Castables In the Steel Making Industry: -
Rh Degrasser:- RH degasser is a secondary refining system that removes dissolved gases such as hydrogen present in molten steel to enable the production of high-grade steel.
Calderys product for RH degasser:- CALDE™ MAG GUN G89 consists of a carefully selected mix of natural alpine and high purity natural MgO, in the matrix. The alpine magnesia aggregate results in the best sintering and contributes to the thermo-chemical behaviour of the product. High-grade magnesia is utilised to extract high refractoriness and hot strength. The grain size distribution has been optimized to achieve a maximum density with Gunning & low rebound perfect for RH degasser.
Reheat Furnaces: - Reheating furnaces are used in hot rolling mills to heat the steel stock (Billets, blooms or slabs) to the rolling temperatures of around 1200° C which is suitable for plastic reconstruction of steel and hence for rolling in the mill.
Calderys product for reheat furnaces: - ACCPLAST SSW is a single component, ready to use plastic / mouldable refractory monolithic. Usage of this material aids in an increased life of the furnace due to improved thermal shock resistance and high HMOR of the product which is a prime requirement for reheat furnaces.
Usage of Monolithic Refractory Castables In the Petrochemical Industries
Crude Oil Heaters: - Crude oil heaters are mainly used for the preheating of the crude oils to reduce the viscosity and thereby improve upstream separation performance.
Calderys product for crude Heaters: - INSULYTE LW is a low-density Insulation Castable with a lightweight aggregate designed for Service temperature up to 1100° C, it is easy to install has low thermal conductivity, Superior Energy saving and excellent service life perfectly suitable for crude furnaces.
Primary Reformer: - A reformer is a critical unit for creating high-quality gasoline and ducking the production of low-octane heavy naphtha.
Calderys product for primary reformer: - INSULYTE MW Li is a high purity & low-density Insulation Castable with a lightweight aggregate designed for Service temperature up to 1300° C perfectly suitable for primary reformers.

Calderys is a wholly-owned subsidiary of Imerys, the world leader in mineral-based specialities for industry. For any type of Refractory solutions requirement, you can visit their online product library
on http://www.caldezone.com/
or contact the company's corporate office at:
Calderys India Refractories Ltd
6th Floor, Fidvi Tower, Opp. Saraf
Chambers, Mount Road, Sadar, Nagpur -440001, Maharashtra, India
Telephone 0712 - 2811600 / 7391052888
Email ID: caldezone.india@calderys.com