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Kalyani Systems

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08048064588

E-mail :
kalyanisystems@rediffmail.com

Kalyani Systems

Castables




These are dry mix hydraulic compositions of graded refractory aggregates with a suitable bonding material, Fillers & (/or) special Additives. On addition of the prescribed quantity of water to these compositions, a wet concrete-like mass is produced which forms useful castables. Ceramic bond is developed when the same is fired at a certain high temperature.

Available Grades of Refractory Castables :

  • Medium purity castables
  • High Purity Dense Castables
  • Low Cement Castables
  • Insulating Castables


High Purity Dense Castables :

  • Ideal for High Temperature applications
  • Available in various grades with low iron content
  • Used for a specific range of operational conditions
  • Hydraulically set with easily mouldable and castable shapes
  • Specifically designed for diverse combustion conditions
  • Applicable for both back-up and furnace exposure


Medium Purity Castables :

  • Ideal for Medium Temperature applications
  • Used in oxidizing atmosphere
  • Hydraulically set, with easily moldable shape
  • Used in : Boiler work, general furnace, burner blocks etc.

 

Low Cement Castables :

  • Low cement concentration
  • Excellent physical properties
    • Low porosity
    • High strength
    • Good abrasion resistance
  • Ideal for
    • Refractory abuses due to abrasion
    • High temperature applications


Insulating Castables :

  • Low densities  are light
  • Adequately strong and of low conductivity
  • Serving as hot face or backup insulating refractory lining used in reduced conditions.
  • Low to medium strength
  • Tailored varieties are also supplied to customer’s requirements.
  • Substitutes for varieties of imported castables.


Characteristics :

  • Low thermal conductivity
  • Superior quality
  • Long functional life
  • Easy to use


Applications :

  • Steel industry
  • Cement industry
  • Foundries
  • Sponge Iron
  • Ceramics industry
  • Non-Ferrous industry
  • Power Plants
  • Petrochemical
  • Chemical Plants
  • Rolling Mills
  • Glass industry


Medium Purity Castables

Particulars KSCRETE
LT
KSCRETE
Normal
KSCRETE Super KSCRETE Special
Service temp. oC (Max.) 800 1400 1450 1350
Refractoriness oC (Min.) 1350 1564 1683 1450
Bulk Density (gm/cc) (Min.) (Sample, cast, cured, dried at 1100°C) 1.8 2.0 2.4 2.2
Permanent Linear Change (%) (Max.) (at Service Temp.) ± 1.0 ± 1.0 ± 1.5 ± 1.0
Cold Crushing Strength Kgf/cm2 (Min.) at
110oC
1350oC
1450oC

250

220 (at

500oC)

250

225

-

350

-

450

400

300

-


Al2O3 (%) (Min.)
30.0 45.0 70.0 45.0
Fe2O3 (Max.) 4.0 5.0 4.0 4.0
Grain Size (mm) (Max.) 5.0 5.0 5.0 5.0

High Purity Dense Castables

Particulars

KSHEAT
A

KSHEAT
80

KSHEAT K

KSHEAT
C

KSHEAT A Super

KSHEAT
K Super

KSHEAT C Super

KSHEAT (HA)

KSHEAT
(HA
Plus)

Service temp. oC (Max.)

1750

1700

1600

1500

1750

1600

1500

1800

1850

RefractorinessoC
(Min.)

1820

1804

1683

1665

1820

1683

1665

1835

1835

Bulk Density (gm/cc) (Min.) (dried at 110o C)

2.8

2.65

2.2

2.1

2.75

2.0

2.0

2.75

2.75

Permanent Linear
Change (%) (Max.)

± 1.0
(at 1550 oC)

± 1.0
(at 1450 oC)

± 1.0
(at 1550 oC)

± 1.0
(at 1550 oC)

± 1.0
(at 1550 oC)

± 1.0
(at 1550 oC)

± 1.0
(at 1550 oC)

± 1.0
(at 1550 oC)

± 1.0
(at 1550 oC)

Cold Crushing
Strength Kgf/cm² (Min.) at 110o C

600

550

350

350

650

450

400

600

400


Al2O3 (%) (Min.)
 

90.0
 

80.0
 

60.0
 

50.0
 

88.0
 

60.0
 

50.0
 

94.3
 

96.0
 

Fe2O3 (Max.)

0.8

1.3

1.0

1.5

0.7

1.5

1.0

0.3

0.3

Grain Size (mm) (Max.)

5.0

5.0

5.0

5.0

5.0

5.0

5.0

5.0

5.0


Low Cement Castables

Particulars KSMON LC 45 KSMON LC 60 KSMON LC 70 KSMON LC 80 KSMON LC 90 KSMON LC 90 ABR KSMON LC 95 KSMON ULCC 90
Service temp1100C (Max.) 1550 1600 1600 1700 1700 1750 +1800 1750
Refractoriness110 0C (Min.) 1717 1804 1804 1820 1820 1820 1835 1835
Bulk Density (gm/cc) (Min.) (dried at 1100C) 2.3 2.6 2.7 2.9 3.0 2.90 3.1 3.0
Permanent Linear Change (%) (Max.). (Temp x 3 Hrs) + 1.0 (at 1500C + 1.0 (at 15000C) + 1.0 (at 15000C) + 0.8 (at 15000C) + 0.8 (at 15000C) + 0.8 (at 15000C) + 0.8 (at 15000C) + 0.8 (at 15000C)
Cold Crushing Strength Kgf/cm (Min.)at
1100C
11000C
15000C



700
900
1000



750
900
1000



750
900
1000



800
1000
1200



950
1100
1200



950
1150
1250



1000
1100
1200



450
1150
1450
Al2O3 (%) (Min.) 4.5 60.0 70.0 80.0 90.0 90.0 94.0 90.0
Fe2O3 (Max.) 1.0 1.5 1.5 1.8 1.0 1.0 0.3 1.4
Grain Size (mm) (Max.) 6.0 6.0 6.0 6.0 6.0 10.0 6.0 6.0
Water Reqd. for Casting (%) 4.8-5.5 4.7-5.4 4.7-5.4 4.5-5.2 4.2-5.0 4.2-5.0 4.2-5.0 4.0-4.8

Insulating Castables

Particulars KSLYTE
7
KSLYTE
9
KSLYTE
11
KSLYTE
13
KSLYTE
15
KSLYTE
11 LI
KSLYTE
13 LI
KSLYTE
15 LI
Service temp. oC (Max.) 1100 1200 1300 1350 1350 1350 1400 1400
Refractoriness oC (Min.)
1337

1398

1398

1398

1430

1398

1430

1430
Bulk Density (gm/cc) (Max.) (dried at 110 oC)
0.85

1.0
1.25 1.45 1.6 1.25 1.45 1.6
Permanent Linear
Change (%) (Max.). (Temp x 3 Hrs)

± 1.2
(at 1100oC)

± 1.0
(at 1200oC)

± 1.0
(at 1300oC)

± 0.7
(at 1300oC)

± 1.0
(at 1300oC)

± 1.0
(at 1300oC)

± 0.7
(at 1350oC)

± 1.0
(at 1350oC)
Cold Crushing Strength Kgf/cm² (Min.) at
110oC
800oC
1100oC
1300oC

12
4
6
-

15
6
10
-

35
25
25
40

50
30
30
50

90
60
60
70

45
30
30
50

80
40
40
45

130
75
75
90
Thermal Conductivity
(Kcal/m²/hr/m/oC)
(Max.)

0.17

0.26

0.3

0.32 0.42 0.32 0.38 0.44

Fe2O3 (%) (Max.)

8.5

6.0
3.5 3.5 3.5 1.5 1.5 1.5
Grain Size (mm) (Max.)
6.0

6.0
6 6 6 6 6 6
Water Required for casting ( %)
60-65

38-43

29-34

26-31

23-28

30-35

27-32

23-28