Refractory Bricks

$Page 1: Refractory Bricks$
PRODUCTSDATA SHEETS

We Are, Where Heat Is On...

Chotila Road, Thangadh - 363 530, Gujarat, India.

Phone : 02751 220371 Fax : +91 (2751) 220771

E Mail : [email protected]

Visit us at : www.ec21.com/jaycera

JAY CERAMICS

INDUSTRIES WE SERVE

We supply our prouducts and provide our services to a variety of companies. Some of the Industries we serve include :

JAY CERAMICS

Aluminium Industries

Cement Industires

Ceramic Industries

Chemicals Plants

Dairy Plants

Electroplating Industries

Fertilizers Plants

Forging Plants

Foundry Industries

Galvanizing

Glass Industries

Heat Treatment Plants

Insulation

Iron & Steel Industries

Oil Refineries

Paints Industries

Paper Industries

Petrochemicals Plants

Petroleum Industries

Plastics Industries

Porcelain Industries

Refractories Industries

Rolling Mills

Rubber Plants

Soap

Sugar Plants

Textiles Plants

Tiles Industries

Manufacturers of Refractories & Kiln Furniture

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01 Technical data on Jay AL - 40%




05 Standard shape & size of Fire Bricks

06 Standard shape of Fire Bricks (Drawings)

07 Standard shape & size of Fire Tiles

08 Standard shape & size of Burner Blocks

09 Product data on Mortars

10 Product data on Insulating bricks

11 Furnace tempratures

12 Colour scale for tempratures

13 Calculation for bricks required per unit volume

14 Calculation for bricks required per sq. foot

15 Combinations to form a ring with two sizes of brick

16 Radial brick formulas

17 Table for use in Designing Radial type brick

18 Elements of Arches

19 Inquiry Form

No. Contents Page No.

JAY CERAMICS

JAY CERAMICS

TECHNICAL DATAJAY AL - 40%

CHEMICAL ANALYSIS

38.00 - 40.00%

38.00 - 42.00%

Max . 3.10%

2.90 - 3.50%

1.00 - 1.50%

Alumina Al O2 3

Silica SiO2

Ferric Oxide Fe O2 3

Titania TiO2

Calcia CaO

PHYSICAL PROPERTIES

Pyrometric Cone Equivalent, Ortron º Reheat change - at 1400 C - 2Hrs, %

Refractoriness under Load - ta Value

Apparent Porosity % 3

Bulk Density, gm /cm 2Cold Crushing, Strength, Kg/cm

º Thermal Conductivity, W/Mok at 650 C º at 1000 C

º ........... Min. 32 (1743 C)

........... Max. (+/-) 0.5%º

........... Min 1400 C

........... 17.0 - 20.0%

........... 2.30 - 2.50

........... 400 - 600

........... 1.70

........... 1.60

THE ABOVE TEST DATA are based on average results of Control tests on dry pressed standard

size bricks and are subject to normal variation on individual tests, hence these results shuold not

be regarded as absolute limits.

IMPORTANT NOTE

JAY AL - 40% is 40% Alumina Brick based on calcined bauxite of Rotary Kiln with

good thermal spalling resistance, medium porosity and good mechnical streingth.

Applications includes Cement Rotary Kilns, Reheat Furnaces, Metallurgical Furnaces,

Boiler Furnaces, Linings for general purpose usein steel plants including Tundish

Lining and Ceramic Kilns.

Page No.: 04

JAY CERAMICS

Page No.: 05


CHEMICAL ANALYSIS

PHYSICAL PROPERTIES

Pyrometric Cone Equivalent, Ortron º Reheat change - at 1400 C - 2Hrs, %

Refractoriness under Load - ta Value

Apparent Porosity. % 3

Bulk Density, gm/cm 2

Cold Crushing, Strength, Kg/cm º

Thermal Conductivity, W/Mok at 650 C º at 1000 C

º .......... Min. 33 (1743 C)

.......... Max. (+/-) 0.5%º .......... Min 1400 C

.......... 17.0 - 20.0%

.......... 2.30 - 2.50

.......... 400 - 600

.......... 1.70

.......... 1.60

48.00 - 53.00%

38.00 - 42.00%

Max . 3.10%

2.90 - 3.50%

1.00 - 1.50%

Alumina Al O2 3

Silica SiO2


Titania TiO2

Calcia CaO

JAY AL - 50% is 50% Alumina Brick based on calcined bauxite of Rotary Kiln with

good thermal spalling resistance, low porosity and excellent mechanical strength,

Applications includes Cement Rotary Kilns, Reheat Furnaces, Metallurgical Furnaces,

Boiler Furnaces, Rosting Kilns, Linings for general purpose use in steel plants including

Tundish Lining and Ceramic Kilns.




IMPORTANT NOTE

JAY CERAMICS

Page No.: 06


º .......... Min. 35 (1785 C)

.......... Max. (+/-) 0.5%º º

.......... 1420 - 1450 C

.......... 19.0 - 22.0%

.......... 2.45 - 2.60

.......... 400 - 600

.......... 1.40

........... 1.20

Pyrometric Cone Equivalent, Ortronº Reheat change - at 1400 C - 2Hrs, %

Refractories under Load - ta Value

Apparent Porosity. %3

Bulk Density, gm/cm2Cold Crushing, Strength, Kg/cm

º Thermal Conductivity, W/Mok at 700 Cº at 900 C

CHEMICAL ANALYSIS

PHYSICAL PROPERTIES

Alumina Al O2 3

Silica SiO2


Titania TiO2

Calcia CaO

58.00 - 62.00%

31.00 - 35.00%

2.50 - 3.10%

2.75 - 3.00%

0.50 - 1.70%

JAY AL - 60% is high Alumina Brick having 60% Alumina Contents based on Refractory grade bauxite calcined in Rotary kiln, High density and excellent

strength, featuring low alkali contents, applications includes Cement and Lime

Rotary and Saft Kilns, Re-heat Furnace, Incinerators, Ceramic Kilns, Boiler

Furnaces, Reverbertory air or holding Furnaces.




IMPORTANT NOTE

JAY CERAMICS

Page No.: 07


Pyrometric Cone Equivalent, OrtronºReheat change - at 1400 C - 2Hrs, %

Refractories under Load - ta Valueº Spalling Test, Water quench - 1300 C

Apparent Porosity. %3

Bulk Density, gm/cm2

Cold Crushing, Strength, Kg/cmº

Thermal Conductivity, W/Mok at 650 Cº at 1000 C

º .......... Min. 36 (1804 C)

.......... Max. (+/-) 2.5%º º .......... 1430 - 1480 C

.......... Min 10 Cycles

.......... 18.0 - 22.0%

.......... 2.65 - 2.75

.......... Min 500

.......... 1.60

........... 1.65

CHEMICAL ANALYSIS

PHYSICAL PROPERTIES

68.00 - 73.00%

19.00 - 25.00%

2.80 - 3.20%

3.40 - 3.90%

1.50 - 2.00%

Alumina Al O2 3

Silica SiO2


Titania TiO2

Calcia CaO

JAY AL - 70% is dense, low porosity, 70% Alumina Brick based on Refractory grade

bauxite calcined in Rotary kiln with excellent resistance to spalling, corrosive slags and

hot metals, Successful applications in Burning zone linings of Tunnel Kiln and Hot Air

Generators, Electric Arc Furnace Roof Steel Teeming Laddles, Induction Furnace,

Sugar Mills, Chemical Plants and many others.




IMPORTANT NOTE

JAY CERAMICS

STANDARD SHAPE AND SIZE OF BRICKS.

Page No.: 08

ARCH BRICKS

C

AB

END ARCH

A

B

C

D

ACB

D

SIDE ARCH

KEY

C

D

A

B

SIDE SKEW

B

D

A

C

END SKEW

D

A

B

C

A B C A B C1

9" x 4 / " x 3"2

1 19" x 4 / " x 2 / "2 2

1 19" x 4 / " x 1 / "2 2

1 9" x 4 / " x 1"2

1 9" x 4 / " x 2"2

230 x 115 x 75

230 x 115 x 65

230 x 115 x 50

230 x 115 x 40

230 x 115 x 25

Dimension in Inches Dimension in Milimetres

19" x 4 / " x 3" x 2.75" 2

1 19" x 4 / " x 3" x 2 / " 2 2

1 19" x 4 / " x 3" x 2 / " 2 4

1 19" x 4 / " x 3" x 1 / " 2 2

1 19" x 4 / " x 3" x 1 / " 2 4

1 19" x 4 / " x 3" x / " 2 4

19" x 4 / " x 3" x 1" 2

19" x 4 / " x 3" x 2" 2

19" x 4 / " x 3" x 1.75" 2

230 x 115 x 75 x 70

230 x 115 x 75 x 65

230 x 115 x 75 x 55

230 x 115 x 75 x 50

230 x 115 x 75 x 45

230 x 115 x 75 x 40

230 x 115 x 75 x 30

230 x 115 x 75 x 25

230 x 115 x 75 x 06

A B C DA B C D

JAY CERAMICS

Page No.: 09

STANDARD SHAPE AND SIZE OF FIRE TILES

STANDARD SHAPE AND SIZE OF BURNER BLOCKS

Dimension in Inches Dimension in Milimetres

A B C A B C

230 x 230 x 75

310 x 310 x 75

385 x 310 x 75

460 x 310 x 75

620 x 310 x 75

385 x 385 x 75

460 x 460 x 75

620 x 460 x 75

310 x 310 x 150

460 x 310 x 150

620 x 310 x 150

310 x 310 x 115

Hole Size

6" x 4"

8" x 4"

10" x 4"

10" x 6"

1 15 / " x 5 / "2 2

Size

9" x 9" x 9"

9" x 9" x 9"

12" x 12" x 12"

14" x 14" x 14"

15" x 15" x 15"

Design

Standard

Wesman

Standard

Wesman

Standard

9" x 9" x 3"

12" x 12" x 3"

15" x 12" x 3"

18" x 12" x 3"

24" x 12" x 3"

15" x 15" x 3"

18" x 18" x 3"

24" x 18" x 3"

12" x 12" x 6"

18" x 12" x 6"

24" x 12" x 6"

12" x 12" x 4.5"

FIRE TILES

C

AB

JAY CERAMICS

Page No.: 10

BEVEL BRICK

CIRCLE BRICK

END ARCH

FEADHER END ON EDGE

SIDE ARCH

LARGE FACE / FLAT

EDGE / SIDE

END FACE

STANDARD SQUARE SPRINGER / SKEW BACK

SPLIT OR SCONESPLIT OR SCONE WHELP

FEADHER SIDE KEY BRICK PUP,SOAP OR CLOSER

END SKEW ON FLAT FEADHER END

CIRCLE BRICK ONE EDGE DOME BRICK

BONDER BULLENOSE ORJAMB BRICK

JAY CERAMICS

MORTARS

INSULATING BRICK

Analysis Cold Face Hot Face

Bulk Density (Max.)(gm/cc)

Apparent Porosity (Min.) %(Volume)

Cold Crushing Strenghth2

(Min. Kg/cm )

Al O (Min.) %2 3

Fe O (Min.) %2 3

OService Temperature C

Permenent Linear ChangerO

( < 2% at C for 2 hrs.)

Thermal Conductivity (Max.)O O O

(Kcal/mh C at 350 C + 10 C)

0.7 + 0.05

70

10

35

2.0

1250

1200

0.20

1.0 + 0.05

58

30

45

1.5

1400

1350

0.30

Page No.: 11

Jay - 30 30 2.0 30 0 - .0.5

Jay - 40 40 2.0 32 0 - .0.5

Jay - 50 50 2.5 34 0 - .0.5

Jay - 60 60 3.0 35 0 - .0.5

Jay - 70 70 3.5 37 0 - .0.5

Jay - 80 80 3.5 38 0 - .0.5

TypeAl2O3

%(Min.)

Fe2O3%

(Max.)

PCE(o.c.)(Min.)

Grain Size(mm.)

Page No.: 12

FURNACE TEMPERATURES

DEGREES C DEGREES FKIND OF FURNACES

Boilers................................................

By - Product Coke Ovens..................

Cement Kilns, Hot Zone.....................

Copper Converters.............................

Copper Refining Furnaces.................

Copper Reverberatories....................

Copper Roasters................................

Gas Producer.....................................

Gas Annealing Furnaces...................

Glass Tanks-bottle.............................

Glass Tanks-plate..............................

Iron and Steel Furnaces :

Annealing Oven............................

Blast Furnaces, tapping................

Bessemer Converter.....................

Electric Furnaces..........................

Heating Furnaces.........................

Malleable Furnaces......................

Open Hearths

Melting Chamber......................

Checkers..................................

Soaking Pits.............................

1000 to 1600 1800 to 2900

1000 to 1500 1830 to 2730

1300 to 1600 2400 to 2900

1200 to 1300 2200 to 2400

1250 to 1550 2300 to 2800

1300 to 1570 2400 to 2850

700 to 810 1300 to 1500

1260 to 1370 2300 to 2500

430 to 540 800 to 1000

1370 to 1600 2500 to 2900

1370 to 1650 2500 to 3000

760 to 980 1400 to 1800

1370 to 1540 2500 to 2800

1540 to 1650 2800 to 3000

1450 to 1700 2650 to 3100

980 to 1310 1800 to 2400

1300 to 1650 2400 to 3000

650 to 1680 1200 to 3050

200 to 1430 400 to 2600

1150 to 1370 2100 to 2500

Lowest Visible Red............................

Lowest Visible Red to Dark Red........

Dark Red to Cherry Red....................

Cherry Red to Bright Cherry Red......

Bright Cherry Red to Orange.............

Orange to Yellow ...............................

Yellow to Light Yellow.........................

Light Yellow to White..........................

White to Dazzling White.....................

475 885

475 to 650 885 to 1200

650 to 750 1200 to 1380

750 to 815 1380 to 1500

815 to 900 1500 to 1650

900 to 1090 1650 to 2000

1090 to 1315 2000 to 2400

1315 to 1540 2400 to 2800

1540 to ......... 2800 to ........

COLOUR SCALE FOR TEMPERATURES

JAY CERAMICS

JAY CERAMICS

Page No.: 13

CALCULATION FOR BRICKS REQUIRED PER UNIT VOLUME

BRICKS REQUIRED PER SQ. FEET OF WALL

A Cubic Metre 513 Nos.

Of Brickwork requires 230 X 115 X 75mm Strainghts

A Cubic Feet 14.2 Nos.1Of Brickwork requires 9" X 4 / " X 3" Straights2

Volume of 1000 Nos. standard

230 X 115 X 75 mm Straights

Closly stacked (approx.) 1.95 Cubic metres

Volume of 1000 Nos. Standard1

9" X 4 / " X 3" Straights2

Closly Stacked (approx.) 71 Cubic Feet

65 mm. (2.5")

75 mm. (3.0")

115 mm. (4.5")

230 mm. (9.0")

340 mm. (13.5")

460 mm. (18.0")

575 mm. (22.5")

690 mm. (27.0")

..........

3.56

5.30

10.70

16.00

21.30

26.70

32.00

3.56

........

6.40

12.80

19.20

25.60

32.00

38.40

Wall Thickness 230 x 113 x 65 mm 230 x 113 x 75 mm

Page No.: 14

COMBINATIONS TO FORM A RINGWITH TWO SIZES OF BRICK

A - A radial brick used with a streight or another radial B, which turns a larger circle than A.

B - A streight brick or a radial brick which turns a larger circle than A, both a and B forming

the same thickness of arch T.

T - The thickness of the arch formed by A and B.

C - The outside chord of brick A.

c - The outside chord of brick B.

E - The inside chord of brick A.

e - The inside chord of brick B.

D - Given outside diameter of desired ring.

d - Given inside diameter of desired ring.

G - Outside diameter of ringformed by radial brick A alone.

J - Number of brick A to form a ring of outside diameter G.

g - Outside diameter of ring formed by brick B alone if it is ardial.

j - Number of brick B to form a ring of outside diameter g.

x - Number of pieces of brick A, used with brick B to form a ring of outside diameter D.

y - Number of pieces of brick B, used with brick A to form a ring of outside diameter D.

S - Total number of pieces of brick A and brick B to form a ring of outside diameter D.

OUTSIDE CHORD DIMENTIONS

INSIDE CHORD DIMENTIONS

A

B

C

A

E

BA B

e

A

B

A

C

JAY CERAMICS

Page No.: 15

COMBINATIONS TO FORM A RINGWITH TWO SIZES OF BRICK (Contd...)

I. WHEN BOTH BRICK A AND B ARE RADIAL AND OUTSIDE CHORDS ARE EQUAL (C =C) BUT INSIDE CHORD ARE UNEQUAL.

II. WHEN BRICK B IS A STRIGHT BRICK AND BRICK A IS REDIAL, C = E AND

III. WHEN BRICK A AND B ARE RADIAL AND BOTH CHORD DIMENSIONS OF A DIFFER FROM THOSE OF B.

IV. WHEN CALCULATING A SERIES OF COMBINATION THE FOLLOWING FORMULAS ARE CONVENIENT :

(1) S = pD = pD

C C

(2) Y = d - SE

e - E

(1) X = J (g - D)

g - G

(2) Y = J (g - D)

g - G

(3) x = 2pT = 6.2832T

C - E C - E

(4) y = pD - xC

c

(5) Cx + cy = pD

(6) EX + ey = pd

JAY CERAMICS

JAY CERAMICS

Page No.: 16

RADIAL BRICK FORMULAS

a - Inside arc of circle type brick

A - Outside arc of circle type brick

c - Inside chord of circle or wedge type brick

C - Outside chord of circle or wedge type brick

r - Inside radius of radial brick

R - Outside radius of radial brick

d - Inside diameter of ring formed by radial Brick

FORMULAS :

C A a c ÆÆ

CIRCLE TYPE

R

Tr

c ÆÆ

WEDGE TYPE

R

Tr

C

KEY TO SYMBOLS

D - Outside diameter of ring formed by radial brickT - Radial dimension of brick

- Theta, the included angle of brickp - Pi - 3.1416S - Total number of a given radial brick required to form a ring

Æ

rC =

r + T

rC

Rc =

= = =(r + T) c Rc 1

Sine /2 ÆC

2R 2rC =

r ror

c

2p T pD pd

C - c C cS == =

º 360 S

= Æ Æ

JAY CERAMICS

TABLE FOR USE IN DESIGNING RADIAL TYPE BRICK

Page No.: 17

5 678910111213141516171819202122232425262728293031323334353637383940414243444546474849505152

0.587790.500000.433880.382680.342020.309020.281730.258820.239320.222520.207910.195090.183750.173650.164590.156430.149040.142310.136160.130530.125330.120540.116090.111970.108120.104530.101170.098020.095060.092270.089640.067160.084810.082580.080470.078460.076550.074730.072990.071340.067760.068250.066800.065400.064070.062790.061590.06038

15.31218.0002074323.51826.31429.12431.94534.77337.60740.44643.28846.13348.98051.68154.68157.53460.38663.24266.09968.95071.81074.66477.52680.37983.24186.10088.95991.81894.67097.540100.402103.258106.120108.985111.843114.708117.570120.434123.305126.156129.014131.868134.731137.615140.471143.335146.199149.056

No.of brick to Circle (1)

Sine ofHalf Angle (2)

No.of brick to Circle (1)

Sine ofHalf Angle (2)

Dia. for 9"Chordin inches (3)

Dia. for 9"Chordin inches (3)

5354555657585960616263646566676869707172737475767778798081828384858687888990919293949596979899100

0.059240.058150.057090.056070.055080.054140.053220.052340.051470.050650.049850.049070.048320.047580.046870.046180.045520.044860.044230.043620.043020.042440.041880.041320.040790.040270.039750.039260.038780.038300.037840.037390.036950.036520.036100.035690.035290.034900.034520.034140.033770.033410.033060.032720.032380.032050.031730.03141

If the outside chord of a radial brick is desired for a given number of pieces per ring, find the number of pieces in coloum 1 and multiply the corresponding sine of the half angle in colomn 2 by the outside diameter of the ring. If brick with an outside chord of approxymately 9'' is desired, find the diameter in colomn 3 that comes closest to the desired outside diameter. Then multiply the corresponding sine of the half angle in colomn 2 by the desired outside diameter to obtain the actual chord. The number of pieces to form a ring will be found in colomn 1.

151.924154.772157.646160.514163.399166.236169.109171.953174.859177.590180.542183.411186.258189.155192.020194.890197.715200.624203.482206.327209.205212.064214.900217.612220.642223.491226.415229.241232.078234.987237.844240.706243.572246.540249.307252.171255.030257.880260.718263.620266.509269.380272.232275.061277.949280.811283.643286.533

JAY CERAMICS

Page No.: 18

KEY TO SYMBOLSS = Span of archH = Rise of archR = Outside radius of archr = Inside radius of archT = Thikness of archA = Outer arch lengtha = Inner arch lengthe = Central Angle

FormulasTo find the rise when radius and span are given :

To find the inside radius when rise and span are given :

To find the angle 0 when the radius and span are given :

To find the lengths when the radius and central angle are given :Outer arc : Inner arc :

1 2 2H = r - / 4r - S2

S

2r

1Sin / =2 Æ

2 2 S + 4H

8Hr =

2pR

ÆA = 360

2pr

Æa = 360

VALUES FOR GIVEN RISES PER FOOT OF SPAN

Rise inInches

Per Footof Span

Inside *Arc isFactor

xS

Inside *Arc isFactor

xS

Diff.ofOuter andIneer Arcsfactor xT

Skewback

X * is Y * is

Factor x T Factor x T

Central Angle

Degrees Part of

Circle

11

1 /4

11 /2

1.6083

1 /4

21

2 /4

2.3021

2 /2

32 /4

3

1.5417

1.2521

1.0625

1.0000

0.9301

0.8333

0.7604

0.7474

0.7072

0.6600

0.6250

37"50.9'

47"4.4'

56"8.7'

60"0.0'

65"2.5'

73"44.4'

82"13.4'

83"58.5'

90"28.8'

98"29.7'

106"15.6'

0.1051

0.1308

0.1560

0.1667

0.1807

0.2048

0.2284

0.2333

0.2513

0.2736

0.2952

0.0184

1.0287

1.0412

1.0472

1.0558

1.0725

1.0913

1.0954

1.1120

1.1346

1.1591

0.0184

1.0287

1.0412

1.0472

1.0558

1.0725

1.0913

1.0954

1.1120

1.1346

1.1591

0.3243

0.3993

0.4706

0.5000

0.5376

0.6000

0.6575

0.6690

0.7101

0.7575

0.8000

0.9460

0.9168

0.8824

0.8660

0.8432

0.8000

0.7534

0.7433

0.7041

0.6528

0.6000

* Inside radius, inside arc, difference of outer and inner arcs, x and y arcs, x and y are

obtained by multiplying the factor in respect with S or T, whichever applies.

a

T

RH

0S

A

X

Y

rELEMENTS OF ARCHES

JAY CERAMICS

FAX FORMTO FAX NUMBER : +91 2751 220771

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JAY CERAMICSChotila Road, THANGADH - 363 530,

Gujarat - INDIA.

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Refractory Bricks