Castable Refractory is the High temperature refractory materials that are made up from rare earth minerals. These castable refractory are composites of Minerals and Oxides of the Minerals. The materials are primarily extracted from the mines as ores and are processed for the end use application. Typically extracted from mines, which possess a characteristic as a barrier for thermal conduction. Basically serves as Thermal Insulators and thus enacts fuel saving.
Heat is the fundamental source of energy for most of process, either in domestic or industrial segment. The most commonly used heat applications in domestic segment is Cooking, Room Heating, Ironing, Hot Water and Drying. In the Industrial segment, it has varied applications in most of the Industries widely as Boilers, Furnace and Dryers. The amount of heat energy consumption is almost equal to the consumption of electricity for any industry and typically we use 1/3rd of our energy utilization as Thermal energy. Fuels like Firewood, Gasoline, Petrol, Diesel, and Furnace Oil are used to produce heat energy, as cost of Electricity to produce heat energy is comparatively higher.
Equipment’s like Boilers, Furnaces, Industrial Heaters and Dryers uses heat energy as the primary source for processing. Fuels operated devices consumes considerable amount of fuel either as Fluid form or Solid Form or Electricity. When these Castable refractory are applied to the firing zone will block the heat energy transfer thereby resulting in lesser heat loss and fuel saving.
Castable refractory are the materials that provides excellent resistance to heat conduction, thereby results in increased efficiency at lesser fuel consumption. The material is basically composites of minerals that are being extracted from earth and then are process for oxidations. The oxides of the minerals are then added with other addictive’s such as Fe and Mg for bonding and chemical reaction purpose. The basic used mineral is oxides of Alumina and Silica. These oxides has a natural tendency of offering excellent barrier to thermal energy conduction and are when blended with other minerals and metallic powder, enable to cast the barrier in desired shape and sized.
The final product is in the form of granules mixed with appropriate ratio of calundum for better bonding and oxidation purpose. The calandum is in the form of powder, which is then mixed with granules blended with minerals and oxides for the final product. The typical operating temperature of these materials ranges from 1200 deg C to 2300 deg C, with excellent thermal resistance and shock absorbance. Further when the dry mix when added and mixed with water, it will be oxidizes for better mechanical bonding to the surface. When the surface is heated with fuel, these barrier offers lower thermal conductivity, thereby resulting in lesser fuel consumption. Further when heat is exposed to the surface, it also provides operation safety as reduces the intensity of heat, for the operator to stand near the equipment.
The product is laboratory tested for the Operating Temperature, Fusion Temperature, Cold Crushing Strength, Apparent Porosity, Chemical Composition, Density, and Shrinkage and Pyrometric tests. Bureau of Indian Standard (BIS) has framed out the regulation for these Castable under section 10570 (2011) that are to be followed mandatorily.
The major features of the product is Energy saving, Fuel Saving and Operational safety. The product is further finds its applications in almost every segments like Food Processing, Metallurgical, Foundry, Sugar Plants, Rice Mills, Petrochemical Industry, Leather Industries, Dyeing Industries and Waste Disposal machinery manufacturers.
These castables are manufactured with additives that offer additional operational life time, which shall prevent frequent maintenance and associated operation costs. Additional care shall be taken while selecting the specification / grade of the material, as the product is available in various chemical compositions. Please consult with your local dealer before the application of the product.
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