Refractory Bricks

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PRODUCTS

DATA 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]

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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

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Manufacturers of Refractories & Kiln Furniture

04 05 06 07 08 09 10 10 11 11 12 12 13 13 14 16 17 18 19 01 Technical data on Jay AL - 40%

02 Technical data on Jay AL - 50% 03 Technical data on Jay AL - 60% 04 Technical data on Jay AL - 70%

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.

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JAY CERAMICS

TECHNICAL DATA

JAY 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

2

Cold 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.

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JAY CERAMICS

TECHNICAL DATA

JAY AL - 50%

CHEMICAL ANALYSIS

PHYSICAL PROPERTIES

º

Reheat change - at 1400 C - 2Hrs, % Refractoriness under Load - ta Value Apparent Porosity. %

3

Bulk Density, gm/cm

2

º

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 Ferric Oxide Fe O₂ ₃ 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.

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JAY CERAMICS

TECHNICAL DATA

JAY AL - 60%

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, Ortron

º

Reheat change - at 1400 C - 2Hrs, % Refractories under Load - ta Value Apparent Porosity. %

3

Bulk Density, gm/cm

2

º

º at 900 C

CHEMICAL ANALYSIS

PHYSICAL PROPERTIES

Alumina Al O₂ ₃ Silica SiO₂ Ferric Oxide Fe O₂ ₃ 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.

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JAY CERAMICS

TECHNICAL DATA

JAY AL - 70%

º

Reheat change - at 1400 C - 2Hrs, % Refractories under Load - ta Value

º

Spalling Test, Water quench - 1300 C Apparent Porosity. %

3

Bulk Density, gm/cm

2

º

º 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 Ferric Oxide Fe O₂ ₃ 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.

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JAY CERAMICS

STANDARD SHAPE AND SIZE OF BRICKS.

ARCH BRICKS

C A B

END ARCH

A B C D A C B D

SIDE ARCH

C D A B B D A C D A B C A B C

A B C

1 9" x 4 / "2 x 3" 1 1 9" x 4 / "2 x 2 / "2 1 1 9" x 4 / "2 x 1 / "2 1 9" x 4 / " 2 x 1" 1 9" x 4 / "2 x 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

1 9" x 4 / " x 3" x 2.75" 2 1 1 9" x 4 / " x 3" x 2 / " 2 2 1 1 9" x 4 / " x 3" x 2 / " 2 4 1 1 9" x 4 / " x 3" x 1 / " 2 2 1 1 9" x 4 / " x 3" x 1 / " 2 4 1 1 9" x 4 / " x 3" x / " 2 4 1 9" x 4 / " x 3" x 1" 2 1 9" x 4 / " x 3" x 2" 2 1 9" 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 D A B C D

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JAY CERAMICS

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 1 5 / " 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 A B

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JAY CERAMICS

BEVEL BRICK

CIRCLE BRICK

END ARCH

FEADHER END ON EDGE

SIDE ARCH LARGE FACE / FLAT

EDGE / SIDE

END FACE SPLIT OR SCONE

SPLIT 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 OR

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JAY CERAMICS

MORTARS

INSULATING BRICK

Analysis Cold Face Hot Face

Bulk Density (Max.) (gm/cc)

Apparent Porosity (Min.) % (Volume)

Cold Crushing Strenghth

2 (Min. Kg/cm ) Al O (Min.) %2 3 Fe O (Min.) %2 3 O Service Temperature C Permenent Linear Changer

O

( < 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 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 Type Al2O3% (Min.) Fe2O3 % (Max.) PCE (o.c.) (Min.) Grain Size (mm.)

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FURNACE TEMPERATURES

DEGREES C DEGREES F KIND 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

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JAY CERAMICS

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.

1

Of 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. Standard

1

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

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COMBINATIONS TO FORM A RING

WITH 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 B A B e A B A C

JAY CERAMICS

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COMBINATIONS TO FORM A RING

WITH 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 =

p

D =

p

D C C (2) Y = d - SE e - E (1) X = J (g - D) g - G (2) Y = J (g - D) g - G (3) x = 2

p

T = 6.2832T C - E C - E (4) y =

p

D - xC c (5) Cx + cy =

p

D (6) EX + ey =

p

d

JAY CERAMICS

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JAY CERAMICS

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 T r c Æ Æ WEDGE TYPE R T r C KEY TO SYMBOLS

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

- Theta, the included angle of brick

p

- Pi - 3.1416

S - Total number of a given radial brick required to form a ring Æ rC = r + T rC R c = = = = (r + T) c _Rc 1 Sine /2 Æ C 2R 2r C = r r or c 2

p

T

p

D

p

d C - c C c S = = = º 360 S = Æ Æ

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JAY CERAMICS

TABLE FOR USE IN DESIGNING RADIAL TYPE BRICK

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 0.58779 0.50000 0.43388 0.38268 0.34202 0.30902 0.28173 0.25882 0.23932 0.22252 0.20791 0.19509 0.18375 0.17365 0.16459 0.15643 0.14904 0.14231 0.13616 0.13053 0.12533 0.12054 0.11609 0.11197 0.10812 0.10453 0.10117 0.09802 0.09506 0.09227 0.08964 0.06716 0.08481 0.08258 0.08047 0.07846 0.07655 0.07473 0.07299 0.07134 0.06776 0.06825 0.06680 0.06540 0.06407 0.06279 0.06159 0.06038 15.312 18.000 20743 23.518 26.314 29.124 31.945 34.773 37.607 40.446 43.288 46.133 48.980 51.681 54.681 57.534 60.386 63.242 66.099 68.950 71.810 74.664 77.526 80.379 83.241 86.100 88.959 91.818 94.670 97.540 100.402 103.258 106.120 108.985 111.843 114.708 117.570 120.434 123.305 126.156 129.014 131.868 134.731 137.615 140.471 143.335 146.199 149.056 No.of brick to Circle (1) Sine of Half Angle (2) No.of brick to Circle (1) Sine of Half Angle (2)

Dia. for 9"Chord in inches (3)

Dia. for 9"Chord in inches (3) 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 0.05924 0.05815 0.05709 0.05607 0.05508 0.05414 0.05322 0.05234 0.05147 0.05065 0.04985 0.04907 0.04832 0.04758 0.04687 0.04618 0.04552 0.04486 0.04423 0.04362 0.04302 0.04244 0.04188 0.04132 0.04079 0.04027 0.03975 0.03926 0.03878 0.03830 0.03784 0.03739 0.03695 0.03652 0.03610 0.03569 0.03529 0.03490 0.03452 0.03414 0.03377 0.03341 0.03306 0.03272 0.03238 0.03205 0.03173 0.03141

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.

151.924 154.772 157.646 160.514 163.399 166.236 169.109 171.953 174.859 177.590 180.542 183.411 186.258 189.155 192.020 194.890 197.715 200.624 203.482 206.327 209.205 212.064 214.900 217.612 220.642 223.491 226.415 229.241 232.078 234.987 237.844 240.706 243.572 246.540 249.307 252.171 255.030 257.880 260.718 263.620 266.509 269.380 272.232 275.061 277.949 280.811 283.643 286.533

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JAY CERAMICS

KEY TO SYMBOLS

S = Span of arch H = Rise of arch

R = Outside radius of arch r = Inside radius of arch T = Thikness of arch A = Outer arch length a = Inner arch length e = Central Angle

Formulas

To 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 2 H = r - / 4r - S₂ S

2r

1 Sin / =₂Æ 2 2 S + 4H 8H r = 2

p

R Æ A = 360 2

p

r Æ a = 360

VALUES FOR GIVEN RISES PER FOOT OF SPAN Rise in Inches Per Foot of Span Inside * Arc is Factor xS Inside * Arc is Factor xS Diff.of Outer and Ineer Arcs factor xT Skewback X * is Y * is Factor x T Factor x T Central Angle Degrees Part of Circle 1 1 1 /4 1 1 /2 1.608 3 1 /4 2 1 2 /4 2.302 1 2 /2 3 2 /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

a T R H 0S A X Y r

ELEMENTS OF ARCHES

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