SHARADAA

SHARADAA CERAMICS PVT LTD

MINISTEEL

REFRACTORIES FOR MOLTEN IRON & STEEL

SLIDE GATE REFRACTORIESLADLE INNER / COLLECTOR NOZZLESTUNDISH NOZZLESPOROUS PLUGWELL BLOCKS FOR LADLE / TUNDISH95%, 90%, 60% CASTABLES90K MORTORNOZZLE FILLING COMPOUND

TUNDISH BOARDSCASTING POWDERREHEAT FURNACE BRICKS / BLOCKSBURNER BLOCKSINDUCTION FURNACE TOP /BOTTOM BLOCKSI.F. RAMMING MASSESCOILKOTE

REFRACTORY MONOLITHIC & INSULATIONSFOUNDRIESFOUNDRY LADLE CASTABLES FOR HIGHER CAMPAIGN LIFENEUTRAL / BASIC / SILICA RAMMING MASS FOR INDUCTION FURNACESPRECAST SHAPES FOR INDUCTION FURNACE / LADLEPATCHING PLASTICS / PLASTER - IMPORT SUBSTITUTIONEXOTHERMIC / INSULATION SLEEVESMOULD COATINGSANTI SLAG COATINGS FOR LADLEREFRACTORIES FOR LONG CAMPAIGN CUPOLASCERAMIC FIBER SLEEVES FOR NON-FERROUS FOUNDRIES

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LADLE AND TUNDISH NOZZLE

General Properties

Service Temperature °C (Max) 1650 1700 1700 1700 1700

Body Alumina Alumina Alumina Alumina Carbon Carbon Carbon Carbon

Insert ZiRCON 95 % - - - -

Physical Properties

Body

Bulk Density (gm/cc)

Dired at 200 C (Min) 2.8 2.8 2.8 3.2 3

AP % 10 10 10 8 10

Insert

Bulk Density (Min) 5.2 - - - -

AP % (Max) 5 - - - -

Chemical Properties

Al2O3(Min) 70 80 80 90 90

Fe2O3(Max) 1 0.5 0.5 0.3 0.2

SiO2(Max) 7 5 5 2 5

Fixed Carbon (Min) 7 5 5 5 -

Thermal Properties

Resistance to Metal Erosion Excellent Excellent Excellent Excellent Excellent

Application Area Tundish Ladle Bottom Ladle Bottom Ladle Bottom Ladle Bottom

PERTICULARS TUNDISH LADDLE COLLECTOR SLIDE GATE POROUS NOZZLE NOZZLE NOZZLE PLATE PLUG

Chemical Analysis (%)SiO2

Fe2O3

C Bulk Density (gm/cc)Cold Crushing Strength (kgf/cm2)Ignition Loss (%)Application Temperature°C

≥89≤12 to 3≥1.25205 to 6≥1650°C

≥90≤12 to 3≥1.4254 to 5≥1650°C

TUNDISH SEALING PACKING COMPOUND

Chemical Analysis (%)SiO2

Fe2O3

Al2O3

MgOCaOCAlkalis (%)Application Temp°C

≥ 85≤ 0.55 to 7

≤ 0.5

3 to 5≥1650°C

≥ 85≤ 0.55 to 7≤ 1.0≤ 2.04 to 7--≥ 1650°C

PARTICULARS

TUNDISH BOARD AND CONE

TUNDISH IMPACT PAD

PARTICULARS

Tundish Sealing and Packing Compound

Tundish Board, Cone and Impact Pad

Vacuum Formed Products and Mixes for Tundishes

Chemical Analysis (%) Cr2O3 >23 % >10 %SiO2 40 ~ 50 % 70 ~ 80 %Fe2O3 <30 % <30 %Al2O3 <5 % <5 %MgO <10 % <10 %Moisture Nil NilPhysical Properties Shape Semi round Semi roundGrain size 0 - 1 mm 0 - 1 mmDensity (gm/cc) 1.6 - 2.0 1.4 - 1.6

Nozzle Filling Compound for Ladle & Tundish - Mini Steel PlantPARTICULARS SPECIAL STEEL CARBON STEEL

FOR STEEL /MINISTEEL

Slide Gate Refractory for Steel / Ministeel

SHARADAA 95SLR SHARADAA A SHARADAA K

Particulars

General Properties

Service Temp°C (max) 1800 1750 1600

Grain size mm (max) 5 5 5

Water Required to Mix

For Ramming 8-10 8-10 8-10

For Casting 10-12 10-12 10-12

Physical Properties

Bd Dried at 110C 2.8 2.75 2.2

Cold Crushing Strength

after Fired at 1550°C 500 650 400

Mor after Fired at 1550°C 100 110 90

Thermal Properties

Permanent Linear Change

after Fired at 1550°C -0.5 -0.8 -1.20

Al203+Spinel (min) 92 90 60

Fe203 (max) 0.8 0.8 1.5

Resistance to Slag Corrosion Excellent Good Good

Resistance to Metal Erosion Excellent Good Good

Application Area Ladle Bottom Repair Ladle Bottom Repair Ladle Side Wall & Lunder

Installation Essential Padle Mixer Padle Mixer Padle Mixer

18°C ICE Water 18°C ICE Water 18°C ICE Water

Store at Cool Dry Place Store at Cool Dry Place Store at Cool Dry Place

Steel Ladle Slag Resistance Castable

PARTICULARS SHARADAA 90KTypes of Setting HEATService Temp°C (max) 1800Refractories (Min.) 37 - 38Grain Size mm (max.) 0 - 0.25Chemical Properties Al203+Spinel (min) 90Fe203 (max) 1Resistance to Slag Corrosion ExcellentResistance to Metal Erosion ExcellentApplication Area Nozzle Fixing at Ladle and TundishInstallation Essential Padle Mixer / 18°C ICE Water Store at Cool Dry Place

Refractory Mortor for Ministeel

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• Brick Lined

• Fully Monolithic Lined ladles are preferred over the brick lining due to following benefits; - Longer Life / Lower Downtime - Jointless lining minimising metal / slag penetration - Lesser Wear pattern - Lower Shell temperature / Energy Saving - Zero Refractory Inclusion - Labour Cost Reduction

High Alumina Castables / Plastics are generally used as an original refractory lining and also used as a topup material to repair the wornout lining. The ladle lining can be broadly classified as follows:

For smaller ladles precast prefired shapes are preferred. The extended heats are achieved by usage of appropriate patching castables.

Foundry Needs

Sleeves & Coatings• Exothermic Sleeves• Insulating Sleeves• Coating Materials a. ZIRCON (Alcohol & Water Based) b. GRAPHITE (Alcohol & Water Based) c. ALUMINO SILICATE (Water Based)• Filters a. SIC Foam Filter b. Mullite Based Ceramic Filter

Induction Furnace• Ramming Mass - Silica / Basic / Neutral• Precast Shoulder / Top Blocks• Coil Coating Materials

Foundry Ladle• Iron Foundries - Velcast SF204 - Ladle Ram with Ladle Coat• Steel Foundries - Velcast 90 SPL

• We offer Debricking / Castable Laying / Heat Curing at our factory of Ladles

• Converters to save space, labour / power costs at your works

LADLE / CONVERTER IN FERROUS / NON-FERROUS /STEEL FOUNDRIES

REFRACTORY MONOLITHIC SOLUTIONS FOR

Ladle Cover

Ceramic Fibre Paper

Converter

Slag Cup Test

Refractory Castablesfor Grey Iron / SG Iron / Steel Casting

Ceramic Fibre Paper 6mm

Installation Options: Trowelling / Vibrocasting / Free Flow / Ramming / Ready Made Plastics

Anti Slag Coating

SLEEVESEXOTHERMIC SLEEVES / INSULATION SLEEVES / CERAMIC FIBRE SLEEVES / DIRECT POUR SYSTEM

BENEFITS AS COMPARED TO CONVENTIONAL REFRACTORY SHAPES

• Small in size but more effective than large sand risers

• Extend the solidification time for the risers

• Improve the yield by reducing the require- ment of riser metal by 70%

• Increase the number of moulds poured per hour

• Eliminate shrinkage defects in casting at riser junctions

• Reduce cutting and fettling costs due to lesser contact area with the castings

• Improve casting contour and casting finish (Supplements the use of breaker cores)

• Consistent perfor- mance of the sleeves results in consistent quality castings

CERAMIC FIBRE SLEEVES FOR

INDUCTION FURNACESNON-FERROUSSILICA / BASIC / NEUTRAL RAMMING MASS FOR

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LONG CAMPAIGN COST EFFECTIVE INCLUSIONFREE LINING FROM SHARADAA

REFRACTORY SOLUTIONS FOR FOUNDRIES LADLES

REFRACTORY CASTABLES FOR IRON LADLE

Parameters Existing Practice Sharadaa Solution

Refractory Used 90% Coventional Castable Velcrete SF-204Backup Insulation Not used 6mm Mica PaperShell Temperature 140-160C 130-150CLife 30 Days 90 DaysRefractory Inclusion High LowCost / Lining 3.30 Lacs 1.90 LacsCost / Heat 138 80Cost / MT 27 16Other Advantages Slag Buildup Very High Very Less Repair Every 5 Days Once in all the area Every 30 Days Once Only in Slag Zone Area Lining Safety Very Bad Very GoodInclusion in Casting Often Present Eliminated

Parameters Existing Practice Sharadaa Solution

Refractory Used 40% Refractory Mass Velcast-90 SPLBackup Insulation Not used 3 mm Asbestos SheetLife 12 Tappings 400 TappingsRefractory Inclusion High LowCost / Lining Rs. 3,000 Rs. 20,000Cost/ Tapping Rs. 250 Rs. 50Cost / MT Rs. 500 Rs. 100Other Advantages Slag Buildup Very High Very Less Lining Safety Very Bad Very GoodInclusion in Casting Often Present Eliminated

REFRACTORY CASTABLES FOR STEEL LADLE

Parameters Existing Practice Sharadaa Solution

Refractory Used Alumina Carbon Nanobond-630 Ramming MassBackup Insulation Nil NilShell Temperature 80-100C 80-100CLife 15 Days 50 DaysRefractory Inclusion High LowCost / Lining 5.4 Lacs 7 LacsCost / MT 180 70Other Advantages Slag Generation Very High Very Less Lining Safety Very Bad Very Good

REFRACTORY CASTABLES FOR WATER COOLED CUPOLA

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Parameters Existing Practice Sharadaa Solution

Refractory Used Alumina Carbon Plastic Velplast-1030 SCBackup Insulation 60% Alumina Castable 60% Alumina CastableShell Temperature Life 24 Hrs. 24 HrsRefractory Inclusion Low LowCost / Lining 0.20 Lacs 0.15 LacsCost / Tapping Rs. 333 Rs. 250Cost / MT Rs. 333 Rs. 250

REFRACTORY PLASTER FOR IRON LADLE

Parameters Existing Practice Sharadaa Solution

Refractory Used Ramming Mass LadleRam with LadleCoatBackup Insulation Nil NilShell Temperature 130 - 160 C 130-160 CLife (Tapping) 300 400Refractory Inclusion High LowCost / Lining 0.5 Lacs 0.4 LacsCost / MT 175 106Other Advantages - Slag Chipping (Removal) Hard Easy- Slag Penetration High Low

LADLERAM WITH LADLECOAT FOR IRON LADLE

LONG CAMPAIGN COST EFFECTIVE INCLUSION FREE LINING

Zircon Coating :Baume :Solids :Application Area :

Applying Method :

Water Base100-12070%Steel Castings, High DutyIrons & Ingot MouldsBrushing

ZIRCOAT (W)

Graphite Coating :Solids :Application Area :Applying Method :

Water Base60%Grey Iron, Non-FerrousBrushing

GRAPHCOAT (W)

Alumina Silicate Coating :Solids :Application Area :

Applying Method :

Water Base60%Grey & Ductile IronComponentsSwabbing, Dipping, Brushing

ALUCOAT (W)

• Excellent surface cast finish• Reduces the fettling process• Reduces the casting defects

- Metal Penetration- Poor casting strip- Mould erosion- Sand inclusion defects

Advantages

• High Refractory Properties• Good Adhesion to the Substrate• Good Suspension Properties

Coating Characteristics

Zircon Coating :Baume :Solids :Application Area :

Applying Method :

Spirit Base55-6265%Steel Castings, Grey & Malleable IronBrushing, Spraying, Swabbing

ZIRCOAT (S)

Graphite coating :Solids :Application Area :Applying Method :

Spirit Base35%Cast Iron, Grey IronBrushing, Spraying

GRAPHCOAT (S)

REFRACTORY COATINGS FOR FOUNDRIES

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FOUNDRY LADLES

LADLE COAT - CIF

General PropertiesType of Material Ready mix mortarNature of bond HeatInstallation Method Hand Patching / BrushingMaximum Service Temperature (°C) 1650

Typical Physical PropertiesAppearance Dark grey mortarSpecific Gravity 1.80 - 2.00

LADLE COAT

LADLE RAM

FOR IRON FOUNDRIES / STEEL FOUNDRIES

PROPERTIES VELCAST SF 204 VELCAST 90 SPLLADLE RAM - CIF

Product CharecteristicsBond Ultra Fine Phospate Ultra FineAggregate Cal. Bauxite Cal. Bauxite Fused AluminaType of Setting Ceramic Hardening Phospate Hardening HydraulicService Temp °C (Max) 1700 1650 1750Grain Size (mm) 6 3 6Chemical Properties Al2O3 80 60 88 Fe2O3 1.2 3.5 0.8

Physical PropertiesBulk Density After Drying at 110°C (gm/cc) 2.90 2.50 3.0Cold Crushing Strength (Kg/cm2) 110°C 500 150 1000 1100°C 900 300 1500°C 1200 600 1200Cold MOR (Kg/cm2) 110°C 90 65 180 1100°C 160 135 1500°C 200 300 200

Thermal PropertiesThermal Conductivity at 600°C HF (Kcal/hr/m/°C ) 1.4 -- 1.8Hot MOR at 1400°C (Kg/cm2) 100 -- Thermal Expansion at 1100°C (%) 0.9 -- 1.2Permanent Linear Change at 1500°C(%)(Max) ±1.0 ±0.5 ±1.0Thermal Shock Resistance at 1100°C + 50 Cycles -- + 40 CyclesApparent Porosity at 1500°C (Max) 16 -- 18

CUPOLA TYPE FURNACES

PROPERTIES VELCRETE SF-20 SC NANOBOND-630 VELCRETE SF-203

HIGH PERFORMANCE CASTABLE & PRECAST SHAPES

Product CharecteristicsType of Cupola Gas Fired Coal Fired Coal & Gas Fired Application area Below Tuyers Below Tuyers Above TuyersAggregate BFA+SIC WTA+SIC CAL.BAUXITEBond Ultra fine Nano Bond Ultra fineType of Setting Ceramic Hardening Hydraulic Ceramic HardeningService Temp °C (Max) 1700 1700 1700Refractorieness °C (Min) 1800 1800 1800Grain Size (mm) 6 6 6Chemical Properties Al2O3 60 40 60SiC+C 30 50 Fe2O3 1 0.6 1.5Physical Properties Bulk Density at 110°C (Min) 2.9 2.8 2.5Cold Crushing Strength (Kgs/cm2) 110°C 400 700 4001100°C 1000 1200 9001500°C 1000 1800 1000Thermal Properties Thermal Conductivity at 600°C Hot face (Kcal/hr/m/ °C ) 3.2 3.8 1.2Thermal Expansion at 1100°C (%) 1.2 1.5 0.6Permanent Linear Change at 1500°C (%) +1.5 +1.5 +0.5Apparent Porosity at 1500°C (Max) 16 16 16Material Required per M3 (Kg) 2900 2800 2500Form demoulding time 8 8 8Temperature of mix 20 - 25 20 - 25 20 - 25Slag Resistance Excellent Excellent

Melting ZoneCastable : Velcrete SiC 42Maintenance : Backups PCF 704

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Well ZoneCastable : Velcrete SF20SiCMaintenance : Plascrete 80D

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StackCastable: Super Patch 1700ºC

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HearthCastable : Velcrete SiC 20Maintenance : Super Patch 1700ºC

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RunnerCastable : Velcrete 504Maintenance : Superpatch 1700

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MONOLITHIC SOLUTIONS FOR HOT BLAST CUPOLAS

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LONG CAMPAIGN CUPOLAS

387, 388 SIDCO Industrial Estate, Ambattur, Chennai-600098Tel : +91 44 26254365 / 26254366Fax : +91 44 42189355Mobile : +91 9600095559 / 9600095574 / 8754530681Email : admin@sharadaamonolithic.com www.sharadaceramics.com

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