Refractory DivisionProduct & ServicesFerrous ► Rotary Kiln  
 
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Rotary Kiln
OCL offers varieties of castable for Sponge rotary kiln depending upon its kiln capacity

 
Kiln Capacity (TPD) Inlet Reaction Zone Out Let Cone Area Transfer Chute
50 EXCELCAST 45 (15 mtr) EXCELCAST 60A EXCELCAST 60A (10 to 12 m) EXCELCAST 60A
100 EXCELCAST 80B (8 to 10 mtr) EXCELCAST 60A EXCELCAST 80B ( 8 to 12 m) EXCELCAST 80B
350 EXCELCAST 80B (8 to 10 mtr) EXCELCAST 60A EXCELCAST 80B (20 to 24 m) EXCELCAST 80B with SS fibre
500 EXCELCAST 80B (15 to 20 mtr) EXCELCAST 60A EXCELCAST 80B (20 to 24 m) EXCELCAST 80B with SS fibre
 
Characteristics of mullitic castable for sponge iron kiln
Sl No Characteristics Excelcast 80B Excelcast 60A Excelcast 45A
1 Material Corundum Mullitic Mullitic
2 CCS at 10000C (kg cm2) 900-1000 800-900 700-800
3 Thermal Conductivity
at 10500C (W/mk)
1.90-1.95 1.80-1.85 0.90-1.00
4 Shell Temparature 250-3000C 250-3000C 250-3000C
5 Removal of Accretion Very Smooth Very Smooth Very Smooth
6 Thermal Shock Very Good Very Good Good
7 Abrasion Resistance Very High Very High High
 
The above table depicts the comparative criteria considered for designing the mullitic castable for sponge iron kiln. These product developed have better strength and lower thermal conductivity, which leads to, controlled heat transmission to the shell thus economizing the entire operation with lower coal consumption.
 
The mullitic grains offset the temperature rise to a fair degree owing to variation in the quality of input material and coal that govern the process temperature. These product developed have better strength and lower thermal conductivity, which leads to, controlled heat transmission to the shell thus economizing the entire operation with lower coal consumption.
 
Other important varieties of castable for different areas depending on operational environment are
EXCELCAST 80B
This is a specially designed material containing highly abrasive corundum grains to withstand the abrasion of input feed at a temperature of 600-800°C. It is characterized by low iron, high abrasion, and high thermal shock resistance at the dynamic reducing environment of rotary kiln: It is reinforced with steel fiber needles to further enhance the abrasion in the transfer chute and if desired in cooler where the working lining is face to face with DRI at high temperature.
 
EXCELCAST 60A
This is a mullite based castable & have some added advantages like
Less weight of castable results less burden on kiln rotary mechanism
Thermal conductivity is less which results low shell temperature and less thermal load on kiln gears and tires
This mullite based castable also shows non wetting properties to accretion melt thus results easy removal of accretion
 
Other important varieties of castable for different areas depending on operational environment are
EXCELCAST 45A
This is a specially designed material containing highly abrasive corundum grains in the matrix along with the base mullitic component. It is designed for pre-reaction zone of smaller kilns of 50 TPD capacities to withstand the abrasion of input feed at a temperature of 600-800°C in. It is characterized by low iron, high abrasion, and high thermal shock resistance at the dynamic reducing environment of rotary kiln.
 
OCCAST 50
This castable is designed for application in low temperature areas of ABC and DSC and in the gas cooling tower in case power generation is tied to the system. This castable is very user-friendly and can be trowelled and vibrated in place and can withstand the abrasion of gas and dust upto 1000°C.
  
(C) OCL India Ltd.
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