Refractory Monolithics

AMANA offers the complete range of Refractory Monolithics whether it is a gunning application in an Induction Furnace or a Casting job in Holding Furnace we have the right solution. We manufacture the complete range of Castables & Mortars and have exclusive tie-ups with global manufacturing companies like Calderys for monolithic supply.

Passive Fire Bricks

High purity dense castables are refractory castables suitable for high temperature applications, all of which contain high purity refractory cement as the refractory binder. The impurity levels of all these castables are very low. These castables are available in various grades. Each grade of castables is suitable for a specific range of operational conditions. These refractory castables are hydraulic setting and can be cast or moulded to any shape and can also be suitably modified for gunning of furnace linings.

High Alumina Binders

The high alumina binders, used for making refractory castables, are calcium aluminate cements. We supply three grades of high alumina binders – Calundum, Cal-Al-70 & Cal-Al-80. Calundum, a medium purity high alumina refractory binder, sets hydraulically and when used with refractory aggregates, provides a high strength refractory castable. Cal-Al-70, a high purity refractory binder, sets hydraulically and when used along with refractory aggregates, provides a refractory castable of superior strength.

Insulation Refractory Castables

Our range of insulating castables from the Insulyte series to conserve heat in furnaces. They are light but adequately strong, and have low conductivity, thus serve as either hot face or back- up insulating refractory lining. INSULYTE castables are produced in the density range of 400 to 1600 kg/m3. They are available mainly in two different grades – medium purity and high purity. In addition to standard products, tailor-made compositions are also supplied to suit customer requirements.

Low Cement Castables

ACCMON is a series of low cement castables, having high PCE and high strength at all temperature levels. These castables are favoured in locations, where refractory abuses due to abrasion as well as application temperature are very high. These have low lime content, low porosity and high strength.

Medium Purity Dense Castables

Medium purity dense castables are suitable for use in medium temperature applications. This group of castable contain medium purity Calundum as the refractory binder. Depending on the type ofrefractory aggregates used in these castables, a series of FIRECRETE group of castable are manufactured. All these castables are used in oxidising atmospheres only. These refractory castables are hydraulic setting and can be cast or moulded to any shape, and can also be suitably modified for gunning of furnace linings.

Refractory Mortars

Refractory Mortars are joining materials for laying refractory bricks. We offer a wide range of fireclay and high alumina mortars. These mortars are used as joining materials for various insulation and high alumina bricks. Mortars like Accoset 50, Mortar 70 are suitable for different types of insulation/fire bricks. Some of the mortars are supplied as two component system, where liquid binder is separately provided with powder material. Where water is used as liquid component, the amount of water used should be such that it results in trowelling Consistency.

Refractory Plastics

Refractory Plastics are delivered in an unfired and formable condition. The mixtures consist of moistened aggregates that can be rammed into place with an air & electric hammer. These products are used both for original installations and for patching. Plastic refractories can be used in many varied applications and locations because they are essentially formed by the installer to fit the specific use area.

Conventional Castable

AMANA is a leading manufacturer of conventional castables. Our conventional castables are made with approved raw materials and include a high amount of cement. Known for their low maintenance and abrasion resistant qualities, conventional castables are used in a variety of industries including iron and steel plants, petrochemical, mineral processing, and hydrocarbon processing.

Ultra Low Cement Castable

When it was discovered that the addition of highly reactive volatilised or fume silica to a castable would dramatically change the physical properties, a new family of castables resulted. These dense strong refractory castables, based on the use of low calcium aluminate cement content, have replaced many conventional castables, plastics, ramming and gunning mixes and are used in many applications that require high refractoriness, corrosion resistance and abrasion resistance. These castables possess a uniform structure with low porosity; have high temperature strength throughout the low and intermediate temperature range. Today virtually every refractory castable manufacturer has a complete line of these low cement castables, ultra-low cement and no cement castables.

No Cement Castable

In industrial conditions, very often, the cost of drying of refractory linings is many folds higher than castable refractories being used as lining materials. Faster drying of cement bonded refractory castables often leads to explosions due to the lower permeability that leads to pressure development inside the lining material. There have been several attempts to overcome this issue in industrial conditions. Most of these attempts have focused on replacing calcium aluminate cement by alternative binders such as colloidal silica, liquid phosphates, forsterite etc,. with potential advantages as well as disadvantages. This work has tried to develop an innovative no cement solid binder for castable which results in excellent permeability and hence fast drying in nature

Self Flow Castable

Erosion Resistant Castable

Nanobonded refractory castables for erosion wear applications is of important interest based on recent publications that suggest the use of this route as an alternative to substitute the calcium aluminate cements. In this work, the cold erosion resistance of high-alumina refractory castables containing colloidal silica and a blend of colloidal silica and hydratable alumina as bonding agents were comparated to commercial calcium aluminate cement containing alumina refractory castable, specified by the producer as a suitable material for erosion wear applications. The results showed higher performance for the colloidal silica bonded castables, suggesting the use of this bonding system in the development of refractory castables for erosion wear applications. The ratio between the hot modulus of rupture and the eroded volume has also been shown as a relevant technique for the refractories selection in such environments.

Phosphate Bonded Castable

Monoaluminium phosphate [Al(H2PO4)3 or MAP] is pointed out as the most applied chemical binder in the refractory field due to its solubility in water, high bonding strength and reaction with basic and amphoteric raw materials at low temperatures. Nevertheless, different routes can induce the in-situ generation of Al(H2PO4)3 in castable compositions. This work evaluates the effect of two Al(OH)3 sources added to refractory formulations or H3PO4 solutions (with distinct concentrations) in order to highlight their influence on the phase evolution and thermo-mechanical properties of the prepared samples. Various experimental tests (flowability, setting time, cold and hot mechanical strength, thermogravimetric measurements, X-ray diffraction and hot elastic modulus) were carried out. According to the attained results, the most promising binding system was obtained by the mixture of H3PO4 solution with 48 wt% of concentration + Al(OH)3 particles prior to preparing the castables. Furthermore, the work suggests that a systemic analysis of various parameters (acid concentration, liquid solution amount, type and amount of setting and sintering agents, etc.) should be conducted in order to attain improved phosphate-bonded products.

Ramming Mass

Acidic Ramming Mass is used in the lining of induction furnaces. Quality of Acidic Ramming mass is directly related to the heating performance of the furnaces. Better quality of lining results in the smooth working of furnaces, optimum output and better metallurgical control. It is manufactured under strict supervision of qualified & experienced work force. Proper check is exercised on magnetic process to assure iron free material and to assure proper composition of granules according to furnace capacity.The granulation of the mix are optimized keeping in view the furnace make and capacity, thus giving maximum and best results. It is characterized by thermal stability, corrosion resistance and wear resistance because it contains less binders, fire clay and moisture compared to plastic refractories.

Patching Refractory

Refractory patching material for blast furnace is usually used for crevice between blast furnace shell and cooling stave.and adopt the method of anhydrous impressing mortar. According to different parts and demands of blast furnaces, the refractory pressing materials of various materials such as carbon,aluminious carbon,high aluminum or clay can be selected for construction.After filling the gap between the blast furnace shell and the cooling wall,After solidification, a compact whole can be formed and can be constructed during the blast furnace downwind period.It will not affect the normal operation of blast furnace.

Gunniting Refractory

Gunning repair is a tested procedure by which refractory material can be applied quickly and economically. It’s used for relining or repairing of ladles, melting furnaces etc. Rotor type gunning machine is used for dry-gunning process widely. Our LZ-3ER refractory gunning machine are specially designed for refractory gunning based on normal shotcrete machine/gunite machine.

Bubble alumina refractory castable

ZIRCAR Ceramics’ Bubble Alumina is a rigid, low-density, insulating refractory comprised of hollow high-purity Alumina spheres bound in a high-purity Alumina cement. Bubble Alumina exhibits high creep resistance to temperatures as high as 1825°C (3317°F).

Vermiculite based insulation refractory castable

Vermiculite, a hydrated Mg/Al/Fe silicate mica-like clay mineral with a laminate structure. Vermiculite is a very versatile material. It has a remarkable ability to expand to many times its original volume (exfoliation) when heated (>300°C). The majority of applications call for vermiculite in its exfoliated form, and it has a wide range of applications that take advantage of its significant properties such as low bulk density, low thermal conductivity, odor-free, chemical inertness, easy handle and fire resistance. These properties make vermiculite a promising material for use as high-temperature insulating refractory material in the metallurgical industry. The service (working) temperature of vermiculite-based refractories is about 1100-1150 °C. In order to increase the working temperature and to produce a wide range of vermiculite-based refractory products, refractory binders and fillers (e.g. alumina cement, fire clays etc.) are added to the lightweight vermiculite. In this paper, the application of vermiculite as a high temperature insulating refractory material was mentioned.

Refractory Dry Out

Boiler Refractory dry out is to ensure proper drying, curing of refractory applied on furnace and other components. The refractory usually undergoes considerable chemical changes, during initial heating. Controlled heating, through these reactions ensures maximum strength. While heating, there must be free air flow over the system to ensure removal of moisture. In order to commence refractory dry out, the following pre-requisites and inputs have to be ensured. Prior to carrying out this test, all the pre-commissioning checks should have been completed. Ensure tlie availability of adequate feed water as per recommendation of the boiler supplier, adequate wooden logs to the required sizes, Draft system and instruments required for the Boiler firing. Ensure the availability of adequate qualified boiler operating staff and operators. Keep open all the vent lines ( 100% open) on the boiler drum, top super heater header throughout the refractory dry out period. Procedure for Boiler Refractory Dry out Refractory baking and dry out cycle requires very slow and controlled heating of refractory as recommended by the refractory manufacturers. Thermal stresses will be produced if heating rate is too rapid. Longer period of low temperature drying causes more even heat distribution resulting better refractory dry out. Fill the drum with the specified quality feed water 50mm below the normal water level since the water level in gauge will raise as heat is absorbed. Maintain normal water level in the drum throughout the period. Place the dry fire wood (2inch diameter and 2 feet length), free from nails and packing metal strips, on the grate. Start ID and FD fan at minimum load to light up the boiler. Ensure that rate of heating is maintained at the rate of 25°C per hour. Raise the temperature of flue gas at boiler outlet to 100°C and hold the temperature to up to 10 hours at 100°C for soaking refractory castables. If the temperature falls, increase the firing rate and maintain the required temperature. Then raise the flue gas temperature at boiler outlet to 250°C and hold it 6 hours for soaking the refractory castables. Again raise flue gas temperature at boiler outlet to 350°C and hold it for 10 hours for soaking the refractory castables. Once the above heating schedule is over, the fire is extinguished and the boiler may be allowed to cool down naturally keeping FD, ID & SA fans off. Fan auxiliary dampers should be in fully closed condition. A thorough examination is to be made to check refractory condition after boiler is cooled down. Minor cracks (up to 3mm) are to be filled with castable refractory. Refractory dry out should be carried out as per the curve given by Refractory manufacturer.