Carborundum Castable Suppliers and Manufacturers

Magnesia Bricks Description Magnesia Bricks are alkaline refractory materials. These products have over 90% magnesium oxide content and adopt periclase as the principal crystalline phase. Magnesia Bricks can be divided into two categories of Burnt Magnesia Bricks and Chemical Bonded Magnesite Brick. They have excellent performance of superior high temperature mechanical strength and volume stability. Magnesia Bricks can service in the high temperature of 1750.. They are ideal products for glass furnace application. Magnesia Bricks Features: It is a kind of alkaline refractory product with periclase as main phase magnesite-alumina spinel clinker as basic material. the product has such characteristics as good temperature vibration, good strength and volume stability in high temperature. Magnesia Bricks Application Basic open-hearth furnace for steelmaking Electric furnace bottom and wall Permanent lining of oxygen converter Non-ferrous metal metallurgy furnace Hyperthermia tunnel kiln Lining of rotary cement kiln Heating furnace bottom and wall Regenerative chamber of glass furnace Magnesia Bricks Properties High Refractoriness Good alkaline slag erosion resistance High apparent initial softening temperature Good thermal conductivity High thermal expansion Magnesia Bricks Manufacturing Process Burnt Magnesia Bricks are manufactured with magnesite clinker as the raw material and fired in the high temperature of 1550~1600 after smashing, burdening, mulling and molding. High-purity products can be fired in the temperature that over 1750. Chemical bonded magnesite brick is produced with certain chemical bonding through mixing, molding and drying.

Insulation Bricks

Refractory Fire Brick

* PHOSCAST Phoscast : Phosphate Bonded Castables * PURPOSE customers using FBC boilers (Particularly underbed feed FBC boilers) for the protection of inbed coils against erosion potential by applying highly abrasive resistant refractory on inbed coils above fuel feed system. BACKGROUND * Two of such actions are providing special alloy studs on inbed coils and applying highly abrasive resistant refractory on the outer bottom loops of inbed Coils which are above the fuel feed nozzles. * GANESHAS has taken number of approaches to identify the key factors affecting erosion rates with an objective to enhance the life of inbed tubes as well as implementing the corrective action to reduce the erosion rates. Phosphate coatings are often used to protect steel parts against rusting and other types of corrosion * Erosion of inbed coils in fluid bed combustor is unavoidable phenomenon however the rate of metal wastage and thus the life of tubes depends on various factors like ash & fuel properties, design of Combustor / feeding system, flue gas velocities operating conditions etc. It has been also observed that maximum erosion prone inbed coils are those which come above fuel feed nozzles and an area of approximately 1 to 1.5 mts around fuel feed systems are badly affected. APPLICATION Phoscast-90 XR can be applied by ramming with wooden mallet having adequately large head @" dia x 5" length x 10â?? Jong handle). The desired lining or repair thickness is built up in several courses while ramming the mass to uniform thickness. Phoscast refractory should never be trawled to obtain smooth surface; ramming only should finish surface. Any excess mass is to be sliced off with trowel edge and then finished by ramming again for bed coil. Tube application of AFBC boiler, the material pasty mass should be finger pressed into the studs of the tube with maximum force. Finish should be given by pressing the hand palm against material applied, using surgical type thin rubber hand gloves.

Ramming mass is commonly used in metallurgy, building materials, non-ferrous metal smelting, chemical, machinery and other manufacturing industries. Ramming mass is widely used in non-core intermediate frequency furnace and core induction furnace. As an intermediate frequency furnace ramming material, refractory ramming is applied to melt gray cast iron, nodular cast iron, malleable cast iron, vermicular cast iron, and cast alloy steel; to melt carbon steel, alloy steel, high manganese steel, tool steel, heat resistant steel, stainless steel, molten aluminum and its alloys; to melt red copper, brass, white brass, bronze and its alloys, etc. Induction furnaces are used for melting cast iron, mild steel and various alloy steels in foundries and making of steel in mini steel plants using sponge iron The refined high silicon, low iron quartz sand and quartz powder are selected and the fused quartz sand is added as the refractory material., with no slag, no crack, damp proof, convenience of repair, and the corrosion resistance, thus greatly improving the furnace service life span and the economic benefit.. Silica ramming mass can safely be used up to an operating temperature of 1600 deg C. Since it expands very little, it is superior to both alumina and magnesia refractories to resist thermal shocks Acid ramming material is the premixed ramming mass of the lining material. The acid ramming mass is used to smelt a series of metal materials such as ordinary steel and carbon steel. The lining practice best suited to a particular furnace depends upon the capacity and design of the furnace, operation practice adopted during making of a heat, and furnace output.

METHOD OF APPICATION: * Mastic compound application consist of two coats of. Primer ,Primer and followed by Mastic compound in recommended thickness, ranging from min. 12mm to 25mm in one or two layers to achieve desired thickness without any pin hole and crack. 1). Surface preparation and application of Primer: Refer application method of Primer. 2). After doing necessary surface preparation and application of primer coating, area to be installed with Mastic compound should be divided in to equal no. bays. To maintain even thickness required, place wooden or aluminum batten. Mastic compound is then broken in small pieces and put it in heating pan. While heating, keep material moving to avoid burning. It is heated until it comes in a uniform consistency and then applied on the surface and works it with wooden float, to achieve uniform thickness and smooth surface free from any pinholes. CHEMICAL RESISTANCE PROPERTIES: * Mastic compound has good resistance to weak, diluted acids, alkalis salts etc. It is not recommended to use against strong acids, oxidizing acid solvents, oil and fats STORAGE & PACKING: * Keep Mastic compound away from direct sunlight, heat solvents etc. Under this condition, its shelf life is unlimited. It is supplied in cake form and approx. wt. is 10 kgs. HEALTH & SAFETY: * Handle melted Mastic compound compound very carefully . Avoid contact with skin. It is advisable to wear protective wears at the time of use of Mastic compound and all other our products. This information, given in good faith, is based on results gained from experience and tests. However, all recommendations or suggestions are made without guarantee since the conditions of use are beyond our control.

APPLICATION OF SK-HB K-SILICATE MORTAR : * K-SILICATE is used for jointing Acid Resisting brick in construction of vessels in suited for construction of fume chambers and stacks handling hot, dry Acid fumes and vapors. It is also used for jointing chemical resisting stoneware pipes. K-SILICATE cement is good bedding material for Acid â?? Resisting bricks and tiles. The concrete surface needed protection should be dryed, clean and rough. The bricks or tiles will be set with K-SILICATE cement over concrete surface applied with a suitable an impermeable interliner. When Bedding and Jointing Materials are the same. On the treated surface bricks or tiles are bedded to a thickness of about 6 mm and tamp gently with a wooden piece till the paste squeezes out of joints. The paste that is squeezed out of the joint should be removed by trowel with good finishing. After the mortar of the joint is dryed treat the joints with 20% Hydrochloric Acid Solution by means of brush. A.R.lining should be always in contact with Acid and not with water. Concrete subtract like Floor, Wall, tanks and similar surface should be protected with a membrane of Bitrok Mastic or compound steel tanks should be protected with rubber or PVC subjected to chemical conditions and temperature of chemical media. The Brick lining is recommended over the protective layer of Bitrok Mastic. When Bedding and Jointing Materials are Different. Spread the silicate type mortar about 6 to 8 mm thick on the back of the tile or brick. Press the tile on the bed leaving required space for joints between tiles for bricks. After the bedding mortar is set, fill Mp the joints with specified cement.PRODUCT DATA SHEET FOR SK-HB ( K-SILICATE) MORTAR A general purpose cement for acid conditions Resistant to High & medium concentrations of most of the common organic and inorganic acids except Hydroflouric acid. Recommended where the concentration of the acid is high suitable for high temperature. Unsuited to aqueous solutions, alkaline conditions. PREPARATIONS OF MORTAR : * Measure 1 part by weight of K-SILICATE solution into a suitable mixing pan. * Add slowly and gradually 3 parts by weight K-SILICATE mortar and mix thoroughly to form a smooth mortar. * In hot season very large batches of mortar will become stiff quite rapidly therefore small batches, not exceeding 4 to 8 kgs. Will be prepared. * The cement mortar will be used before it starts setting.

This is chemical setting Furan based chemical resistant mortar which is combination of Liquid and Powder, when mixed in proper proportion from workable mortar which after setting and curing give of liquid and give black highly cross linked composites. Furan When set and cured is resistant to highly corrosive acids, alkalis and to powerful organic solvents such as ketones, Aromatic and Chlorinated solvents. It has extreme resistant to Acidic & alkalis, Salts, Greases and Detergents. It resists to Organic & Inorganic acids at their boiling temperature. It is suitable against mild chlorine Gas (dry) phosphorous trichloride, pyridine at room temperature. Furan is especially useful where resistance to mixed media such as aqueous acids /alkalis and organic solvents is needed in chemical plant process and waste streams. Carbon filled Furan is used against corrosive effect of hydrofluoric acid & its salts. PREPARATION OF FURANE MORTAR : Mortar consist of Furan solution and Furan powder. The average mixing ratio necessary to obtain mortar with good working consistency is 1 part by weight Solution & 3 part by weight powder. The ratio will vary slightly depending on temperature and working conditions.Stir the liquid thoroughly before using. Place liquid in a suitable shallow mixing pan. Add powder by weight in the solution mix thoroughly and rapidly until all lumps are dispersed and the mortar is completely homogenous. Spread out the mortar in a thin layer, not more than ¾ thick, to dissipate the heat of reaction and lengthen the working life. Batch size can be varied depending upon the temperature and the speed with which the masons are working. Very large batches will become stiff quite rapidly. Make sure that all the Furan Motrar is used from the pan before another batch is mixed.When working at temperature above 40 C, very small batches not more than 2 Kgs, should be prepared. When working at temperature below 15C the liquid should be kept warm.

DATA SHEET FOR EPOXY EPOXY COATING :- INTRODUCTION - EPOXY COATING (HYB) is a two part high solids solvent free epoxy phenolic resin based coating system designed for hard wearing, smooth surface finish for floors, walls and on steel structures. Nonskid surface finish can be achieved on floor, if required. FEATURES: 1) Hard Wearing 2) Non Dusting 3) Excellent Surface Finish 4) Non Smelling 5) Good Aesthetics 6) Highly Chemical Resistant APPLICATION: 1.Stir well before mixing Part A and Part B and mix in the prescribed ratio. 2.Apply one coat of EPOXY primer on the clean and dry surface. 3.EPOXY COATING (HYB) should be applied on the surface by brush or roller within 24 hrs. After application of primer coat it should be allowed to air dry for min. 4 hrs. Preferable in a dust free atmosphere. 4.Apply min. 2 coats with the intercoat interval of 6-8 hrs. PRODUCT SPECIFICATIONS: Application - Brush, Roller Mixing Ratio - As Directed on Packing Port Life - 30 Mins. Drying Time - Touch Dry- 30 Min, Hard Dry 6 Hrs. - Intercoat Interval 6-8 Hrs. Min. - Dry Film Thickness 125-150 Microns/per coat - depending on porosity Covering Capacity - 6-8 sq.met/kg per coat depending on porosity, roughness & method of application. Color Shades - All Standard Shades RECOMMENDED USES: 1) Food & Pharmaceutical 2) Work Shop 3) Clean Room Application 4) Chemical Resistant Coating for Concrete& Steel 5) Petrochemical, Fertilizer plants METHOD OF APPLICATION: SURFACE PREPARATION The long-term durability of the applied Epoxy coating (HYB) epoxy coating is dependent on the adhesion between sub-base and coating material. It is most important therefore, that the substrate surfaces are correctly prepared prior to application. 1.Before application of the Epoxy coating (HYB) surface should be free from loose partials, rust, oils, grease or earlier coatings and should be totally dry. 2.New concrete or cementations surface should be placed at least 28 days and have a moisture content of less than 5% before application of Epoxy coating (HYB) 3.After surface is dry, all repair work like sealing of joints, cracks filling of cavities and crevices should be carried out. HEALTH & SAFETY - Keep the containers tightly closed when not in use. Avoid contact with skin & eyes. It comes in contact with the body, wash affected parts with plenty of water and contact a doctor. Other known sector for Epoxy floor lining, Epoxy garage floor lining, Concrete epoxy lining, Concrete floor epoxy lining, Epoxy pipe lining, Marine epoxy lining, Sub marine epoxy lining, Basement lining epoxy floor shield, Louisiana, Oregon, Chip lining color epoxy floor, Aviation lining epoxy interior.

Bitumen Primer * Bitumen Primer is Bituminous air curing ready mixed Acid & Alkali resistant special primer. Application * Concrete surface must be clean, dry and rough. No primer should be applied over smooth and wet surface. * After cleaning the concrete surface, one coat of Bitumen Primer should be applied with brush and allow to dry thoroughly. * The drying time will depend upon the temperature. * 24 Month at the temperature 30C (+2OC) Packing * Bitumen Primer: 25 Liter Drum Note * Bitumen Primer contains volatile and slightly toxic solvent. Keep away from spark and open flames at working area. * Bitumen premier it is manufactured using bitumen solution which is used for sealing of prime porous and non-porous surface, and also to protect residential and commercial building. * Bitumen Primer is used to protect substrate against corrosive attack, is suggested to apply anti-corrosive primer.It is best for protection against sub-striate against atmospheric corrosion and chemical corrosion. It is a mixed substance made up of organic liquids that are highly sticky, water proof, viscous,acid proof as with all surface coating, good Bitumen Premier is used for long life of the system. it is applied by brush or roller and allowed to dry before any water proofing treatment so to avoid solvent it is used in defects such as cracks, broken mortar joints, etc. are to be repaired prior to Bitumen primer application. Product Details: Grade Standard Technical Grade Physical State - Liquid Usage - Industrial Color - Black Characteristics: Appearance/Color - Pasty liquid/ black Chemical Base - Bituminous rubber emulsion. Density - 1.0 kg/l Curing Speed/ Rate - 3 - 4 hours Tack free after - 5 - 10 hours Cured after - 2 - 4 days (Dependent on ambient Solid Content by - temperature, substrate temperature, Weight - relative Water Content by weight - humidity and thickness of the coating) Bitumen Content - 41% by weight - Thixotropic (The viscosity can be adjusted by - Viscosity adding up to max. 5% of clean water. - Stir well prior use) - For light protection: 1.0 mm min. Coating - For greater protection: ~ 1.5 - 2.0 mm Thickness applied - in two coats. Water Penetration - 48 h, 1 bar: 78.5 cm2: 0 ml under Hydrostatic - 96 h, 4 bar: 78.5 cm2: 33 ml Pressure - Water vapor 6 x 10-7 mg / hmPa Permeability Service - -30 C to 200 C Temperature - Adhesion Concrete - Very good, Timber: Very good, Metal: Moderate Glass: Poor

PRODUCT DATA SHEET ACID RESISTANT BRICK Material : RED SHALE Type Acid Resistant Brick Size (mm) 230 (LENGTH) X 115 (WIDTH) X 100,76,65,50,40,38,30,25 (THICK) Specification : ASTM C279, ASTM C410, IS 4860-1982 DESCRIPTION : We offer premium quality acid resistant bricks Red â?? Shale , tiles and special shapes. We also offer customized sizes as per clients' requirements. Our acid bricks comply with ASTM C279 Type-III, ASTM C410 Type H, L, and Indian Standard 4860 - 1982 Class-I for all applications where low absorption and high acid resistance is required. FEATURES OF ACID RESISTANT BRICK: Excellent resistant against wide range of chemicals except hydrofluoric acid, high abrasion resistance, low wearing properties, High Thermal resistant to sudden change in temperature AREA OF APPLICATION: Chemical Analysis (Average) Acid and Alkali Storage Tank Farms Demineralization plants and Water treatment plants Chimney inside lining, FGD linings Towers and Columns Process Vessels and Tanks Sewerage Treatment Plants and Lines Industrial Flooring and Bund Areas Chimney and Flue Gas Linings Hoppers and Chutes SiO266.4 Al2 0324 TiO21.1 Fe2 O31.1 K2 O + Na2 O2.5 NOT RECOMMENDED: HF acid or other fluoride solutions Heavy thermal shock Typical Physical Properties of GANESHAS Acid and Chemical Resistant Brick Characteristic RED SHALE ACID RESISTANT BRICK Test Standard Bulk Density, gm/cc - 2.3 to 2.35 ASTM C-20 -Water Absorption, % - 0.1 to 1.5 IS 4860-1968 Apparent Porosity, % -0.5 to 1.75 S 4860 Acid Solubility (H2SO4), Loss in Mass,% -0.1 to 1.8 ASTM C-279 Modulus of Rupture, PSI -2133 to 3555 ASTM C-67 Compressive Strength, Kg/cm2 - 700-900 IS 4860-1968 Abrasion Resistant , Volume in mm3 -69 to 85 EN 102 Surface Hardness, MOHS Scale - 7

PRODUCT DATA SHEET ACID RESISTANT BRICK Material : FIRECLAY Type Acid Resistant Brick Size (mm) : 230 (LENGTH) X 115 (WIDTH) X 100,76,65,50,40,38,30,25 (THICK) Specification : ASTM C279, ASTM C410, IS 4860-1982 DESCRIPTION : * We offer premium quality acid resistant bricks Red â?? Shale , tiles and special shapes. We also offer customized sizes as per clients' requirements. Our acid bricks comply with ASTM C279 Type-III, ASTM C410 Type H, L, and Indian Standard 4860 - 1982 Class-I for all applications where low absorption and high acid resistance is required. FEATURES OF ACID RESISTANT BRICK: * Excellent resistant against wide range of chemicals except hydrofluoric acid, high abrasion resistance, low wearing properties, High Thermal resistant to sudden change in temperature AREA OF APPLICATION: Chemical Analysis (Average) Acid and Alkali Storage Tank Farms Demineralization plants and Water treatment plants Chimney inside lining, FGD linings Towers and Columns Process Vessels and Tanks Sewerage Treatment Plants and Lines Industrial Flooring and Bund Areas Chimney and Flue Gas Linings Hoppers and Chutes SiO266.4 Al2 0324 TiO21.1 Fe2 O31.1 K2 O + Na2 O2.5 NOT RECOMMENDED: HF acid or other fluoride solutions - Heavy thermal shock Characteristic Fireclay Type Acid Resistant Brick - Test Standard Bulk Density, lbs/ft3 - 2.25 to 2.30 ASTM C-20 Water Absorption, % - 0.1 to 1.8 ASTM C-20 Apparent Porosity, % - 4.05 to 4.14 ASTM C-20 Acid Solubility (H2SO4), Loss in Mass,% - 6.1 to 6.8 ASTM C-279 Modulus of Rupture, Mpa - 14.6 ASTM C-67 Compressive Strength, PSI - 15500 to 17250 ASTM C-67 Abrasion Resistant , Volume in mm3 - 71 to 96 EN 102 Surface Hardness, MOHS Scale - 7 Thermal Conductivity, BTU-in/hr-ft-F - 6.94 to 7.12 ASTM C-236 Thermal Expansion Coefficient,in/in/Fx10-6 - 2.6 to 2.8 EN 103

Acid / Alkali Resistant Tiles/Bricks * Our Acid proof tiles, Acid alkali resistant tiles, Chemical resistant tiles are fully vitrified tiles which are manufactured using special non ferrous clay, processed at extremely high temperatures this process causes the raw materials to fuse and form a compact mass with an extremely low water absorption of less than 0.5% resulting in the formation of a very strong body with a flexural strength of 38 N/mm2, solid through color fade proof with a very hard surface Mohs hardness of 7. * The acid resistant tiles come in a range of sizes and thicknesses from ranging from 8-25mm. Our acid proof tiles meet stringent specification norms of IS 4457:2007 and relevant ASTM/DIN standards which ensure excellent performance in Acid/Alkali/Chemical (expect Hydrofluoric acid and its derivatives). Corrosion Protection Applications * Factory Floors subject to corrosion from Chemicals, Acids, Oil & Solvents * Pickling tank and surrounding areas * Food & Beverage Industry flooring * Battery rooms and Control rooms * Demineralization plants * Walls of washing and Paint shop areas * Acid Resistant Tiles Manufacturers India * Our acid proof tiles provide excellent abrasion resistance, anti-skid properties for worker safety and high aesthetic appeal. We also provide specialized corner tiles for reducing chances for acid attack through construction joints. Our standard sizes are 200x100, 200x200 & 300x300 millimeters.