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Uniceram Advanced Materials, Inc. ………..A provider of quality ceramic products………….
3883 Rogers Bridge Road, Suite 304B Duluth, GA 30097
Refractory Solution for the Cement Industry Uniceram offers products and technical services for suspension preheater / precalciner and the cement rotary kiln. The product range for cement includes magnesia chrome / magnesia alumina spinel bricks, high alumina bricks, insulation bricks, conventional and low cement castables, gunning mixes and insulating castables. These products are designed to combat dynamic wear mechanisms encountered in cement manufacture. Wear linings based on these products are distinguished by their abrasion, impact and alkali resistance. To ensure highest possible life in service, we believe in designing customized products for unique kiln operating condition and clinker chemistry. This is preceded by a comprehensive study of the kiln operation under optimal thermal load and analysis of the clinker using such modern tools as XRF and XRD. We also provide support during application of the refractories and monitor the same on a continuous basis. Post performance analysis of worn out refractories is done to ensure that product performance is further optimized in the future. Preheater / PreCalciner: See the vertical figure on the side . PRODUCT BRAND
General Description of the Refractory Types mentioned above:
Basic Refractories:
Magnesite This range of fired and chemically bonded magnesite bricks is suitable for use in backup applications of EAF, LD converter, steel ladle and can be supplied with or without steel cladding. Dense Magnesite Dense fired magnesite bricks containing up to 92% MgO are supplied for utilities such as EAF sub hearth and working lining, hot metal mixer wear out lining and converter back up.
Low Iron Magnesite With the increased focus on fuel efficiency in glassmaking and increase in furnace life necessitated by economy, the use of high purity magnesite bricks in glass regenerator has become universal. Uniceram offers the MGIS range of low iron high purity Magnesite bricks manufactured with high grade Sea water and sintered natural magnesia. These refractories are distinguished by their high density and resistance to alkali, sulfur, silica carry over and fume attack. Refractory solutions based on this range can be customized depending on the cost economics, capacity and the life expectancy of the glass furnace. Magnesite Chrome Conventional and dense fired conventional Magnesia chrome bricks are offered for utilities such as steel ladle, LRF, AOD, VOD, EAF/EOF for back up and working lining applications. Chrome Magnesite In this range Uniceram offers general purpose varieties for back up application, reheating furnace and other non ferrous industries. Direct Bonded Magnesite Chrome The DBMC range is based on high grade magnesite chrome co-sintering and firing at a very high temperature. These are very good corrosion, erosion and thermal shock resistant bricks suitable for non-ferrous applications and AOD working lining. For the cement rotary kiln burning zone, a superior product, UAM DBMCA has been developed. Magnesia Alumina Spinel The MGAL range is specifically designed for chrome free rotary cement kiln application. These are manufactured from very high grade sintered magnesia and electrofused spinel and are capable of a high coatability in service.
Insulation Refractories: Conventional Insulations: These bricks are manufactured by the sawdust process using selected grades of china clay and kyanite for hot face as well as back up applications. Particularly notable is the HFK brick, which is one of the most economical insulations in its classification temperature. Uniceram also manufactures high CCS insulation tiles, UAM HSI for glass melter bottom and can supply the same in any size. Vibro-cast Insulations: This range of bricks has been entirely developed through indigenous research. The bricks are formed by the vibro-casting method. Vibro-casting ensures extremely low thermal conductivity and proportionately high strength. These bricks are engineered for cold face as well as hot face applications and can withstand temperatures of upto 1500°C. Customized solutions for kilns and furnaces based on vibro-cast bricks can be developed along with the cost benefit analysis in terms of energy savings.
High Alumina insulations: This range of insulation bricks have alumina content extending upto 95% alumina and are mostly use for applications starting from 1500°C.These products are distinguished by their pure chemistry, high hot strength and excellent volume stability in service. Especially notable are bubble alumina based bricks, UAM BA90AL which are manufactured by vibrocasting and can withstand continuous hot face temperatures of upto 1800°c. These bricks have always given valuable returns in terms of durability and fuel savings.
General purpose castables: The UAC CRETE range of conventional castables is suitable for moderate and high heat duty applications. These are calcium aluminate bonded refractory concrete for application for temperatures upto 1400° c. These can be either vibration cast or poured. The grading of these products is formulated such that they can be gunned if required. High alumina High purity Conventional Castables: The UACHEAT range of high alumina conventional castables is made with aluminous aggregate and high purity high alumina refractory cement. These are suitable for use in critical applications upto 1800°C. They exhibit high volume stability, good thermal shock resistance and excellent hot strength. These castables are installed by both vibration and hand placement.
Low Cement Castables: The UACVIB range of low cement castable is available in 45% to 90% Al2O3 content. They are made with aluminous and mullite aggregates and high purity high alumina cement. These are suitable for extreme service conditions and have application temperatures upto 1800° c. These products are distinguished by their high volume stability, low porosity, better corrosion and erosion resistance, good thermal shock resistance and excellent hot strength. Installation of these castables is by vibration only.
Large aggregate Low cement castables: Uniceram also manufactures large aggregate (upto 10mm) based low cement castables. They exhibit excellent volume stability, spalling resistance and high temperature mechanical properties. Application of these castables is recommended in severe service conditions where the thickness exceeds 75mm. The castables are most suitably installed by vibration casting. Self flow castables: The UACFLOW range is a set of customized self flow castables. Depending on the end use, these could be either silicate bonded or alumina bonded. This range is available in a wide range of alumina content. Their installation is recommended by pouring against the form work. Extreme purity of the bond system and easy placement make them highly acceptable for various applications. Insulating castables: The UACLITE range of insulating castables is based on high purity insulating grog manufactured in-house. The service temperature goes upto 1800°C for bubble alumina based 95% Al2O3 castable and bulk densities achieved are as low as 500 gms/dm3. This prolific range of castables find use as both hot face and backup refractory lining.
Fe2O3 (%) max 11.00 8.50 6.00 3.50 3.50 3.20 The above values are from test samples and should be only used for guidance. We can also provide highly customized products, made to the end-user’s specifications or application. Nature of Bond : Hydraulic Installation : Rodding / Tamping Storage Life : 6 Months Delivery State : Dry
The above values are from test samples and should be only used for guidance. We can also provide highly customized products, made to the end-user’s specifications or application. Nature of Bond : Hydraulic Installation : Vibrating Storage Life : 3 Months Delivery State : Dry
SiO2 (%) max 0.30 0.30 - - Fe2O3 (%) max 0.30 0.30 4.00 2.50 CaO max 5.00 2.80 - -
The above values are from test samples and should be only used for guidance. We can also provide highly customized products, made to the end-user’s specifications or application. Nature of Bond : Hydraulic Installation : Pouring / Casting Storage Life : 6 Months Delivery State : Dry
The above values are from test samples and should be only used for guidance. ** ABRASION RESISTANCE MORGAN MARSHAL 20-30 Remarks: The above data relates to standard size pressed bricks. These are subject to variation for bigger pressed and hand molded shapes. Standard Tolerance on Size: ± 1.5% or ±2 mm whichever is greater.
Direct Bonded Magnesite Chrome For Copper, Zinc in Non Ferrous and VOD, AOD in Steel and Cement Industry UAM-DBMC-I 68 12 3.0 ⎯ ⎯ 18 2.95 350 1650 UAM-DBMC-II 70 10 2.5 ⎯ ⎯ 18 3.00 400 1700 UAM-DBMC-III 75 8 2.0 4 ⎯ 18 3.05 400 1700 UAM-DBMC-SPL 65 18 1.0 ⎯ ⎯ 18 3.10 400 1700 UAM-DBCM-SPL 50 28 1.0 ⎯ 0.6 17 3.15 400 1700 The above values are from test samples and should be only used for guidance.
The above values are from test samples and should be only used for guidance.
Remarks: The above data for Special Refractories and Magnesite Alumina relates to standard size pressed bricks. These are subject to variation for bigger pressed and hand molded shapes. Standard Tolerance on Size: ± 1.5% or ±2 mm whichever is greater. For further details contact us at [email protected]