SUGGESTED HEATING PROCEDURES Low Cement Castables … Cement - May 20… · Low Cement Castables...

Low Cement

Castables

Kricon

EZ Cast

EZ Cubed

Vibrocast PC

Vibrocast

Permacon

Vibrocast EZ

ProCast

Kricon

EZ Cast

EZ Cubed

Vibrocast PC

Vibrocast

Permacon

Vibrocast EZ

ProCast

Furnacubed

SUGGESTED HEATING PROCEDURES

for RESCO LOW, ULTRA-LOW, AND NO CEMENT CASTABLES

The following schedule is recommended for Resco Products' Low, Ultra-Low, and No Cement Castables. Controlled release of water in the castable is necessary to prevent possible build-up of steam pressure and potential steam spalling. Heating can be done before or during unit start-up.

The following schedule is recommended FOR SINGLE COMPONENT LININGS UP TO 9” THICK.

1. At anytime following the initial 24 hour curing period, raise the temperature to 300oF (149oC).

2. Hold at 300oF (149oC) for 1½ hours per inch (25 mm) of lining thickness up to a maximum period of 8 hours.

3. Raise temperature at a rate of 50ºF (28oC) per hour to operating temperature or 1000oF (540oC), whichever is less.

If the operating temperature is above 1000oF (540oC), then heat at a rate of 100ºF (56oC) per hour from 1000oF (540oC) to operating temperature if the lining is up to 6” thick (152 mm); heat at a rate of 50ºF (28oC) per hour from 1000oF (540oC) to operating temper-ature if the lining is 6” to 9” thick (152 mm to 229 mm).

If the unit is not going into operation, but will be cooled down, hold at the operating temperature for a minimum period of 1½ hours per inch (25 mm) of lining thickness up to a maximum period of 8 hours.

The following schedule is recommended FOR SINGLE COMPONENT LININGS OVER 9” THICK.

1. At anytime following the initial 24 hour curing period, raise the temperature to 300oF (149oC) at a rate of 50ºF (28oC) per hour.

2. Hold at 300oF (149oC) for one hour per inch (25 mm) of lining thickness.

3. Raise temperature at a rate of 50ºF (28oC) per hour to 450oF (232oC).

4. Hold at 450oF (232oC) for one hour per inch of lining thickness.

5. Heat at a rate of 25ºF (14oC) per hour to 600oF (315oC).

6. Hold at 600oF (315

oC) for one hour per inch (25 mm) of lining thickness.

7. Heat at a rate of 50ºF (28oC) per hour to 1000oF (540oC).

8. Hold at 1000oF (540oC) for one hour per inch (25 mm) of lining thickness.

If the unit is not going into operation, but will be cooled down, hold at the operating temperature for a minimum period of 1½ hours per inch (25 mm) of lining thickness up to a maximum period of 8 hours.

NOTES:

If, for any reason, the heating schedule is interrupted by a loss of heat and/or power into the unit, Resco Products recommends that the heating schedule be initiated from the beginning once power and/or heat is restored. At the end user or contractor’s discretion, they may elect to attempt to restart the cycle and “stabilize” the lining temperature at the point of interruption. Af-ter the lining has been stabilized, the heat up cycle may be resumed as scheduled from that point on. Resco assumes no liability for this procedure, as it is difficult to determine that point at which the entire lining is stable to prevent the possibility of a steam spall.

Temperatures shown are measured at the hot face of the lining for in place heating.

Allow the lining to cool down naturally; do not exceed 100ºF (56oC) per hour.

The dry out of refractory entails more than just following a heating schedule. Issues such as burner sizing and location, exhaust location, air volume and velocity, etc need to be addressed. Resco recommends that an experienced dry out company be consulted.

Temperatures should be monitored at the refractory surface at several locations in the unit.

If steaming is observed at any time during the schedule, the temperature should be held constant until the steaming subsides. The schedule can resume when steaming ends.

This schedule is recommended for situations where proper heating equipment and air circulation are used, weep holes

are present and unclogged, and the ambient temperature ranges from 60o to 90

oF. If all of these parameters are not

met, a more conservative dry out schedule is needed. Consult your Resco Products, Inc salesman, the RESCO website

(www.rescoproducts.com), or call 888.283.5505.

http://www.rescoproducts.com/

Brand Page Brand Page

EZ CAST® 3000 .........................................15 KRICON

® 28 ......................................... 14

EZ CAST® 3200 .........................................15 KRICON

® 30 ......................................... 14

EZ CAST® 3250 .........................................15 KRICON

® 32 ......................................... 14

EZ CAST® 3400 .........................................15 KRICON

® 32-70........................................14

EZ CAST® 3400-SP .........................................12 KRICON

® 34.............................................14

EZ3®

34 ZLC .........................................8-9 KRICON® 34-10.............................................12

EZ3®

70PC .........................................8-9 PERMACON® 95 .........................................13

EZ3®

75PC .........................................8-9 ProCAST® 80 ......................................... 13

EZ3®

80PC .........................................8-9 VIBROCAST® 2800 .........................................3

EZ3®

AZS .........................................8-9 VIBROCAST® 3000 .........................................3

EZ3®

20-60 .........................................10 VIBROCAST® 50 .........................................3

EZ3®

3000 .............................................8-9 VIBROCAST® 50 PC .........................................3

EZ3®

3200 .........................................8-9 VIBROCAST® 56SC .........................................10

EZ3®

3200 .........................................8-9 VIBROCAST® 56SCHP .........................................10

EZ3®

60 LQY .........................................8-9 VIBROCAST® 60 .........................................3

EZ3®

60-M ............................................8-9 VIBROCAST® 60 PC .........................................3

EZ3®

80-15............................................11 VIBROCAST® 70 .........................................4

EZ3®

85............................................8-9 VIBROCAST® 70M .........................................4

EZ3®

FS-6LC...............................................5 VIBROCAST® 75 .........................................4

EZ3®

FS-6PC...............................................5 VIBROCAST® 80SC .........................................11

FURNA3™ 65 .........................................7 VIBROCAST

® 80SCHP .........................................11

FURNA3™ 70 .........................................7 VIBROCAST

® 85 .........................................4

FURNA3™ 75 .........................................7 VIBROCAST

® 85ULM .........................................12

FURNA3™ 85 .........................................7 VIBROCAST

® 87 AS .........................................4

FURNA3™ FS .........................................5 VIBROCAST

® ASC-7LTPC .........................................12

FURNACON™ 3000 .........................................6 VIBROCAST® ASC-8LT(C-C) .........................................12

FURNACON™ 50W .........................................6 VIBROCAST® EZ 3250 .........................................13

FURNACON™ 70W. .........................................6 VIBROCAST® EZ 80 .........................................13

FURNACON™ 70W. .........................................6 VIBROCAST® FS-6 .........................................5

FURNACON™ 95 .........................................6

INDEX

Resco Products, Inc

Penn Center West

Building 2, Suite 430

Pittsburgh, PA 15276

Phone: 888.283.5505

Phone: 412.494.4491

Fax: 412.294.1080

www.rescoproducts.com

Page 15

EZ CAST® 3250 is a low cement

castable with an alumina content of 78%. It has excellent abrasion resistance and superior hot strength to as high as 2700ºF. These properties combined with excellent thermal shock resistance have resulted in many successful installations in bottoms and lip rings of steel ladles. This proven prod-uct has been successfully used in a wide variety of appli-cations, often substituted for higher alumina content prod-ucts, making it a highly cost-effective and versatile compo-sition. Its combination of strength, toughness, alumina content, and other composi-tional features make it an ex-cellent product for many appli-cations.

EZ CAST® 3400 is a self-flowing,

99% alumina, low cement casta-ble for applications up to 3400°F. It has low porosity and low per-meability without a sacrifice in

thermal shock resistance. This product is not recommended for pumping, but it can be installed with or without vibration.

EZ CAST® 3000 is

a self-flowing, low iron, 56% alumina, low cement casta-ble designed to provide high strength and good thermal shock and abrasion re-sistance. It offers good slag re-sistance for severe applications up to 3000°F. In the la-boratory, this prod-uct has shown ex-cellent resistance to CO atmos-pheres found in coke ovens and blast furnaces. Large volumes of this castable have been used suc-cessfully in a wide variety of appli-cations. This product can be pumped.

EZ CAST® 3200 is a self-flowing,

76% alumina low cement castable designed to provide longer service life and superior performance in steel applications with tempera-tures up to 3200°F. It also has out-standing strength and abrasion

resistance. In laboratory testing this product has shown excellent resistance to CO atmospheres found in coke ovens and blast fur-naces. This product can be pumped.

EZ CAST 3000 EZ CAST 3000 EZ CAST 3200 EZ CAST 3200

Self Level Vib Cast Self Level Vib Cast

Maximum Service Temp. oF 3000 3000 3200 3200

Typical Water Required for Mixing

% 5.5-6.8 4-5.5 5.5-6.5 4.0-5.0

Bulk Density lb/Ft3, 1500

oF 147 to 151 153 to 157 164 to 170 170 to 174

Cold Crushing Strength lb/in2, 1500

oF

4000 to 8000 11000 to 15000 5000 to 9000 10000 to

Modulus of Rupture lb/in2, 1500

oF 1000 to 1600 1400 to 2200 1100 to 1500 1700 to 2200

Apparent Porosity % 13-17 10-14 15-17 11-14

Permanent Linear Change

%, 1500oF -0.4 to 0 -0.2 to 0.2 -0.2 to 0 -0.4 to 0

Chemical Analysis, %

Al2O3 56.0 56.0 76.2 76.2

SiO2 38.4 38.4 19.2 19.2

Fe2O3 1.0 1.0 0.9 0.9

TiO2 1.8 1.8 2.1 2.1

CaO 1.3 1.3 1.2 1.2

MgO 0.0 0.4 0.0 0.0

Alkalies 1.1 1.1 0.2 0.2

EZ CAST 3250 EZ CAST 3250 EZ CAST 3400

Self Level Vib Cast Self Level

Maximum Service Temp. oF 3250 3250 3400


% 5.0-6.5 3.5-4.5 4.8-5.3


oF 165 to 171 169 to 173 187 to 191


oF 6900 to 12900 15000 to 20000 2000 to 4000


oF 1300 to 2300 1900 to 2900 700 to 1100

Apparent Porosity % 15-19 11-14 ---


%, 1500oF -0.4 to 0.2 -0.6 to -0.2 -0.2 to 0.0


Al2O3 77.7 77.7 98.7

SiO2 18.2 18.2 tr

Fe2O3 0.8 0.8 tr

TiO2 1.7 1.7 tr

CaO 1.2 1.2 1.1

Alkalies 0.2 0.2 0.1

VIBROCAST® 2800 is an economical 2800

oF low-cement vibratable castable designed to yield

high fired strengths at maximum density with low porosity and linear change. This material will withstand high temperature corrosion and erosion.

VIBROCAST® 3000 is a 3000

oF low-cement vibratable castable which will give high fired strength at

maximum density with minimum porosity and linear change. This material will withstand the severe high temperature corrosion and erosion that are common in today’s Lime and Cement applications.

VIBROCAST® 50 is a 3000

oF, low-cement vibratable castable that offers excellent resistance

to alkalies. This product is designed to give minimum porosity and low linear change with max-imum density and high fired strengths, and can withstand severe high temperature corrosive environments.

VIBROCAST® 50PC is a pumpable, 3000

oF, low-cement castable that offers excellent re-

sistance to alkalies. In addition to being pumpable, VIBROCAST® 50PC requires substantially

less vibration than standard low cement castables. Light vibration should be used to de -air the castable. This pumpable castable can also be shotcreted using RESCO’s shotcrete activator.

VIBROCAST® 60 is a 60% alumina, mullite based, 3100

oF, low-cement castable which is designed to

give minimum porosity and low linear change with maximum density and high fired strengths. This ma-terial will withstand severe high temperature corrosive and erosive and erosive environments and in-stalled using vibration casting methods.

VIBROCAST® 60PC is a 60% alumina, mullite based, pumpable, 3100

oF low-cement castable designed to

provide minimum porosity and low linear change with maximum density and high fired strengths. This ma-

terial will withstand severe high temperature corrosive and erosive environments. This pumpable castable

can also be shotcreted using RESCO’s shotcrete activator.

Vibrocast 2800

Vibrocast 3000

Vibrocast 50 Vibrocast

50PC Vibrocast 60

Vibrocast 60PC

Vib Cast Vib Cast Vib Cast Pump Cast Vib Cast Pump Cast

Maximum Service Temp. oF 2800 3000 3000 3000 3100 3100


% 6.0-6.5 5.3-5.8 5.4-6.0 5.4-6.0 5.0-6.0 6.2-6.7


oF 137 143 145 148 156 160


oF

4500 to 8000

9000 to 11000

9000 to 11000

9000 to 11000

10000 to 14000

10000 to 14000


oF --- 1200 to 1700

1200 to 1700

1200 to 1700

2000 to 2400

1400 to 2000

Apparent Porosity % 16 16 16 15 16 17


%, 1500oF -0.3 to +0.2 --- 0 to -0.3 0 to -0.3 0.0 to -0.4 -0.1 to -0.3


Al2O3 40.0 48.9 45.0 45.9 60.8 60.8

SiO2 56.1 46.9 50.9 50.0 34.5 34.5

Fe2O3 0.8 0.9 0.7 0.9 1.0 1.0

TiO2 1.2 1.6 1.1 1.4 1.8 1.8

CaO 1.7 1.5 2.0 1.5 1.6 1.6

Alkalies 0.0 0.0 0.0 0.0 0.3 0.0

Data and descriptions for QuikTurn and R-Max low cement Castables can be found in RESCO’s QuikTurn and R-Max brochures

Page 14

KRICON® 28 is a good general purpose, 45% alumina, low iron, low cement castable for ser-

vice temperatures up to 2800°F. It should be installed using vibration casting methods.

KRICON® 30 is a low iron, 46% alumina castable with good

slag resistance up to 3000°F, and is installed using vibration

casting methods.

KRICON® 32 is a low cement 60% alumina castable that is

designed for service temperatures up to 3200°F. It has low

iron content with excellent hot strengths and is installed using

vibration casting methods.

KRICON® 32-70 is a very popular 77% alumina, low iron

castable with a 3200°F temperature limit. It offers improved slag resistance and positive reheat

expansion at steel making temperatures to insure tight, crack-free linings in cast ladles and tun-

dishes. This castable should be installed using vibration casting methods.

KRICON® 34 is designed for service temperatures up to 3400°F. It is a high purity alumina, low

cement castable featuring low porosity and low permeability while maintaining good thermal

shock resistance. This mix is very pure at 99% alumina with a very low content of total impuri-

ties, and is installed using vibration casting methods.

KRICON 28 KRICON 30 KRICON 32 KRICON 32-70 KRICON 34

Vib Cast Vib Cast Vib Cast Vib Cast Vib Cast

Maximum Service Temp.

oF 2800 3000 3200 3200 3400

Typical Water Re-quired for Mixing

% 4.5-5.5 4.5-6.0 4.5-5.5 4.5-6.0 4.6-5.2


oF 140 to 146 143 to 150 157 to 163 170 to 174 190 to 194

Cold Crushing Strength

lb/in2, 1500

oF 4800 to 10800 6700 to 12700 4900 to 10900 8000 to 16000 6000 to 9000


oF 1500 to 2500 1100 to 2100 1700 to 2700 1400 to 2200 1500 to 1800

Apparent Porosity % 8-12 10-14 11-15 16-18 14-16


%, 1500oF -0.6 to 0.1 -0.5 to 0.1 0 to -0.1 -0.3 to -0.1 -0.1 to 0


Al2O3 45.2 46.5 63.4 77.0 98.7

SiO2 48.4 45.4 31.7 18.2 0.1

Fe2O3 1.2 1.2 1.1 1.0 0.1

TiO2 1.8 1.9 2.2 2.2 Tr

CaO 1.4 1.2 1.2 1.2 1.0

MgO 0.3 0.3 0.2 0.2 Tr

Alkalies 1.6 0.7 0.2 0.2 0.1


VIBROCAST® 70 is a low-cement vibratable castable which is designed to give minimum

porosity and linear change with maximum density and super high fired strengths.

VIBROCAST® 70M is a low-cement vibratable castable which is designed to give mini-

mum porosity and linear change with maximum density and super high fired strengths. These materials are designed to withstand the severe high temperature corrosion and erosion in today’s steel applications.

VIBROCAST® 75 is a high alumina, 3200

oF service limit, low cement vibratable castable used in

a wide variety of applications including forging furnace floors, heat treating furnace floors, crema-tory furnace floors, precast burner blocks, gas fired non-ferrous melting furnaces and incineration chambers.

VIBROCAST® 85 is a low-cement, 85% alumina vibratable castable designed to give

minimum porosity and linear change with maximum density and super high fired strengths. This material will withstand the severe high temperature corrosion and erosion that are com-mon in today’s Steel appliations.

VIBROCAST® 87 AS is an 87% alumina, ultra-low cement

castable. This product should be installed using vibration

casting methods only. This product has been used to

manufacture precast shapes for steel applications, but can

be used for a variety of different high temperature applica-

tions.

Vibrocast 70 Vibrocast 70M Vibrocast 75 Vibrocast 85 Vibrocast 87

AS


Maximum Service Temp. oF 3200 3200 3200 3200 3200


% 5.1-5.6 5.5-6.0 5.8-6.3 4.9-5.4 5.5


oF 164 164 168 176 180


oF 8500 to 12500 8500 to 12500 10000 to 13000 10000 to 15000 4000 to 8000


oF 2400 to 2800 2400 to 2800 2700 to 3100 1300 to 1800 ---

Apparent Porosity % 17 17 --- --- ---


%, 1500oF --- --- -0.1 to -0.4 --- -0.3 to 0.0


Al2O3 71.5 70.8 79.1 83.0 87.0

SiO2 22.5 23.4 14.4 11.3 7.5

Fe2O3 1.2 1.3 1.4 1.5 1.1

TiO2 2.8 2.6 2.9 2.4 3.4

CaO 1.6 1.5 1.5 1.6 0.8

MgO 0.0 0.0 0.0 0.0 0.1

Alkalies 0.0 0.0 0.0 0.0 0.1

Page 13

VIBROCAST® EZ 80 is a low cement 80% alumina castable that features improved flow characteristics

during casting. This product should be installed using vibration casting methods only.

VIBROCAST® EZ 3250 is a 75% alumina low cement castable that is installed by vibration casting. This

product has been formulated for improved service life in steel ladle applications

ProCAST® 80 is an 84% alumina, ultra-low cement castable. This vibration mix performs well in steel

ladles, EAF deltas, and other applications requiring high strength, good thermal shock resistance, and good abrasion resistance. This product should be installed by vibration casting.

PERMACON® 95 is an ultra-low cement, 95% alumina castable, designed for severe service conditions

at temperatures up to 3300°F. It offers superior resistance to spalling, cracking, impact, and abrasion; and greater resistance to chemical attack than low cement or conventional castables. This product should be installed by vibration casting.

Vibrocast EZ 80 Vibrocast EZ

3250 ProCast 80 Permacon 95

Vib Cast Vib Cast Vib Cast Vib Cast



% 5.0-5.5 4.5-5.0 4.0-6.0 3.0-4.0


oF 168 170 182-188 189-195


oF

10000 to 13000 15,000 5800 to 6100 to 12100


oF 2700 to 3100 2,000 1100 to 2100 2100 to 3100

Apparent Porosity % --- --- 13-17 11-15


%, 1500oF -0.4 to 0.1 -0.4 to 0.0 -0.4 to 0.2 -0.4 to 0.3


Al2O3 79.1 75.7 84.0 94.1

SiO2 14.4 20.2 10.2 4.9

Fe2O3 1.4 0.8 1.2 0.2

TiO2 2.9 1.7 3.0 0.2

CaO 1.5 1.2 1.1 0.3

MgO 0.0 0.2 0.3 0.1

Alkalies 0.0 0.2 0.2 0.2


VIBROCAST® FS-6 is a fused silica, low cement vibratable castable. VIBROCAST

® FS-6

offers high strength, very good resistance to abrasion, and low reversible thermal expan-

sion, resulting in a highly thermal shock resistant material.

EZ3®

FS-6LC is a low cement, self-leveling, fused silica castable that offers high strength, excellent resistance to abrasion, and low reversible thermal expansion. This product may be cast or pumpcast.

EZ3®

FS-6PC is a pumpable, low cement, fused silica castable that offers high strength, excellent resistance to abrasion, and low reversible thermal expansion. This product may be cast or pumpcast.

FURNA3™ FS is a non-wetting, fused silica-based castable for aluminum contact. It has excellent

strength and low porosity with good abrasion resistance. It possesses excellent thermal shock re-sistance because of a very low reversible coefficient of thermal expansion. The product provides ex-tremely good dross resistance and outstanding resistance to spalling at a reasonably low density.

Vibrocast FS-6 EZ3 FS-6LC EZ

3 FS-6PC FURNA

3 FS FURNA

3 FS

Vib Cast Vib Cast Pump Cast Self Level Vib Cast



% 5.9-6.5 6.3-7.0 6.0-6.5 7.8-8.8 6.8-7.8


oF 131 136 130 to 134 118 to 122 122 to 126


oF 7000 to 10000 8000 to 11000 8000 to 11000 4000 to 7000 7000 to 10000


oF 1300 to 1700 1300 to 1700 1300 to 1700 1000 to 1600 1200 to 1600

Apparent Porosity % 17 13 13 12-14 9-11


%, 1500oF 0 to -0.3 0 to -0.2 0 to -0.3 -0.4 to 0 -0.4 to 0


Al2O3 20.2 28.5 22.5 11.0 11.0

SiO2 77.5 69.3 74.9 87.8 87.8

Fe2O3 0.4 0.1 0.3 tr tr

TiO2 0.4 0.1 0.3 tr tr

CaO 1.6 1.8 1.7 1.1 1.1

MgO 0.0 Tr 0.1 0.0 0.0

Alkalies 0.0 0.2 0.2 0.1 0.1

Jambs & Lintel– Pechiney – Ravenswood,

WV

• Two 220,000 lb. round

top charge melters.

• One 220,000 lb. tilting

holding furnace.

Fused Silica Castables


Page 12

KRICON® 34-10 is a low cement castable with a 10% chromia content for extremely corrosive envi-

ronments. The high chromia content can also offer improvement in thermal shock resistance when

compared to high alumina products of similar density.

VIBROCAST® 85ULM is an ultra low cement castable designed to have maximum slag

and hot metal resistance for use in LMF ladles and related steel -making applications.

VIBROCAST® ASC-7LTPC is a high purity, low-cement, alumina-spinel castable de-

signed to provide maximum resistance to molten steel and steelmaking slags. VIBRO-CAST ASC-7LTPC is designed for pumping or shotcreting placement in steel ladles and related steelmaking applications.

VIBROCAST® ASC-8LT(C-C) is a high purity, low-cement, alumina-spinel castable de-

signed to provide maximum resistance to molten steel and steelmaking slags.

VIBROCAST ASC-8LT(C-C) is designed for production of cast shapes or monolithic place-ment in steel ladles and related steelmaking environments and should be installed by vi-bration casting.

EZ CAST® 3400-SP is a tabular alumina-based castable containing magnesium aluminate spinel.

This self-flowing product is a good alternative to chromia-containing materials where slag and corro-sion resistance are essential. This product is not recommended for pumping.

KRICON 34-10

Vibrocast 85ULM

Vibrocast ASC-7LTPC

Vibrocast ASC-8LT (C-C)

EZ CAST 3400 SP

Vib Cast Vib Cast Pump Cast Vib Cast Self Level



% 3.7-4.7 5.2-5.7 7.8-8.3 4.5-5.2 4.7-5.7


oF 217 to 221 171 175 185 180 to 184


oF 9000 to 13000 6000 to 12000 1500 to 3000 5000 to 8000 5000 to 8500


oF 2000 to 2400 --- --- --- 1350 to 1800

Apparent Porosity % 8-12 --- 18 20 19-23


%, 1500oF 0 to 0.4 -0.3 to 0.0 --- --- -0.2 to 0.2


Al2O3 88.4 80.7 95.7 94.0 91.1

SiO2 0.1 15.0 0.1 0.2 0.4

Fe2O3 0.1 0.9 0.1 0.0 0.2

TiO2 0.0 2.4 0.0 0.0 0.8

CaO 1.2 0.6 1.4 1.6 1.8

MgO 0.0 0.0 2.3 4.0 5.6

Cr2O3 10.0 0.0 0.0 0.0 0.0

Alkalies 0.2 0.1 0.0 0.0 <0,1

Spinel and Chromia Containing Castables

FURNACON™ 3000 is a high purity alumina low cement

castable designed for installation at or above the dross line

of aluminum-melting furnaces. It will resist molten alumi-

num penetration and reaction after exposure to tempera-

tures as high as 3000°F, such as occur with thermiting of

magnesium containing drosses or overheating of the side-

walls.

FURNACON™ 50W is designed as a low cost refractory to resist mild alloys. It is cost-effective in metal contact ar-eas and where salt fluxes are used. FURNACON™ 50W is available only in a winterized version for faster setting at lower temperatures.

FURNACON™ 70 resists the most aggressive alloys, es-pecially magnesium-containing aluminum alloys. It is a cost-effective refractory for severe operating conditions. In addition to its non-wetting properties, it has exceptional strength and toughness to resist thermal and mechanical abuse. It is one of the most widely used castables for low-er sidewalls and aluminium furnace hearths. A winterized version, FURNACON™ 70W, is available for fast-setting at low temperatures.

FURNACON™ 95 resists spalling and cracking from ther-mal and mechanical abuse. Its high purity, high alumina base makes it ideally suited for troughs and tapholes.

FURNA3™ 70 is a 74% alumina, non-wetting to aluminum, low cement castable that can be vibration cast, self-flow

cast, or shotcreted. This product has excellent thermal shock resistance to 2000ºF. It has been used for pre-formed blocks in an aluminum furnace and has been shot-creted in aluminum furnace upper and lower walls. Unlike other FURNA3™ products, this product is recommended for use only in aluminum furnace applications. Therefore, its maximum non-metal contact use temperature is 2500ºF.

FURNA3™ 75 is a self-flowing, 76% alumina castable de-signed for non-wetting applications up to 2200°F. It can be used for other applications up to 3000°F where increased strength and abrasion resistance are needed.

FURNA3™ 65 is a self-flowing, 64% alumina castable de-signed for non-wetting applications up to 2200°F. It can be used for other applications up to 3000°F where increased strength and abrasion resistance are needed.

FURNA3™ 85 is an 85% alumina, non-wetting to alumi-num, low cement castable designed to replace 85% alumi-na brick in aluminum furnaces. This product has excep-tional strength and abrasion resistance particularly at 1500°F. It is also very strong and thermal shock resistant at 1500ºF. It can be placed by vibration casting, self-flow casting, or shotcreting. Its high strength and toughness after shotcreting are ideal for aluminum furnace mainte-nance gunning or as an easy-to-install initial working lin-ing.

FURNACON 3000

FURNACON 50 W

FURNACON 70 FURNACON

70 W FURNACON

95




% 4-4.8 4.5-6.0 4.0-5.5 4.0-5.5 4.0-5.5


oF 197 to 201 143 to 146 167 to 173 167 to 172 189 to 194


oF 5500 to 9500 7000 to 11000 11000 to 17000 12000 to 16000 15000 to 19000


oF 1750 to 2150 1500 to 1900 2800 to 3800 2700 to 3900 4000 to 4500

Apparent Porosity % --- 7-13 11-15 10-13 10-13


%, 1500oF -0.1 to 0.0 0 to -0.4 -0.4 to +0.2 -0.2 to +0.2 -0.3 to -0.1


Al2O3 92.8 45.6 72.4 70.9 93.8

SiO2 0.1 47.8 21.6 23.2 5.0

Fe2O3 Tr 1.3 1.0 1.1 Tr

TiO2 Tr 1.8 2.1 2.1 Tr

CaO 1.1 1.5 2.5 2.5 1.1

MgO Tr 0.3 0.2 0.1 Tr

Alkalies 0.1 1.8 0.2 0.1 0.1

Aluminum Contact Castables

Page 11

VIBROCAST® 80SC is an 80% SiC castable that uses low cement binder technology. Its

low porosity, excellent abrasion resistance and high heat transfer value make this prod-uct an excellent choice for the tube walls in the combustion zones of power generating units. The high heat transfer characteristic of the SiC reduces surface slagging and al-kali build-up, thereby improving the operating efficiency of your unit. VIBROCAST 80SC is best applied by vibration casting.

VIBROCAST® 80SCHP is an 80% SiC refractory material that uses low cement binder

technology. Its low porosity, excellent abrasion resistance and high heat transfer value make this product an excellent choice for the tube walls in the combustion zones of pow-er generating units. The high heat transfer characteristic of the SiC reduces surface slagging and alkali build-up, thereby improving the operating efficiency of your unit.

VIBROCAST® 80SCHP is best applied by hand

packing.

EZ3®

80-15 is a corrosion resistant 75% alumina castable, nominally containing 17% silicon carbide, that can be poured as a self-leveling mix, pumped, shotcreted, or vibrated. It is an ultra-low cement mix developing excellent green and dry strengths. It of-fers high hot strength and excellent thermal shock resistance.

Vibrocast 80SC Vibrocast 80SCHP EZ3 80-15 EZ

3 80-15 EZ

3 80-15

Vib Cast Hand Pack Self Level Shotcrete Vib Cast



% 4.5-5.1 5.9-6.3 5.5-6.0 4.5-5.0 3.5-4.5


oF 155 to 160 160 to 165 178 to 182 182 to 186 182 to 186


oF 10000 to 15000 14000 to 18000 6000 to 10000 8000 to 13000 12000 to 17000


oF 2300 to 3300 5000 to 6000 1500 to 2000 20000 to 2500 2500 to 3000

Apparent Porosity % --- --- 15-19 14-18 13-17


%, 1500oF -0.1 to -0.4 -0.1 to -0.3 -0.3 to 0.1 -0.3 to 0.1 -0.3 to 0.1


Al2O3 8.7 11.3 75.5 75.5 75.5

SiO2 9.2 7.5 5.0 5.0 5.0

Fe2O3 0.2 0.1 0.3 0.3 0.3

TiO2 tr 0.0 1.5 1.5 1.5

CaO 2.0 1.7 1.2 1.2 1.2

SiC 79.8 79.2 16.3 16.3 16.3

MgO 0.0 0.1 0.7 0.7 0.7

Alkalies 0.0 0.1 0.1 0.1 0.1

Silicon Carbide Containing Castables


FURNA3 65 FURNA

3 85 FURNA

3 85 FURNA

3 85

Vib Cast Self Level Pump/Shotcrete Vib Cast



% 5-6.5 4.5-5.5 4.0-5.0 4.0-5.0


oF 170 176 to 182 176 to 182 180 to 185


oF 16,790 23500 to 29500 12000 to 19000 27000 to 33000


oF 2500 to 3500 4600 to 6000 2950 to 3950 4200 to 6200

Apparent Porosity % --- 15-19 14-18 10-14


%, 1500oF 0.0 to +0.5 -0.4 to 0.2 -0.9 to -0.2 -0.5 to 0.1


Al2O3 64.3 83.5 83.5 83.5

SiO2 24.6 9.6 9.6 9.6

Fe2O3 1.0 0.8 0.8 0.8

TiO2 1.8 2.1 2.1 2.1

CaO 2.0 2.8 2.8 2.8

MgO 0.0 0.0 0.0 0.0

Alkalies 0.3 0.3 0.3 0.3

FURNA3 70 FURNA

3 70 FURNA

3 75 FURNA

3 75 FURNA

3 75

Self Level Pump/Shotcrete Self Level Pump/Shotcrete Vib Cast



% 5-6 4-5 5.5-6.5 5-6 4.5-5.5


oF 166 to 170 155 to 161 168 to 172 158 to 161 169 to 174


oF 5500 to 10000 3000 to 7000 5000 to 9000 6000 to 9000 10000 to 16000


oF 1100 to 2800 700 to 900 1100 to 1500 1200 to 1500 1700 to 2200

Apparent Porosity % 15-18 18-22 15-17 18-20 11-14


%, 1500oF -0.4 to 0.2 -0.4 to 0.2 -0.5 to 0.0 -0.3 to -0.1 -0.4 to 0.0


Al2O3 74.0 74.0 75.6 75.6 75.6

SiO2 17.6 17.6 18.3 18.3 18.3

Fe2O3 0.9 0.9 1.1 1.1 1.1

TiO2 2.0 2.0 2.3 2.3 2.3

CaO 1.2 1.2 2.5 2.5 2.5

SiC 0.0 0.0 0.0 0.0 0.0

MgO 0.0 0.0 0.0 0.0 0.0

Cr2O3 0.0 0.0 0.0 0.0 0.0

ZrO2 0.0 0.0 0.0 0.0 0.0

Alkalies 0.2 0.2 0.1 0.1 0.1

Aluminum Contact Castables


Page 10

EZ3®

20-60 is a self-flow, pumpable, shotcretable mix that has excellent corrosion resistance and con-tains 60% silicon carbide. It has developed into a premium product to resist alkali buildup in cement kiln preheaters and coolers. Its great ability for adherence has made EZ

3® 20-60 the mix of choice when

shotcreting overhead is necessary.

VIBROCAST® 56SC is a 56% SiC castable that uses low cement binder technology. Its low po-

rosity, excellent abrasion resistance and high heat transfer value make this product an excel-lent choice for the combustion zones of POWER GENERA-TION units and for the riser lines and preheater sections of CEMENT PLANTS. The high heat transfer characteristic of the SiC reduces surface slagging and alkali build-up, there-by, improving the operating efficiency of your unit.

VIBROCAST® 56SC is best applied by vibration casting.

VIBROCAST® 56SCHP is a 56% SiC castable that uses low

cement binder technology. Its low porosity, excellent abra-sion resistance and high heat transfer value make this prod-uct an excellent choice for the combustion zones of POWER GENERATION units and for the riser lines and preheater sections of CEMENT PLANTS. The high heat transfer characteristic of the SiC reduces surface slagging and alkali build-up, thereby, improving the operating efficiency of your unit.

Vibrocast® 56SCHP is best applied by hand packing.

EZ3 20-60 EZ

3 20-60 EZ

3 20-60 Vibrocast 56SC Vibrocast 56SCHP

Self Level Shotcrete Vib Cast Vib Cast Hand Pack



% 5.5-6.5 4.8-5.8 4.0-5.5 4.5-5.0 5.8-6.1


oF 156 to 162 156 to 159 161 to 167 157 to 162 157 to 162


oF 5400 to 11400 11500 to 13500 9800 to 15800 10000 to 15000 10000 to 15000


oF 600 to 1600 800 to 1500 1100 to 2100 2500 to 3500 2500 to 3500

Apparent Porosity % 15-19 15-17 11-15 17 17


%, 1500oF -0.3 to 0.3 -0.1 to 0 -0.3 to 0.3 -0.1 to -0.4 -0.1 to -0.4


Al2O3 22.3 22.3 22.3 19.8 19.8

SiO2 14.9 14.9 14.9 21.5 21.5

Fe2O3 0.5 0.5 0.5 0.3 0.3

TiO2 0.4 0.4 0.4 0.3 0.3

CaO 1.4 1.4 1.4 1.7 1.7

SiC 60.3 60.3 60.3 56.2 56.2

Alkalies 0.1 0.1 0.1 0.0 0.0

Silicon Carbide Containing Castables

EZ3 34ZLC is a 2910

oF Zircon based low

cement castable which requires no vibra-

tion to install. Super high strengths and

abrasion resistance are achieved even

when the material is mixed to a “Free

Flowing” or “Self-Leveling” consistency.

EZ3®

3000 is a self-flowing, low iron, 56%

alumina, low cement castable designed to

provide high strength, and good thermal

shock and abrasion resistance. It offers

good slag resistance for severe applica-

tions up to 3000°F. In the laboratory, this

product has tested well for resistance to

CO (carbon monoxide) disintergration en-

countered in coke ovens and blast furnac-

es. This product can be vibrated,

pumped, or shotcreted.

EZ3®

3200 is a shotcretable or self-flowing, low iron, 76% alumina, low ce-

ment castable designed to provide longer

service life and superior performance in

steel applications with temperatures up to

3200°F. It also has outstanding strength

and abrasion resistance. In laboratory

testing this product has shown excellent

resistance to CO atmospheres found in

coke ovens and blast furnaces.

EZ3®

3200 Fine is a slightly finer grain

size version of EZ3®

3200. It can be used in the same applications, and it is recom-

mended when pumping for long distanc-

es, particularly long vertical runs.

EZ3®

60 LQY is an alkali-resistant 60% alumina castable that can be installed us-

ing vibration casting, pumping, or wet

shotcreting methods. This product has

been formulated to be resistant to alkali

attack.

EZ3®

60-M is a mullite-based 60% alumi-

na castable that can be pumped, vibrated,

or shotcreted. It is recommended for ap-

plications requiring thermal shock re-

sistance, wear resistance, and good re-

fractoriness.

EZ3®

85 is an 85% alumina, low cement

castable that exhibits superior physical

properties when vibrated, poured, or shot-

creted. The excellent thermal shock, cor-

rosion, and abrasion resistance attributes

combined with other excellent physical

properties make this a premium product.

Normally, very high alumina containing

products are more difficult to shotcrete

due to higher rebounds. EZ3®

85 is re-

markably easy to shotcrete and adheres

well at low water levels yielding superior

physical properties.

EZ3®

70PC is a pumpable, low-cement castable which is designed to give minimum porosity and linear change with maximum density and super h igh fired strengths.

EZ3®

75PC is a pumpable, low-cement castable which is designed to give minimum porosity and linear change with maximum density and super h igh fired strengths. This material will

withstand severe high temperature corrosion and erosion.

EZ3®

80PC is a pumpable, low-cement, 80% alumina, vibratable castable designed to give minimum porosity and linear change with maximum den sity and super high fired strengths.

This material will withstand the severe high temperature corrosion and erosion that are common in today’s Steel Industry.

EZ3®

AZS is a low cement castable, that contains an alumina-zirconia-silica (AZS) aggregate, that can be vibration cast, pumped, and shotcreted. This product was formulated specifically for cement pre-

heater tower applications that require an abrasion-resistant monolithic refractory that resists dust build up.

EZ3 34ZLC EZ

3 3000 EZ

3 3000 EZ

3 3000 EZ

3 3200 EZ

3 3200 EZ

3 3200 EZ

3 3200 Fine EZ

3 3200 Fine EZ

3 3200 Fine EZ

3 60 LQY

Self Level Self Level Shotcrete Vib Cast Self Level Shotcrete Vib Cast Self Level Shotcrete Vib Cast Vib Cast

Maximum Service Temp. oF 2910 3000 3000 3000 3200 3200 3200 3200 3200 3200 3100


% 4.3-4.8 6.5-7.0 5.5-6.0 4.8-6.8 5.5-6.5 5.0-6.0 4.7-5.5 5.5-6.5 5.0-6.0 4.5-5.5 5.7


oF 170 150 to 151 151 to 155 153 to 157 164 to 170 152 to 151 170 to 174 164 to 170 152 to 157 170 to 174 157


oF 11000 to 16000 5200 to 11200 6000 to 12000 12000 to 16000 5000 to 9000 3700 to 8200 10000 to 16000 5000 to 9000 3700 to 8200 10000 to 16000 11,050


oF to 800 to 1800 800 to 1800 1500 to 2300 1100 to 1500 500 to 1500 1700 to 2200 1100 to 1500 500 to 1500 1700 to 2200 4,510

Apparent Porosity % 15 15-19 15-19 10-14 15-17 20-24 11-14 15-17 20-24 11-14 ---


%, 1500oF 0 to -0.3 -0.6 to 0 -0.2 to 0 -0.2 to 0.2 -0.2 to 0 -0.3 to 0 -0.4 to 0 -0.2 to 0 -0.3 to 0 -0.4 to 0 -0.3


Al2O3 34.0 56.6 56.6 56.6 76.8 76.8 76.8 75.9 75.9 75.9 55.0

SiO2 41.5 36.1 36.1 36.1 18.5 18.5 18.5 19.2 19.2 19.2 40.6

Fe2O3 0.5 1.9 1.9 1.9 1.1 1.1 1.1 0.9 0.9 0.9 1.0

TiO2 0.8 2.2 2.2 2.2 2.3 2.3 2.3 2.1 2.1 2.1 1.7

CaO 1.4 1.3 1.3 1.3 1.1 1.1 1.1 1.5 1.5 1.5 1.5

ZrO2 21.5 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

Alkalies 0.3 0.8 0.8 0.8 0.1 0.1 0.1 0.1 0.1 0.1 0.2

EZ3 60-M EZ

3 60-M EZ

3 60-M EZ

3 85 EZ

3 85 EZ

3 85 EZ

3 70PC EZ

3 75PC EZ

3 80PC EZ

3 AZS EZ

3 AZS

Self Level Shotcrete Vib Cast Self Level Shotcrete Vib Cast Pump Cast Pump Cast Pump Cast Self Level Vib Cast

Maximum Service Temp. oF 3100 3100 3100 3250 3250 3250 3200 3200 3200 2800 2800


% 5.75-6.75 4.75-5.75 4-5 4.5-5.5 4.0-5.0 4.5-5.0 5.8-6.5 5.4-5.9 6.1-6.5 5.3 5.1


oF 152 to 157 153 to 158 158 to 163 178 to 184 176 to 182 181 to 187 160 170 167 180 180


oF

7500 to 13500 11000 to 17000

19000 to 25000 12500 to 16500

11000 to 17000

14500 to 18500 10000 to 14000 9000 to 12000 9000 to 13000 12,500 12,500


oF 1750 to 2750 2250 to 3250 3500 to 4500 2700 to 3200 2200 to 3200 3200 to 3800 1300 to 1700 1200 to 1700 1300 to 1800 --- ---

Apparent Porosity % 15-19 13-17 10-14 15-19 14-18 12-16 17 18 --- --- ---


%, 1500oF -0.5 to 0.1 -0.3 to 0.3 -0.7 to -0.1 -0.1 to 0.1 -0.2 to 0.4 -0.1 to 0.1 -0.1 to -0.3 0 to -0.3 0.0 to -0.3 -0.2 -0.2


Al2O3 63.3 63.3 63.3 85.5 85.5 85.5 69.4 77.6 79.2 52.7 52.7

SiO2 32.3 32.3 32.3 9.8 9.8 9.8 25.7 16.2 15.4 19.5 19.5

Fe2O3 0.9 0.9 0.9 0.8 0.8 0.8 1.1 1.4 1.1 0.2 0.2

TiO2 1.7 1.7 1.7 2.2 2.2 2.2 1.9 2.6 2.3 0.3 0.3

CaO 1.5 1.5 1.5 1.2 1.2 1.2 1.5 1.5 1.5 1.5 1.5

SiC 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 4.9 4.9

MgO 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.2 0.0 0.2 0.2

ZrO2 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 20.5 20.5

Alkalies 0.2 0.2 0.2 0.4 0.4 0.4 0.0 0.5 0.5 0.2 0.2

Self-flowing, Pumpable. Shotcretable Castables

Page 9


SUGGESTED HEATING PROCEDURES Low Cement Castables … Cement - May 20… · Low Cement Castables...

Documents

Transcript of SUGGESTED HEATING PROCEDURES Low Cement Castables … Cement - May 20… · Low Cement Castables...