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Transcript of Alumina Bricks
PRODUCTSDATA SHEETS
We Are, Where Heat Is On...
Chotila Road, Thangadh - 363 530, Gujarat, India.
Phone : 02751 220371 Fax : +91 (2751) 220771
E Mail : [email protected]
Visit us at : www.ec21.com/jaycera
JAY CERAMICS
INDUSTRIES WE SERVE
We supply our prouducts and provide our services to a variety of companies. Some of the Industries we serve include :
JAY CERAMICS
Aluminium Industries
Cement Industires
Ceramic Industries
Chemicals Plants
Dairy Plants
Electroplating Industries
Fertilizers Plants
Forging Plants
Foundry Industries
Galvanizing
Glass Industries
Heat Treatment Plants
Insulation
Iron & Steel Industries
Oil Refineries
Paints Industries
Paper Industries
Petrochemicals Plants
Petroleum Industries
Plastics Industries
Porcelain Industries
Refractories Industries
Rolling Mills
Rubber Plants
Soap
Sugar Plants
Textiles Plants
Tiles Industries
Manufacturers of Refractories & Kiln Furniture
04
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18
19
01 Technical data on Jay AL - 40%
02 Technical data on Jay AL - 50%
03 Technical data on Jay AL - 60%
04 Technical data on Jay AL - 70%
05 Standard shape & size of Fire Bricks
06 Standard shape of Fire Bricks (Drawings)
07 Standard shape & size of Fire Tiles
08 Standard shape & size of Burner Blocks
09 Product data on Mortars
10 Product data on Insulating bricks
11 Furnace tempratures
12 Colour scale for tempratures
13 Calculation for bricks required per unit volume
14 Calculation for bricks required per sq. foot
15 Combinations to form a ring with two sizes of brick
16 Radial brick formulas
17 Table for use in Designing Radial type brick
18 Elements of Arches
19 Inquiry Form
No. Contents Page No.
JAY CERAMICS
JAY CERAMICS
TECHNICAL DATAJAY AL - 40%
CHEMICAL ANALYSIS
38.00 - 40.00%
38.00 - 42.00%
Max . 3.10%
2.90 - 3.50%
1.00 - 1.50%
Alumina Al O2 3
Silica SiO2
Ferric Oxide Fe O2 3
Titania TiO2
Calcia CaO
PHYSICAL PROPERTIES
Pyrometric Cone Equivalent, Ortron º Reheat change - at 1400 C - 2Hrs, %
Refractoriness under Load - ta Value
Apparent Porosity % 3
Bulk Density, gm /cm 2Cold Crushing, Strength, Kg/cm
º Thermal Conductivity, W/Mok at 650 C º at 1000 C
º ........... Min. 32 (1743 C)
........... Max. (+/-) 0.5%º
........... Min 1400 C
........... 17.0 - 20.0%
........... 2.30 - 2.50
........... 400 - 600
........... 1.70
........... 1.60
THE ABOVE TEST DATA are based on average results of Control tests on dry pressed standard
size bricks and are subject to normal variation on individual tests, hence these results shuold not
be regarded as absolute limits.
IMPORTANT NOTE
JAY AL - 40% is 40% Alumina Brick based on calcined bauxite of Rotary Kiln with
good thermal spalling resistance, medium porosity and good mechnical streingth.
Applications includes Cement Rotary Kilns, Reheat Furnaces, Metallurgical Furnaces,
Boiler Furnaces, Linings for general purpose usein steel plants including Tundish
Lining and Ceramic Kilns.
Page No.: 04
JAY CERAMICS
Page No.: 05
TECHNICAL DATAJAY AL - 50%
CHEMICAL ANALYSIS
PHYSICAL PROPERTIES
Pyrometric Cone Equivalent, Ortron º Reheat change - at 1400 C - 2Hrs, %
Refractoriness under Load - ta Value
Apparent Porosity. % 3
Bulk Density, gm/cm 2
Cold Crushing, Strength, Kg/cm º
Thermal Conductivity, W/Mok at 650 C º at 1000 C
º .......... Min. 33 (1743 C)
.......... Max. (+/-) 0.5%º .......... Min 1400 C
.......... 17.0 - 20.0%
.......... 2.30 - 2.50
.......... 400 - 600
.......... 1.70
.......... 1.60
48.00 - 53.00%
38.00 - 42.00%
Max . 3.10%
2.90 - 3.50%
1.00 - 1.50%
Alumina Al O2 3
Silica SiO2
Ferric Oxide Fe O2 3
Titania TiO2
Calcia CaO
JAY AL - 50% is 50% Alumina Brick based on calcined bauxite of Rotary Kiln with
good thermal spalling resistance, low porosity and excellent mechanical strength,
Applications includes Cement Rotary Kilns, Reheat Furnaces, Metallurgical Furnaces,
Boiler Furnaces, Rosting Kilns, Linings for general purpose use in steel plants including
Tundish Lining and Ceramic Kilns.
THE ABOVE TEST DATA are based on average results of Control tests on dry pressed standard
size bricks and are subject to normal variation on individual tests, hence these results shuold not
be regarded as absolute limits.
IMPORTANT NOTE
JAY CERAMICS
Page No.: 06
TECHNICAL DATAJAY AL - 60%
º .......... Min. 35 (1785 C)
.......... Max. (+/-) 0.5%º º
.......... 1420 - 1450 C
.......... 19.0 - 22.0%
.......... 2.45 - 2.60
.......... 400 - 600
.......... 1.40
........... 1.20
Pyrometric Cone Equivalent, Ortronº Reheat change - at 1400 C - 2Hrs, %
Refractories under Load - ta Value
Apparent Porosity. %3
Bulk Density, gm/cm2Cold Crushing, Strength, Kg/cm
º Thermal Conductivity, W/Mok at 700 Cº at 900 C
CHEMICAL ANALYSIS
PHYSICAL PROPERTIES
Alumina Al O2 3
Silica SiO2
Ferric Oxide Fe O2 3
Titania TiO2
Calcia CaO
58.00 - 62.00%
31.00 - 35.00%
2.50 - 3.10%
2.75 - 3.00%
0.50 - 1.70%
JAY AL - 60% is high Alumina Brick having 60% Alumina Contents based on Refractory grade bauxite calcined in Rotary kiln, High density and excellent
strength, featuring low alkali contents, applications includes Cement and Lime
Rotary and Saft Kilns, Re-heat Furnace, Incinerators, Ceramic Kilns, Boiler
Furnaces, Reverbertory air or holding Furnaces.
THE ABOVE TEST DATA are based on average results of Control tests on dry pressed standard
size bricks and are subject to normal variation on individual tests, hence these results shuold not
be regarded as absolute limits.
IMPORTANT NOTE
JAY CERAMICS
Page No.: 07
TECHNICAL DATAJAY AL - 70%
Pyrometric Cone Equivalent, OrtronºReheat change - at 1400 C - 2Hrs, %
Refractories under Load - ta Valueº Spalling Test, Water quench - 1300 C
Apparent Porosity. %3
Bulk Density, gm/cm2
Cold Crushing, Strength, Kg/cmº
Thermal Conductivity, W/Mok at 650 Cº at 1000 C
º .......... Min. 36 (1804 C)
.......... Max. (+/-) 2.5%º º .......... 1430 - 1480 C
.......... Min 10 Cycles
.......... 18.0 - 22.0%
.......... 2.65 - 2.75
.......... Min 500
.......... 1.60
........... 1.65
CHEMICAL ANALYSIS
PHYSICAL PROPERTIES
68.00 - 73.00%
19.00 - 25.00%
2.80 - 3.20%
3.40 - 3.90%
1.50 - 2.00%
Alumina Al O2 3
Silica SiO2
Ferric Oxide Fe O2 3
Titania TiO2
Calcia CaO
JAY AL - 70% is dense, low porosity, 70% Alumina Brick based on Refractory grade
bauxite calcined in Rotary kiln with excellent resistance to spalling, corrosive slags and
hot metals, Successful applications in Burning zone linings of Tunnel Kiln and Hot Air
Generators, Electric Arc Furnace Roof Steel Teeming Laddles, Induction Furnace,
Sugar Mills, Chemical Plants and many others.
THE ABOVE TEST DATA are based on average results of Control tests on dry pressed standard
size bricks and are subject to normal variation on individual tests, hence these results shuold not
be regarded as absolute limits.
IMPORTANT NOTE
JAY CERAMICS
STANDARD SHAPE AND SIZE OF BRICKS.
Page No.: 08
ARCH BRICKS
C
AB
END ARCH
A
B
C
D
ACB
D
SIDE ARCH
KEY
C
D
A
B
SIDE SKEW
B
D
A
C
END SKEW
D
A
B
C
A B C A B C1
9" x 4 / " x 3"2
1 19" x 4 / " x 2 / "2 2
1 19" x 4 / " x 1 / "2 2
1 9" x 4 / " x 1"2
1 9" x 4 / " x 2"2
230 x 115 x 75
230 x 115 x 65
230 x 115 x 50
230 x 115 x 40
230 x 115 x 25
Dimension in Inches Dimension in Milimetres
19" x 4 / " x 3" x 2.75" 2
1 19" x 4 / " x 3" x 2 / " 2 2
1 19" x 4 / " x 3" x 2 / " 2 4
1 19" x 4 / " x 3" x 1 / " 2 2
1 19" x 4 / " x 3" x 1 / " 2 4
1 19" x 4 / " x 3" x / " 2 4
19" x 4 / " x 3" x 1" 2
19" x 4 / " x 3" x 2" 2
19" x 4 / " x 3" x 1.75" 2
230 x 115 x 75 x 70
230 x 115 x 75 x 65
230 x 115 x 75 x 55
230 x 115 x 75 x 50
230 x 115 x 75 x 45
230 x 115 x 75 x 40
230 x 115 x 75 x 30
230 x 115 x 75 x 25
230 x 115 x 75 x 06
A B C DA B C D
JAY CERAMICS
Page No.: 09
STANDARD SHAPE AND SIZE OF FIRE TILES
STANDARD SHAPE AND SIZE OF BURNER BLOCKS
Dimension in Inches Dimension in Milimetres
A B C A B C
230 x 230 x 75
310 x 310 x 75
385 x 310 x 75
460 x 310 x 75
620 x 310 x 75
385 x 385 x 75
460 x 460 x 75
620 x 460 x 75
310 x 310 x 150
460 x 310 x 150
620 x 310 x 150
310 x 310 x 115
Hole Size
6" x 4"
8" x 4"
10" x 4"
10" x 6"
1 15 / " x 5 / "2 2
Size
9" x 9" x 9"
9" x 9" x 9"
12" x 12" x 12"
14" x 14" x 14"
15" x 15" x 15"
Design
Standard
Wesman
Standard
Wesman
Standard
9" x 9" x 3"
12" x 12" x 3"
15" x 12" x 3"
18" x 12" x 3"
24" x 12" x 3"
15" x 15" x 3"
18" x 18" x 3"
24" x 18" x 3"
12" x 12" x 6"
18" x 12" x 6"
24" x 12" x 6"
12" x 12" x 4.5"
FIRE TILES
C
AB
JAY CERAMICS
Page No.: 10
BEVEL BRICK
CIRCLE BRICK
END ARCH
FEADHER END ON EDGE
SIDE ARCH
LARGE FACE / FLAT
EDGE / SIDE
END FACE
STANDARD SQUARE SPRINGER / SKEW BACK
SPLIT OR SCONESPLIT OR SCONE WHELP
FEADHER SIDE KEY BRICK PUP,SOAP OR CLOSER
END SKEW ON FLAT FEADHER END
CIRCLE BRICK ONE EDGE DOME BRICK
BONDER BULLENOSE ORJAMB BRICK
JAY CERAMICS
MORTARS
INSULATING BRICK
Analysis Cold Face Hot Face
Bulk Density (Max.)(gm/cc)
Apparent Porosity (Min.) %(Volume)
Cold Crushing Strenghth2
(Min. Kg/cm )
Al O (Min.) %2 3
Fe O (Min.) %2 3
OService Temperature C
Permenent Linear ChangerO
( < 2% at C for 2 hrs.)
Thermal Conductivity (Max.)O O O
(Kcal/mh C at 350 C + 10 C)
0.7 + 0.05
70
10
35
2.0
1250
1200
0.20
1.0 + 0.05
58
30
45
1.5
1400
1350
0.30
Page No.: 11
Jay - 30 30 2.0 30 0 - .0.5
Jay - 40 40 2.0 32 0 - .0.5
Jay - 50 50 2.5 34 0 - .0.5
Jay - 60 60 3.0 35 0 - .0.5
Jay - 70 70 3.5 37 0 - .0.5
Jay - 80 80 3.5 38 0 - .0.5
TypeAl2O3
%(Min.)
Fe2O3%
(Max.)
PCE(o.c.)(Min.)
Grain Size(mm.)
Page No.: 12
FURNACE TEMPERATURES
DEGREES C DEGREES FKIND OF FURNACES
Boilers................................................
By - Product Coke Ovens..................
Cement Kilns, Hot Zone.....................
Copper Converters.............................
Copper Refining Furnaces.................
Copper Reverberatories....................
Copper Roasters................................
Gas Producer.....................................
Gas Annealing Furnaces...................
Glass Tanks-bottle.............................
Glass Tanks-plate..............................
Iron and Steel Furnaces :
Annealing Oven............................
Blast Furnaces, tapping................
Bessemer Converter.....................
Electric Furnaces..........................
Heating Furnaces.........................
Malleable Furnaces......................
Open Hearths
Melting Chamber......................
Checkers..................................
Soaking Pits.............................
1000 to 1600 1800 to 2900
1000 to 1500 1830 to 2730
1300 to 1600 2400 to 2900
1200 to 1300 2200 to 2400
1250 to 1550 2300 to 2800
1300 to 1570 2400 to 2850
700 to 810 1300 to 1500
1260 to 1370 2300 to 2500
430 to 540 800 to 1000
1370 to 1600 2500 to 2900
1370 to 1650 2500 to 3000
760 to 980 1400 to 1800
1370 to 1540 2500 to 2800
1540 to 1650 2800 to 3000
1450 to 1700 2650 to 3100
980 to 1310 1800 to 2400
1300 to 1650 2400 to 3000
650 to 1680 1200 to 3050
200 to 1430 400 to 2600
1150 to 1370 2100 to 2500
Lowest Visible Red............................
Lowest Visible Red to Dark Red........
Dark Red to Cherry Red....................
Cherry Red to Bright Cherry Red......
Bright Cherry Red to Orange.............
Orange to Yellow ...............................
Yellow to Light Yellow.........................
Light Yellow to White..........................
White to Dazzling White.....................
475 885
475 to 650 885 to 1200
650 to 750 1200 to 1380
750 to 815 1380 to 1500
815 to 900 1500 to 1650
900 to 1090 1650 to 2000
1090 to 1315 2000 to 2400
1315 to 1540 2400 to 2800
1540 to ......... 2800 to ........
COLOUR SCALE FOR TEMPERATURES
JAY CERAMICS
JAY CERAMICS
Page No.: 13
CALCULATION FOR BRICKS REQUIRED PER UNIT VOLUME
BRICKS REQUIRED PER SQ. FEET OF WALL
A Cubic Metre 513 Nos.
Of Brickwork requires 230 X 115 X 75mm Strainghts
A Cubic Feet 14.2 Nos.1Of Brickwork requires 9" X 4 / " X 3" Straights2
Volume of 1000 Nos. standard
230 X 115 X 75 mm Straights
Closly stacked (approx.) 1.95 Cubic metres
Volume of 1000 Nos. Standard1
9" X 4 / " X 3" Straights2
Closly Stacked (approx.) 71 Cubic Feet
65 mm. (2.5")
75 mm. (3.0")
115 mm. (4.5")
230 mm. (9.0")
340 mm. (13.5")
460 mm. (18.0")
575 mm. (22.5")
690 mm. (27.0")
..........
3.56
5.30
10.70
16.00
21.30
26.70
32.00
3.56
........
6.40
12.80
19.20
25.60
32.00
38.40
Wall Thickness 230 x 113 x 65 mm 230 x 113 x 75 mm
Page No.: 14
COMBINATIONS TO FORM A RINGWITH TWO SIZES OF BRICK
A - A radial brick used with a streight or another radial B, which turns a larger circle than A.
B - A streight brick or a radial brick which turns a larger circle than A, both a and B forming
the same thickness of arch T.
T - The thickness of the arch formed by A and B.
C - The outside chord of brick A.
c - The outside chord of brick B.
E - The inside chord of brick A.
e - The inside chord of brick B.
D - Given outside diameter of desired ring.
d - Given inside diameter of desired ring.
G - Outside diameter of ringformed by radial brick A alone.
J - Number of brick A to form a ring of outside diameter G.
g - Outside diameter of ring formed by brick B alone if it is ardial.
j - Number of brick B to form a ring of outside diameter g.
x - Number of pieces of brick A, used with brick B to form a ring of outside diameter D.
y - Number of pieces of brick B, used with brick A to form a ring of outside diameter D.
S - Total number of pieces of brick A and brick B to form a ring of outside diameter D.
OUTSIDE CHORD DIMENTIONS
INSIDE CHORD DIMENTIONS
A
B
C
A
E
BA B
e
A
B
A
C
JAY CERAMICS
Page No.: 15
COMBINATIONS TO FORM A RINGWITH TWO SIZES OF BRICK (Contd...)
I. WHEN BOTH BRICK A AND B ARE RADIAL AND OUTSIDE CHORDS ARE EQUAL (C =C) BUT INSIDE CHORD ARE UNEQUAL.
II. WHEN BRICK B IS A STRIGHT BRICK AND BRICK A IS REDIAL, C = E AND
III. WHEN BRICK A AND B ARE RADIAL AND BOTH CHORD DIMENSIONS OF A DIFFER FROM THOSE OF B.
IV. WHEN CALCULATING A SERIES OF COMBINATION THE FOLLOWING FORMULAS ARE CONVENIENT :
(1) S = pD = pD
C C
(2) Y = d - SE
e - E
(1) X = J (g - D)
g - G
(2) Y = J (g - D)
g - G
(3) x = 2pT = 6.2832T
C - E C - E
(4) y = pD - xC
c
(5) Cx + cy = pD
(6) EX + ey = pd
JAY CERAMICS
JAY CERAMICS
Page No.: 16
RADIAL BRICK FORMULAS
a - Inside arc of circle type brick
A - Outside arc of circle type brick
c - Inside chord of circle or wedge type brick
C - Outside chord of circle or wedge type brick
r - Inside radius of radial brick
R - Outside radius of radial brick
d - Inside diameter of ring formed by radial Brick
FORMULAS :
C A a c ÆÆ
CIRCLE TYPE
R
Tr
c ÆÆ
WEDGE TYPE
R
Tr
C
KEY TO SYMBOLS
D - Outside diameter of ring formed by radial brickT - Radial dimension of brick
- Theta, the included angle of brickp - Pi - 3.1416S - Total number of a given radial brick required to form a ring
Æ
rC =
r + T
rC
Rc =
= = =(r + T) c Rc 1
Sine /2 ÆC
2R 2rC =
r ror
c
2p T pD pd
C - c C cS == =
º 360 S
= Æ Æ
JAY CERAMICS
TABLE FOR USE IN DESIGNING RADIAL TYPE BRICK
Page No.: 17
5 678910111213141516171819202122232425262728293031323334353637383940414243444546474849505152
0.587790.500000.433880.382680.342020.309020.281730.258820.239320.222520.207910.195090.183750.173650.164590.156430.149040.142310.136160.130530.125330.120540.116090.111970.108120.104530.101170.098020.095060.092270.089640.067160.084810.082580.080470.078460.076550.074730.072990.071340.067760.068250.066800.065400.064070.062790.061590.06038
15.31218.0002074323.51826.31429.12431.94534.77337.60740.44643.28846.13348.98051.68154.68157.53460.38663.24266.09968.95071.81074.66477.52680.37983.24186.10088.95991.81894.67097.540100.402103.258106.120108.985111.843114.708117.570120.434123.305126.156129.014131.868134.731137.615140.471143.335146.199149.056
No.of brick to Circle (1)
Sine ofHalf Angle (2)
No.of brick to Circle (1)
Sine ofHalf Angle (2)
Dia. for 9"Chordin inches (3)
Dia. for 9"Chordin inches (3)
5354555657585960616263646566676869707172737475767778798081828384858687888990919293949596979899100
0.059240.058150.057090.056070.055080.054140.053220.052340.051470.050650.049850.049070.048320.047580.046870.046180.045520.044860.044230.043620.043020.042440.041880.041320.040790.040270.039750.039260.038780.038300.037840.037390.036950.036520.036100.035690.035290.034900.034520.034140.033770.033410.033060.032720.032380.032050.031730.03141
If the outside chord of a radial brick is desired for a given number of pieces per ring, find the number of pieces in coloum 1 and multiply the corresponding sine of the half angle in colomn 2 by the outside diameter of the ring. If brick with an outside chord of approxymately 9'' is desired, find the diameter in colomn 3 that comes closest to the desired outside diameter. Then multiply the corresponding sine of the half angle in colomn 2 by the desired outside diameter to obtain the actual chord. The number of pieces to form a ring will be found in colomn 1.
151.924154.772157.646160.514163.399166.236169.109171.953174.859177.590180.542183.411186.258189.155192.020194.890197.715200.624203.482206.327209.205212.064214.900217.612220.642223.491226.415229.241232.078234.987237.844240.706243.572246.540249.307252.171255.030257.880260.718263.620266.509269.380272.232275.061277.949280.811283.643286.533
JAY CERAMICS
Page No.: 18
KEY TO SYMBOLSS = Span of archH = Rise of archR = Outside radius of archr = Inside radius of archT = Thikness of archA = Outer arch lengtha = Inner arch lengthe = Central Angle
FormulasTo find the rise when radius and span are given :
To find the inside radius when rise and span are given :
To find the angle 0 when the radius and span are given :
To find the lengths when the radius and central angle are given :Outer arc : Inner arc :
1 2 2H = r - / 4r - S2
S
2r
1Sin / =2 Æ
2 2 S + 4H
8Hr =
2pR
ÆA = 360
2pr
Æa = 360
VALUES FOR GIVEN RISES PER FOOT OF SPAN
Rise inInches
Per Footof Span
Inside *Arc isFactor
xS
Inside *Arc isFactor
xS
Diff.ofOuter andIneer Arcsfactor xT
Skewback
X * is Y * is
Factor x T Factor x T
Central Angle
Degrees Part of
Circle
11
1 /4
11 /2
1.6083
1 /4
21
2 /4
2.3021
2 /2
32 /4
3
1.5417
1.2521
1.0625
1.0000
0.9301
0.8333
0.7604
0.7474
0.7072
0.6600
0.6250
37"50.9'
47"4.4'
56"8.7'
60"0.0'
65"2.5'
73"44.4'
82"13.4'
83"58.5'
90"28.8'
98"29.7'
106"15.6'
0.1051
0.1308
0.1560
0.1667
0.1807
0.2048
0.2284
0.2333
0.2513
0.2736
0.2952
0.0184
1.0287
1.0412
1.0472
1.0558
1.0725
1.0913
1.0954
1.1120
1.1346
1.1591
0.0184
1.0287
1.0412
1.0472
1.0558
1.0725
1.0913
1.0954
1.1120
1.1346
1.1591
0.3243
0.3993
0.4706
0.5000
0.5376
0.6000
0.6575
0.6690
0.7101
0.7575
0.8000
0.9460
0.9168
0.8824
0.8660
0.8432
0.8000
0.7534
0.7433
0.7041
0.6528
0.6000
* Inside radius, inside arc, difference of outer and inner arcs, x and y arcs, x and y are
obtained by multiplying the factor in respect with S or T, whichever applies.
a
T
RH
0S
A
X
Y
rELEMENTS OF ARCHES
JAY CERAMICS
FAX FORMTO FAX NUMBER : +91 2751 220771
Refractory Bricks for kilns.
Refractory Bricks for Electric Furnaces.
Refractory Articles for Kiln Furniture.
Refractory for Special Casting.
Refractory for Mini Steel Plant.
Refractory for Boilers.
Refractory for Mortars.
Others ( Please Specify ) .....................
I am interested in............ ( Please mark )
Please Send me more details.
Please quote for following.
Product Quality
Delevery Schedule Quantity
Name :
Company :
Address :
City : Pin / Zip :
State / Country :
Phone / Fax :
E Mail / Web :
JAY CERAMICSChotila Road, THANGADH - 363 530,
Gujarat - INDIA.