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Refractory Bricks for Cement Plant

Dalmia’s refractory bricks for cement plants can be put to different uses. These refractory products show characteristics like excellent resistance to spalling, abrasion, low porosity, and high refractoriness. Besides refractory bricks for cement plants, Dalmia’s range of refractory materials also includes high fire clay bricks, high alumina bricks, conventional castables, special castables, and ramming masses & mortars.

EQUIPMENT	AREA OF INSTALLATION	QUALITY	CHEMICAL ANALYSIS		PHYSICAL PROPERTIES			THERMAL PROPERTIES		SPECIAL FEATURES
			Al₂O₃ (%)	Fe₂O₃ (%)	AP (%)	BD (g/cc)	C.C.S (Kg/ Cm2)	R.U.L (Ta^OC)	Thermal Conductivity (K.Cal/m/hr/^OC at1000OC )
PRE-HEATER & CALCINER VESSELS	UPPER CYCLONES	MH 30-35	30	3.50	25	2.10	250	1300	1.20	ALKALI RESISTENT
	LOWER CYCLONES, INLET CHAMBER, CALCINER VESSEL	HG 40-30	40	3.00	22	2.20	350	1400	120	ALKALI RESISTENT
ROTARY KILN	Discharge Zone	HASR 70-30	70	3.00	18	2.60	600	1470	1.80	Good resistance to spalling, Abrasion, Low porosity, High refractorine ss.
		HA 80-30	80	3.00	23	2.70	500	1450	1.80	Resistance to spalling, Corrosion, Having righ refractoriness
	Burning Zone	DALSINT	70	2.50	18	2.65	600	1500	1.85	Excellent resistance to spalling, Abrasion, Low porosity, High refractoriness.
		LF 70-25	70	2.50	23	2.60	500	1480	1.80	Resistance to spalling, Abrasion, High refractoriness.
		HA 70-30	70	3.00	23	2.60	500	1450	1.80	Resistance to spalling, Corrosion, Having righ refractoriness
		HA 70-30	70	3.00	23	2.60	500	1450	1.80	Resistance to spalling, Corrosion, Having righ refractoriness
	Pre Burning Zone and Transition Zone	DALSI NT - A	70	2.00	15	2.70	600	1520	1.90	Excellent resistance to spalling, Abrasion, low porosity, high refractoriness.
		DALKA R 60	60	2.00	18	2.55	500	1470	1.80	Good resistance to spalling, Abrasion, Low porosity, High refractoriness
	Calcination zone	ALITE	20	2.50	30 min.	1.75 Max	200	1300	0.60	Good resistance to spalling, Abrasion, Low porosity, High refractoriness
		HG 40-30	40	3.00	22	2.20	350	1400	1.20	Alkali resistant
COOLER		HASR 70-30	70	3.00	18	1.75 Max	200	1300	0.60	Good resistance to spalling, Abrasion, Low porosity, High refractoriness
TERTIARY AIR DUCT		LF 30-20	30	2.00	20	2.10	400	1300	1.20	Low porosity and good strength

Fire Clay Bricks

Fire-clay refractory bricks are essentially hydrated aluminum silicates with minor proportions of other minerals. As a type these refractory bricks are extremely versatile and therefore can be put to numerous uses. These bricks are usually least costly of all refractory bricks and are extensively used in various industries including iron and steel industry, nonferrous metallurgy, glass industry, and cement industry.

QUALITY	CHEMICAL ANALYSIS		PHYSICAL PROPERTIES			THERMAL PROPERTIES	RAW MATERIAL BASE	SPECIAL FEATURE	AREA OF USAGE	USER INDUSTRY
	Al₂O₃ (%)	Fe₂O₃ (%)	A P (%)	B D (g/cc)	C.C.S. (Kg/Cm²)	R.U.L (Ta°C)
MH 30-35	30	3.50	25	2.10	250	1300	Fire clay grog	Alkali Resistant	Preheater, Cupola, Foundry	Cement, Steel & general
HH 40-35	40	3.50	25	2.15	250	1350	Fire clay, HA clay grog	Alkali, Slag Resistant	Preheater, Cupola, Foundry	Cement, Steel & general
HG 40-30	40	3.00	22	2.20	350	1380	HA clay grog	Alkali Resistant	Calciningzone, Preheater, Precalciner, Cooler, Ladle, Reheat furnace	Cement, Steel
HG 40-20	40	2.00	22	2.20	350	1400	China clay grog	Corrosion resistant brick	Pre calciner, Cal zone, Coke oven, Glass tank furnace	Cement, Coke, Glass
HG 45-30	45	3.00	22	2.25	350	1420	Cal.Diaspore, HA clay grog	High refractoriness, Alkali resistance	Cal zone, Kiln hood, Inlet chamber, Grate cooler, Gas plants	cement, General
HG 45-15	45	1.50	19	2.25	400	1450	Cal.Diaspore, China clay grog	Resistant to slag and reducing atmosphere	Coke ovens, Metallurgical furnaces	Coke, Met

High Alumina Bricks

QUALITY	CHEMICAL ANALYSIS		PHYSICAL PROPERTIES			THERMAL PROPERTIES	RAW MATERIAL BASE	SPECIAL FEATURE	AREA OF USAGE	USER INDUSTRY
	Al₂O₃ (%)	Fe₂O₃ (%)	A P (%)	B D (g/cc)	C.C.S. (Kg/Cm²)	R.U.L (Ta°C)
HA 50-30	50	3.00	23	2.35	400	1400	Bauxite, Clay grog	Abrasion resistant, Slag resistant	Kiln hood, Cooler, Hot air generator	Cement
HA 60-30	60	3.00	23	2.50	400	1420	Bauxite, Clay grog	High refractoriness & Abrasion resistant	Preburning zone, Trans zone, Lime rotary kiln, Shaft kiln	Cement, Lime
HA 70-30	70	3.00	23	2.60	500	1450	Bauxite, Clay grog	Excellent resistance to spalling, Corrosion and Slag, high Refractoriness	Cement, Lime kiln Burning zone, Electric Arc Furnace roof, Steel ladles	Cement, Steel
HA 80-30	80	3.00	23	2.70	500	1450	Bauxite	High resistance to Abrasion, Slags, Corrosive Slags and Spalling	Ladles, EAF roofs, Smelting furnaces, Cooling zone of cement kiln	Cement, Steel
HG 50-20	50	2.00	21	2.35	350	1450	Cal.Diaspore, China Clay Grog	High Refractoriness, Resistant to slag & reducing Atmosphere	Coke Ovens	Coke, Metal
SL 60-20	60	2.00	21	2.45	400	1500	China Clay, Grog, Mullite, Cal.Diaspore, Sillimanite	High refractoriness, Controlled linear change, High spalling resistance	Glass tank furnace, Element holding bricks	Glass, Furnaces, smelters
LF 70-25	70	2.50	23	2.60	500	1480	Bauxite	Excellent mechanical, Thermal properties, Resistant to slag	Burning zone, EAF roof, Ladles, Tundishes, Metallurgical furnaces	Cement, Steel
LF 70-20	70	2.00	23	2.60	500	1500	Bauxite, Sillimanite	High refractoriness, Excellent resistance to spalling, Slag and abrasion	Burning & Post burning zone, Teaming ladles, Ladle furnaces & Metallurgical furnaces	Cement, Steel
LF 80-20	80	2.00	22	2.70	500	1500	Bauxite, Corundum	High refractoriness, Resistance to reducing atmospheres, Spalling, Slag attack and Abrasion	Cooler side wall, Sponge iron burning zone, EAF delta zone and Ladle furnace.	Cement, Steel and Sponge iron

Special Quality Bricks

QUALITY	CHEMICAL ANALYSIS		PHYSICAL PROPERTIES			THERMAL PROPERTIES		RAW MATERIAL BASE	SPECIAL FEATUREE	AREA OF USAGE	USER INDUSTRY
	Al₂O₃ (%)	Fe₂O₃ (%)	AP (%)	BD (g/cc)	C.C.S. (Kg/Cm²)	R.U.L (Ta°C)	Thermal Conductivity (K.Cal/m/hr/°C) at 1000OC
HASR 70-30*	70	3.00	18	2.60	600	1470	1.80	Bauxite	Good resistance to spalling, Abrasion, Low porosity, High refractoriness.	Kiln discharge zone and cooler	Cement
DALKAR 60*	60	2.00	18	2.55	500	1470	1.80	Bauxite, China clay grog	-DO-	Preburning zone and Transition zone	Cement
DALSINT - A*	70	2.00	15	2.70	600	1520	1.90	Special grade bauxite	Excellent resistance to spalling, Abrasion, Low porosity, High refractoriness.	Preburning zone and Transition zone	Cement
DALSINT B*	70	2.50	18	2.65	600	1500	1.85	Bauxite	-DO-	Rotary Kiln Burning Zone	Cement
ALITE*	20	2.50	30 Min.	1.75 Max.	200	1300	0.60	Insulation grog	Low density, good strength, Very low thermal conductivity.	Calcination zone	Cement
LF 30-20	30	2.00	20	2.10	400	1300	1.20	High grade chamotte	Low porosity and good strength	Tertiary air duct	Cement

Conventional Castables

Castables refer to materials of hydraulic setting in nature. These are the materials that often contain cement binder, which imparts hydraulic setting properties to castables when they are mixed with water. Conventional castables from Dalmia ensure best performance every time they are put to use. Besides conventional castables, Dalmia also supplies low cement castables and special castables.

QUALITY	CHEMICAL ANALYSIS		PHYSICAL PROPERTIES				THERMAL PROPERTIES			RAW MATERIAL BASE	SPECIAL FEATUREE	AREA OF USAGE	USER INDUSTRY
	Al₂O₃	Fe₂O₃	C C S		Dry Density	Grain Size	Permanent Linear Change		Max. Service Temp.
			At Temp °C	Kg / Cm²		(mm)	(+/- %)	At Temp °C / 3hrs
DALCAST 135 N	40	5.00	110 1350	250 225	2.10	6	1.00	1350	1350	HA clay grog	Moderate abrasion resistant	Conical Portion, Feed Pipes. Cooler Cold Zone.	Cement, General
DALCAST 135 S	40	4.00	110 1350	300 250	2.20	6	1.00	1350	1350	HA clay grog	Moderate abrasion resistant	Conical Portion, Feed Pipes. Cooler Cold Zone.	Cement
DALCAST 140 N	70	5.00	110 1450	350 400	2.55	6	1.50	1450	1450	Bauxite	Abrasion resistant	Foundry ladles	Cement, Steel
DALCAST 150 N	50	1.50	110 1500	350 300	2.15	6	1.50	1500	1500	Bauxite, Pure HA clay grog	High purity, Resistant to abrasion and thermal shock	Cooler, Lower cyclones	Cement, General
DALCAST 160 N	60	1.50	110 1500	350 300	2.20	6	1.50	1500	1600	Bauxite, Pure HA clay grog	-DO-	-DO-	Cement, General
DALCAST 160 S	60	1.50	110 1500	400 300	2.30	6	1.50	1500	1600	Bauxite, Pure HA clay grog	-DO-	Conical Portion, Feed Pipes. Calciner.	Cement
DALCAST 170 N	85 - 90	0.5 - 1.0	110 1550	500 400	2.80	6	1.00	1550	1750	Bauxite, Corrundum	-DO-	Ladle & EAF patching	Cement, steel, General
DALCAST 180 N	90	0.50	110 1550	500 500	2.90	6	0.50	1550	1800	Bauxite, Corrundum	-DO-	-DO-	Cement, steel, General

Low Cement Castables

QUALITY	CHEMICAL ANALYSIS		PHYSICAL PROPERTIES				THERMAL PROPERTIES			RAW MATERIAL BASE	SPECIAL FEATUREE	AREA OF USAGE	USER INDUSTRY
	Al₂O₃	Fe₂O₃	C C S		Dry Density	Grain Size	Permanent Linear Change		Max. Service Temp.
	(%)	(%)	At Temp °C	Kg / Cm²		(mm)	(+/- %)	At Temp °C / 3hrs
QUICKPACK LC 45	45	1	1450	800	2.30	6	1.00	1450	1450	Pure HA clay grog	High purity, Resistant to abrasion and thermal shock	Inlet chamber, Riser duct & cooler	Cement
QUICKPACK LC 60	60	1.50	1500	900	2.60	6	1.00	1500	1500	Bauxite, Pure HA clay grog	High purity, Resistant to abrasion and thermal shock	General	Cement, steel
QUICKPACK LC 80	80	2	1500	1000	2.90	8	1.00	1500	1600	Corrundum	High purity, Resistant to abrasion and thermal shock	Tip casting area of cement rotary kiln, Grate coolers and steel tundish permanent lining	Cement, Steel
QUICKPACK LC 90	90	1	1550	1000	3.05	8	0.80	1550	1750	Corrundum	Resistant to high abrasion, Spalling and reducing atmosphere	-DO-	Cement, Steel

Special castables

QUALITY	CHEMICAL ANALYSIS		PHYSICAL PROPERTIES				THERMAL PROPERTIES			RAW MATERIAL BASE	SPECIAL FEATUREE	AREA OF USAGE	USER INDUSTRY
	Al₂O₃	Fe₂O₃	C C S		Dry Density	Grain Size	Permanent Linear Change		Max. Service Temp.
	(%)	(%)	At Temp °C	Kg / Cm²	(gm/cc)	(mm)	(+/- %)	At Temp °C / 3hrs
RAPIDENSE 40	40	1.20	1450	800	2.30	8	0.50	1450	1450	Pure HA clay grog	High purity, Resistant to abrasion and thermal shock	Inlet Chamber, Riser Duct & Anti Coating Areas	Cement
RAPIDENSE 50	50	1.10	1500	1000	2.40	10	0.50	1500	1500	Bauxite, Pure HA clay grog	-DO-	Burner pipe, cooler side walls	Cement
RAPIDENSE 60	60	1.10	1500	1100	2.65	8	0.50	1500	1600	Andalusite, Pure HA clay grog	-DO-	Tip casting, Cooler side walls, Burner pipe and bull nose area	Cement
DALRESICOAT B	30		1100	700	2.45	8	0.20	1100	1500	Pure HA clay grog, Silicon carbide	Resistant to high abrasion, Alkali attack and anti coating	Inlet Chamber, Riser Duct & Anti Coating Areas	Cement
QUICKPACK LC 80 ARX	78 - 82	0.80	1000	1200	2.90	8	0.80	1550	1750	Fused Alumina, Silicon carbide	Resistant to high abrasion and alkali & sulphur attack	Burner pipe	Cement

Ramming Masses & Mortars

QUALITY	SETTING	CHEMICAL ANALYSIS		PHYSICAL PROPERTIES		THERMAL PROPERTIES
		Al₂O₃	Fe₂O₃	Grade	Fineness, 95 % passing through	P.C.E. Orton Cone/^OC
		(%)	(%)	(mm)	(mm)
DALRAM HH 40-35	CHEMICAL	40	3.50	0 - 3	3
DALRAM SH 70-30	CHEMICAL	70	3.00	0 - 3	3
DALRAM LF 80-20	CHEMICAL	80	2.00	0 - 3	3
MH 30-35 HSM	HEAT	30	3.50	0 - 0.5	0.50	30 / 1665
MH 30-35 ASM	AIR	30	3.50	0 - 0.5	0.50	30 / 1665
HH 40-35 HSM	HEAT	40	3.50	0 - 0.5	0.50	31 / 1683
HH 40-35 ASM	AIR	40	3.50	0 - 0.5	0.50	31 / 1683
DALSET 50-35 ASM	AIR	50	3.50	0 - 0.5	0.50	33 / 1743
SH 60-35 HSM	HEAT	60	3.50	0 - 0.5	0.50	35 / 1785
SH 60-35 ASM	AIR	60	3.50	0 - 0.5	0.50	35 / 1785
SH 70-35 HSM	HEAT	70	3.50	0 - 0.5	0.50	36 / 1804
SH 70-35 ASM	AIR	70	3.50	0 - 0.5	0.50	36 / 1804
LF 70-25 HSM	HEAT	70	2.50	0 - 0.5	0.50	37 / 1820
LF 70-25 ASM	AIR	70	2.50	0 - 0.5	0.50	37 / 1820
SH 80-35 HSM	HEAT	80	3.50	0 - 0.5	0.50	37 / 1820
SH 80-35 ASM	AIR	80	3.50	0 - 0.5	0.50	37 / 1820

Note: 1. Ramming masses are used in the critical areas like Electric Arc Furnace roofs & ladles of the steel plant. 2. Mortars are used for bonding the bricks.

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Awards & Recognition

Recognition

2004

Confederation of Indian Industry Commendation in SHE Performance

2003

Confederation of Indian Industry Commendation in SHE Performance

2008-09

National Council for Cement and Building Materials Second Best Environmental Excellence award in plant operation

2007-08

New and Renewable Energy,Govt.of India Best Performing Wind Farms ( Aralvoimozhy )

2007-08

Confederation of Indian Industry Excellent Energy Efficient Unit

2006-07

Confederation of Indian Industry Excellent Energy Efficient Unit

2005-06

New and Renewable Energy,Govt.of India Best Performing Wind Farms ( Aralvoimozhy )

2005-06

Confederation of Indian Industry Energy Efficient Unit

2004-05

Confederation of Indian Industry Energy Efficient Unit

2003-04

Confederation of Indian Industry Energy Efficient Unit

2003-04

National Council for Cement and Building Materials National Award for Best Electrical Energy Performance in Indian Cement Industry

2002-03

National Council for Cement and Building Materials National Award for Ist Place in Energy Efficiency in Indian Cement Industry

2002-03

National Council for Cement and Building Materials National Award for Ist Place in Thermal Efficiency in Indian Cement Industry

2002-03

Bureau of Energy Efficiency - Ministry of Power, New Delhi 1st Place in National Energy Conservation Award

2002-03

Confederation of Indian Industry Energy Efficient Unit

2001-02

Confederation of Indian Industry Excellent Energy Efficient Unit

2001-02

National Council for Cement and Building Materials National Award for IInd Place in Thermal Efficiency in Indian Cement Industry

2001-02

Bureau of Energy Efficiency - Ministry of Power,New Delhi 1st Place in National Energy Conservation Award

1999-00

National Council for Cement and Building Materials 1st Place in National Energy Conservation Award

2002

Tamilnadu Govt. Highest reduction in accident - II nd Place & Lowest Weighted frequency of accidents - II nd Place

2000

Tamilnadu Govt. Factory Inspectorate State Safety Award IIIrd Place