Ultra-low cement castable (ULCC) is a specialized type of refractory castable material known for its exceptional durability and superior performance in high-temperatures often above 1500°C. It is widely used in conditions exposed to extreme heat, abrasion, and chemical attack.
ULCC’s distinguished characteristic from LC castable is the cement percentage which is normally max 03% compared to LC castables which is max 05%. This low cement content is achieved by incorporating advanced bonding agents and additives which benefits in enhancing the material’s properties and performance.
Overall, ULCCs are considered an advanced version of LCCs, but it all depends on the specific requirements of the application and the level of performance needed.
Features of HRWPL ULC castable:
- Lower porosity and Permeability: ULCC has much lower porosity than our LCC due to the lower cement content which leads to improved mechanical strength, thermal shock resistance, and resistance to penetration by molten materials or corrosive gases.
- Enhanced Erosion and Abrasion Resistance: Our unique composition of ULCCs, coupled with the use of carefully selected aggregates and additives, provides exceptional resistance to erosion and abrasion, making them ideal for environments where mechanical wear is a concern.
- Higher density and strength: Our ULCC’s contribute to the materials higher density and strength which enhances the mechanical and thermal shock resistance.
- Chemical Stability: HRWPL’s ULCCs formulations are designed to resist chemical attack from molten metals, slags, and corrosive gases. Our improved densification contributes to its superior chemical stability.
Below is the range of Ultra Low Cement castable that HRWPL caters to its customers.
|Brand Name: –||HR ULCC 45||HR ULCC 60||HR ULCC 80||HR ULCC 90||HR ULCC 95|
|Type||45 % Alumina ULC Castable||60 % Alumina ULC Castable||80 % Alumina ULC Castable||90 % Alumina ULC Castable||95 % Alumina ULC Castable|
|Nature of Bond||Hydraulic||Hydraulic||Hydraulic||Hydraulic||Hydraulic|
|Installation||Vibration Casting||Vibration Casting||Vibration Casting||Vibration Casting||Vibration Casting|
|Raw Material Base||Calcined Clay||Calcined Clay & Calcined Bauxite||Calcined Bauxite||Brown Fused Alumina (BFA)||White Tabular Alumina (WTA)|
|Max Service Temp.||1550°C||1600°C||1700°C||1750°C||1800°C|
|Max Grain Size||6 mm||6 mm||6 mm||6 Mm||6 mm|
|Water Required for Casting||5.0-6.0%||5.0-6.0%||5.0-6.0%||4.5-5.5%||4.5-5.5%|
|Chemical Analyses: – (%)||Typical||Specification||Typical||Specification||Typical||Specification||Typical||Specification||Typical||Specification|
|Al2O3 :||46.20||45.0 Min||60.90||60.0 Min||80.5||80.0 Min||90.5||90.0 Min||94.5||94.0 Min|
|Fe2O3 :||0.90||1.00 Max||1.40||1.50 Max||1.70||1.80 Max||0.80||1.00 Max||0.20||0.30 Max|
|CaO :||0.95||1.00 Max||1.20||1.30 Max||0.90||1.0 Max||0.90||1.0 Max||0.90||1.0 Max|
|Physical Properties: –|
B. D (gm/cc)
Drying at 110°C/24 hrs.
|2.36||2.35 Min||2.62||2.60 Min||2.93||2.90 Min||3.02||2.90 Min||3.05||3.00 Min|
|Cold Crushing Strength (Kg/cm2):|
|Drying at 110°C/24 hrs.||430||375 Min||500||450 Min||500||450 Min||550||450 Min||500||450 Min|
|Fired at 800°C/3hrs.||830||800 Min||840||800 Min||900||800 Min||1050||1000 Min||750||700 Min|
|Fired at 1100°C/3hrs.||850||825 Min||920||900 Min||1100||1000 Min||1150||1100 Min||1100||1000 Min|
|Fired at 1550°C/3hrs.||950||900 Min||1050||1000 Min||1300||1200 Min||1300||1200 Min||1270||1250 Min|
|Thermal Properties: –|
|Refractoriness, Orton / 0 C||+32||32/1717 Min||+36||36/1804 Min||+37||37/1820 Min||+38||38/1835 Min||+38||38/1835 Min|
|Fired at 800°C/3hrs.||-0.05||± 0.2 Max||-0.09||± 0.2 Max||-0.05||± 0.2 Max||-0.05||± 0.2 Max||-0.05||± 0.2 Max|
|Fired at 1100°C/3hrs.||-0.10||± 0.2 Max||-0.18||± 0.3 Max||-0.15||± 0.3 Max||-0.15||± 0.3 Max||-0.15||± 0.3 Max|
|Fired at 1550°C/3hrs.||-0.55||± 0.7 Max||-0.60||± 1.00Max||-0.55||± 0.8 Max||-0.60||± 0.8 Max||-0.50||± 0.8 Max|
|Water requirements indicated are based on laboratory test conditions. Actual water requirement may vary subject to site conditions. The properties shown are for vibratory cast material only unless specified otherwise. All values are based on test results on standard bars of size 160x40x40 mm. Test methods are guided by and based on various Indian Standards (IS).|