Copper, Cement & Glass

"Elevate your Cement and Glass Industry operations with our top-tier products and expertise. As a trusted supplier and manufacturer, we deliver unparalleled quality, innovation, and reliability, setting new standards for excellence in the Cement and Glass sectors. We are the premier cement and glass industry supplier and manufacture.

Copper Production

Cement and Glass Industry supplier and manufacture

Copper is one of the few metals that can occur in nature in a directly usable metallic form. This led to very early human use in several regions, from c. 8000 BC. Thousands of years later, it was the first metal to be smelted from sulfide ores, c. 5000 BC; the first metal to be cast into a shape in a mold, c. 4000 BC; and the first metal to be purposely alloyed with another metal, tin, to create bronze. Most copper is mined or extracted as copper sulfides from large open pit mines.

DBMC Bricks

Furnaces used for producing molten copper from concentrates and scrap – flash: smelters, converters, and anode and fire-refining furnaces – present a unique combination of challenges to refractory life. Highly aggressive slags, mechanical stresses, batch operation, and increasingly higher operating temperatures all combine to destroy most refractory materials. Raj Ceramics has a variety of Direct Bonded Magnesia Chrome (DBMC)refractory materials biased on the MgO-Cr2O3 system to meet the challenges of copper industry. We also provide SiC-Al2O3 castable in various combinations for copper furnace lining.

 

Product

MgO %

Cr2O3 %

SiO2 %

A.P %

B.D gm/cc

CCS kg/cm2

RUL (Ta)OC

Application

RC-CR-5820

58

20

0.8

18

3.15

400

1720

Copper,Glass, VOD & Zinc Furnaces

RC-CR-6018

60

18

1.5

18

3.00

400

1700

Copper,Glass, VOD & Zinc Furnaces

RC-CR-5524

55

24

1.0

17

3.18

550

1750

Copper smelting & converting Furnaces

RC-CR-5818

58

18

1.0

18

3.15

400

1700

Snorkel & Lower vessel of RH degasser

Cement Production

Cement manufacturing is a complex process that begins with mining and then grinding raw materials that include limestone and clay, to a fine powder, called raw meal, which is then heated to a sintering temperature as high as 1450 °C in a cement kiln.

Cement production is growing worldwide but due to increase in life of refractory material supplied to the industry, consumption of refractory per tonne of cement produced has gone down considerably. Raj Ceramics has various long-life refractory products  for both small and large cement kilns. With the experience in refractories since 4 decades, Raj Ceramics is aware of the effects on refractories in this industry and the products are designed to withstand:

  • Thermal effects caused due to solid fuel/ AF program, uncoated exposure, reducing atmosphere and condensation of clinker material.
  • Mechanical effects caused due to speed of rotation, kiln thrust, drive pier location, tire condition and tire overhang.
  • Operator effects due to start-up, shut-down procedures, operator reaction to coating failure, feed on/off procedures, feed-speed ratio.
  • Chemical effects due to secondary materials input, insufflation practices, kiln dust return and clinker type changes.

Raj ceramics makes a variety of refractory products for cement industry as under:

  • Direct bonded dolomite bricks
  • In-setu spinel bonded bricks
  • Sintered spinel bonded bricks
  • Fused spinel bonded bricks
  • Ferro-aluminate spinel bonded bricks

Apart from the above bricks Raj ceramics also supplies tailor made coating products for cement industry.

Glass Production

Best Manufacture of Refractory bricks

Glass

Glass production involves two main methods – the float glass process that produces sheet glass, and glassblowing that produces bottles and other containers. Batch processing is one of the initial steps of the glass-making process. The batch house simply houses the raw materials in large silos and holds anywhere from 1–5 days of material. The batch is fed into the furnace at a slow, controlled rate by the batch processing system. The furnaces operate at temperatures up to 1,575 °C (2,867 °F).

Slide

Glass Melting

Refining

Raj Ceramics has developed a large range of materials to service the glass industry with best in class solutions for refractories.
We deliver a wide range of fired, monolithic and precast products for Glass Industry.
Refractories for Regenerator
We have high purity refractories based on Fused Mullite for regenerators. We offer a wide range of Mullite /Andalusite, Aluminium and Zirconia, based refractories which exhibits high stability, high thermal shock resistance, low thermal expansion and high refractoriness.
In addition to above characteristics our Fused Mullite based refractory material, demonstrates excellent creep resistance and alkali resistance, which is an important factor for glass industry.
Refractories for Melter
We have a range of products that are recommended for sub paving and melter-superstructure . These refractories made with high purity zircon minerals exhibit high refractoriness, chemical stability, load bearing capacity and corrosion resistance against molten glass. We supply a range of products made out of high purity fused grains for areas that encounter alkaline vapour attack and thermal shock.
For furnaces having temperatures exceeding 1650 C in the melter crown, fused mullite based refractory is recommended for its low creep and chemical stability.

To know more about our products, download the catalogue:

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