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Ultra Low Cement Castables

Salient Features

• Low CaO content ensures high refractoriness.

• Excellent ho: strength and MOR all temperature.

• Lower apparent porosity after firing offers better corrosion resistance.

• High abrasion and spalling resistance.

• High Volume Stability.

UC 45 UC 95
Physical Properties
Max Service Temparature 0C 1550 1750
Density gm /cc (min) 2.35 3.05

Dried at 110 0 C
Water required for casting % by weight of castable 5.3 - 5.7 4.0 - 4.7
Cold Crushing Strength kg/cm 2 (min.)

110 o C/24 hrs 375 450

800°C/3 hrs 800 1150

1100°C/3 hrs 825 1200

1450°C/3 hrs 825 1300

1550°C/3 hrs 900 1450


Modulus of Rupture k/ cm 2 (min)

1100 C/24 hrs 80 85

800°C/3 hrs 125 160

1100°C/3 hrs 130 200

1450°C/3 hrs 130 225

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1550°C/3 hrs 140 250


P. L. C.% (max)

800°C/3 hrs Nil Nil

1100°C/3 hrs 0.2 Nil

1450°C/3 hrs 0.3 0.4

1550°C/3 hrs 0.7 0.6


Thermal conductivity

k cal/m/hr/ ° C (min) (hot face)

400°C 1.0 1.8

600°C 1.1 1.9

800°C 1.2 2.0

1000°C 1.3 2.1

1200°C 1.4 2.2


Chemical Anayalasis
Al 2 O 3 (%) max 43 90
SiO 2 (%) max 50 68
Fe 2 O 3 (%) max 0.7 1.3
CaO (%) max 0.7-0.8 0.3 – 0.5

UC9S
Physical Properties
Water required for casting 3.8-404
Bulk Density gm/cc (min) 2.9
Modulus of Rupture kg/cm 2 (min)

110 o C/24 Hrs 80

800 o C/3 Hrs 150

110 o C/3 Hrs 200

1550 o C/3 Hrs 250


Cold Crusting Strength kg/cm 2 (min)

110 o C/24 Hrs 0.2

800 o C/3 Hrs 0.5

1100 o C/3 Hrs 1.0

1550 o C/3 Hrs


P.L.C. % (max)

800 o C/3 Hrs 0.2

1100 o C/3 Hrs 0.5

1550oC/3 Hrs 1.0


Thermal Conductivity

K cal/m/hr/ o C(max)(hot face)

800 o C 2.0

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Chemical Analysis
Al 2 O 3 (%) max 92.0
Fe 2 O 3 (%) max 0.5
SiO 2 (%) max 7.0
CaO (%) max 0.5

UC 40 UC 90
Physical Properties
Max Service Temparature 0C 1500 1700
Density gm /cc (min)
2.25 2.95
Dried at 110 0 C
Water required for casting % by weight of castable 5.5 - 6.0 3.8 - 4.0
Cold Crushing Strength kg/cm 2 (min.)

110 o C/24 hrs 450 450

800°C/3 hrs 740 1150

1100°C/3 hrs 900 1200

1450°C/3 hrs 900 1300

1550°C/3 hrs 950 1450


Modulus of Rupture k/ cm 2 (min)

1100 C/24 hrs 70 75

800°C/3 hrs 100 325

1100°C/3 hrs 100 350

1450°C/3 hrs 100 360

1550°C/3 hrs 110 430


P. L. C.% (max)

800°C/3 hrs Nil 0.2

1100°C/3 hrs 0.3 0.2

1450°C/3 hrs 0.4 0.4

1550°C/3 hrs 0.7 0.6


Thermal conductivity

k cal/m/hr/ o C (min) (hot face)

400°C. 1.0 1.8

600°C. 1.1 1.9

800°C. 1.2 2.0

1000°C 1.3 2.1

1200°C 1.4 2.2


Chemical Anayalasis
Al 2 O 3 (%) max 40.0 90.0
SiO 2 (%) max 50.0 5.0
Fe 2 O 3 (%) max 0.7 1.5
CaO (%) max Nil Nil

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Note: Data represents average physical properties and do not constitute a specification

ACCMON
ACC has pioneered a series of refractories and castables, developed indigenously by the company's R & D division. ACCMON is
another pioneering, in-house development. Regarded as a revolutionary advance, Compared with the conventional range of similar
products, ACCMON is designed to break new ground in castable applications.

Low lime content


Less cement means less lime content which also means reduced fear of linings weakening under pressures of high temperatures.

Low porosity
Less cement also means less water is required when using ACCMON castables. This, in turn, reduces porosity by almost 50% -
against conventional varieties. This results in products with high density and low porosity.

High Strength
Less cement/lime ensures that aggregates are in direct contact with the surface of the lining. This results in extraordinary strength
for ACCMON castables.

Decreased cost
Replacing the conventional range of refractory products with ACCMON reduces installation and material costs- a direct consequence
of longer lining life with ACCMON castables.

ACCMON is offered in three varieties: Low Cement, Ultra low Cement No Cement castables each for a specific use.

Application
The utility of monolithic refractories is now well established. With the excellent properties and maturity of ACCMON castables, more
and more application for monolithic refractories are envisaged.

PROPERTIES ACCMON ACCMON ACCMON ACCMON ACCMON ACCMON


LC-45 LC-60 LC-70 LC-80 LC-90 LC-95
Refractoriness Orlon/ o C 32(1717) 36(1804) 36(1804) +36(+1804) 37(1820) +40(1900)

Maximum Service Temperature °


1550 1600 1600 1650 1700 +1800
C
Chemical Analysis %

Al 2 O 3 (%) min 45.0 60.0 70.0 80.0 90.0 94.0

Fe 2 O 3 (%) max 0.8-1.0 1.5 1.5 1.8 0.8-1.0 0.3

Dry Density (gm/cc) min 110 o C 2.3 2.6 2.7 2.85 3.0 3.1

Cold Crushing Strength (kg/cm 2 )

at 110 o C 750 750 750 800 950 1000

at 800 o C 800 800 800 900 1000 1050

at 1100 o C 900 900 900 1000 1150 1100

at 1500 o C 1000 1000 1000 - - -

at 1550 o C - - - 1200 1200 1250


P.L.C%(Max)

at 800 o C +/-0.2 +/-0.2 +/-0.2 +/-0.2 +/-0.2 +/-0.2

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at 1100 o C +/-0.3 +/-0.3 +/-0.3 +/-0.3 +/-0.3 +/-0.3

at 1500 o C +/-1.0 - - - - -

at 1550 o C - - +/-0.8 +/-0.6 +/-0.5 +/-0.5


% Water Required for casting 6-6.5 6.5 6.5 5.0-5.5 4.5-5.0 4.0-4.5

Maximum Grain size(mm) 6 6 6 6 6 6

Note: -Data represents typical average properties and do not constitute a specification.

WHYTHEAT CASTABLES
Classification

WHYTHEAT castables are product at present in 3 grades, designated as WHYTHEAT A, WHYTHEAT K, and WHYTHEAT C, All contain
the special high-purity, high alumina refractory binder CAL-AL-75. Typical properties of WHYTHEAT A, WHYTHEAT K and WHYHEAT
C, including data on strength, conductivity and chemical composition are given below Each grade of WHYTHEAT castables is used
for a specific service temperature and environment.

WHYTHEAT A

WHYTHEAT A is a high purity, high alumina castable of exceptional Quality with an AIE03 content of over 90% arid with very low
silica and iron contents. Hence, it is used for service temperatures upto 1750°C and can resist attack from process gas atmospheres
containing carbon monoxide and hydrogen.

WHYTHEAT K

WHYTHEAT K, which has alumina content of 60%, can be used for service temperatures upto 1600°C. This c astable also has a low
iron content and can resist carbon monoxide attack.

WHYTHEAT C

WHYTHEAT C is a castable with about 50% alumina and serves as a general purpose high temperature testable castable required for
service temperatures upto 1500°C

Beside, Whytheat has castables are offered in higher strength and with special properties and applications.

WHYTHEAT ‘K' & ‘C' High strength for withstanding better SPECIAL abrasion attack WHYTHEAT 'A' (FH) Facilitates quick startup,
slashes downtime in critical shutdowns & minimises production loss.

WHYTHEAT ‘M' Highly cost effective castable for oxidizing atmosphere for services temperature upto 1700°C.

WHYTHEAT - A WHYTHEAT - K WHYTHEAT - C


Recommended Service 1750 1600 1500
Temp.°C(max)
Refractoriness °C(min) 1800 1680 1650
Dry Density Kg/M 3 (Min) 2800 2200 2100
Linear Change % (max) ±1.5 ±1.5 ±1.0

1550°C 1550°C 1500°C

3hrs 3hrs 3hrs


CCS Kg/Cm 2 (min) 110 o C 550 350 350
Chemical Analysis %

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Al 2 O 3 (%) min 90 60 50

Fe 2 O 3 (%) max 0.8 1.0 1.5

Maximum Grain Size (mm) 5 5 5

Note: CCS and linear change values are on 4 x 4 x 16 cm prisms.

Above are average test data subject to reasonable variations.

FIRECRETES
Fire creates are scientifically designed ready mixed castables made from ACC's CALUNDUM - a medium purity calcium aluminate
binder and selected refractory grog. These retractory castables are hydraulic-setting, and can be cast or moulded to any shape and
also used for gunning of furnace linings.

Classification

Firecrete castable are produced at present in three standard grades designated as Firecrete, Firecrete Special & Firecrete Super.

Tailor-made grades to customer's specifications are also produced

FIRECRETE

Firecrete is a refractory castable with 45% Al2O3 and will have a Fe2O3 Content of 4% (max). It can be used in oxidising atmosphere
for service upto temperatures of 1400°C.

FIRECRETE SPECIAL

Firecrete Special is a refractory castable with 45% Al2O3 and Fe2O3 of 4% (max). This castable develops high strengths for abrasion
resistance applications and withstands service temperatures upto 1350°C in oxidising atmospheres.

FIRECRETE SUPER

Firecrete Super is a superior refractory castable of medium purity having Al2O3 content of 70% and Fe2O3 content ol 5% (max). This
can withstand service temperatures of 1450°C in oxi dising atmospheres.

FIRECRETE FIRECRETE FIRECRETE LT CASTABLE


SUPER SPECIAL
Recommended Service
1400 1450 1350 500
Temp.°C(max)
Refractoriness °C(min) 1580 1680 1450 -
Dry Density Kg/M 3 (Min) 2100 2500 2250 2200
Linear Change % (max) ±1.0 ±1.0 ±0.8

1400°C/2hrs 1400°C/3hrs 1500°C/3hrs -


CCS Kg/Cm 2

(min) 110 o C 250 350 400 400

1350 o C 225 - 300 500(200 o C)

1450 o C - 450 - 400(400 o C)


Chemical Analysis %

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Al 2 O 3 (%) min 45 70 45 -

Fe 2 O 3 (%) max 4 5 4 -
Maximum Grain Size (mm) 5 5 5 5

Note: Above are average test data subject to reasonable variations.

*Coarse grading can be supplied on request.

Note: -Data represents typical average properties and do not constitute a specification.

INSULYTE CASTABLES LOW IRON

INSULYTE INSULYTE INSULYTE INSULYTE INSULYTE INSULYTE


PROPERTIES
7 9 9HS 11 13 15
Recommended Service Temp.
1100 1100 1100 1350 1350 1350
( °C )

Dry Density (Kg/M 3 ) 750 - 850 900 - 1000 900 - 1000 1100 - 1250 1300 - 1450 1500 - 1600

Thermal Conductivity
0.14 0.28 0.28 0.31 0.33 0.44
(K Cal/m/hr/ ° C)
CCS(Kg/Cm 2 )

110 ° C 12 - 14 15 - 20 20 - 25 50 - 60 90 - 100 90 – 100

800 ° C 4 -6 6-8 8 - 10 30 - 40 60 - 70 60 – 70

1100 ° C 6-8 10 -14 15 - 20 30 - 40 60 – 70 60 – 70

1300 ° C - - - 50 - 70 70 - 90 70 - 90
PLC (%)

110 ° C - - - - - -

500 ° C - +/-0.2 - - - -

800 ° C +/-1.0 +/-0.6 - - - -

1100 ° C +/-1.6 +/-1.0 +/-1.5 +/-0.2 +/-0.2 +/-0.2

1300 ° C - - - +/-1.0 +/-0.6 +/-0.6

Fe 2 O 3 (%) max 8.5 6 3 3.5 3.5 3.2

Note: CCS and PLC values are on 4 x 4 x 16 cm prisms. Thermal Conductivity — prefired hot face 500 ° C.

INSULYTES CASTABLES LOW IRON

INSULYTE INSULYTE INSULYTE INSULYTE INSULYTE


PROPERTIES
11 LI 11 LI(z) 11-SPL 13 LI 15 LI
Recommended Service Temp.
1350 1300 1350 1350 1350
( ° C)

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1100 - 1080 -
Dry Density (Kg/M 3 ) 900 - 1000 1300 - 1450 1500 - 1600
1250 1100
Thermal Conductivity
0.34 0.22 0.30 0.40 0.44
(K Cal/m/hr/ ° C)
CCS(Kg/Cm 2 )

110 ° C 45 - 55 10 - 15 30 - 40 80 - 100 130 - 50

800 ° C 30- 35 5-7 25 - 30 40 - 50 75 - 80

1100 ° C 30 - 40 6 - 10 25 - 30 40- 50 75 - 80

1300 ° C 50 - 60 15 - 25 35 - 40 40 - 50 90 - 100
PLC (%)

110 ° C - - - - -

500 ° C - - - - -

800 ° C - - - - +/-0.2

1100 ° C +/-0.2 +/-1.0 +/-0.2 +/-0.2 +/-0.5

1300 ° C +/-1.0 +/-1.5 +/-1.0 +/-0.6 +/-1.0


Fe 2 O 3 (%) max 1.5 1.2 1.5 1.5 1.5

Note: CCS and PLC values are on 4 x 4 x 16 cm prisms. Thermal Conductivity - pre-fired hot face 500 ° C.
Note: - Data represents typical average properties and do not constitute a specification.

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