Insulating & Dense Castables

BNZ manufactures a variety of insulating and dense castable refractories to meet the exacting needs of the high temperature processing industries. These hydraulic setting products are suitable for installation by various methods including gunning, casting or slap-troweling. Each product is specifically formulated to economically obtain the desired properties for the application and service temperature for which it is intended.

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BNZ Blazelite™ AHP Insulating Castables

Hydraulic-Setting Monolithic Refractories Cast or Gun
Free of ALKALINE HYDROLYSIS degradation
No API 560 dry out required
Rapid firing rate of 100^oF to 200^oF per hour with no holds
Minimal rebound loss during gunning installation

BNZ’s Blazelite AHP insulating castables provide best in class performance combining superior insulation, high strength, and low shrinkage.

BNZ’s Blazelite AHP insulating castables will not suffer Alkaline Hydrolysis backed by BNZ’s limited warranty.

BNZ’s Blazelite AHP insulating castables can be rapid fired at rates up to 200^oF per hour with no holds allowing processes to go online sooner.

Blazelite 23 LI AHP

Continuous use limit 2300^oF (1260^o C)
- Low shrinkage, high strength, excellent insulator free of Alkaline Hydrolysis
APPLICATIONS
- Fired Heaters
  - Convection sections
  - Radiant sections
  - Transition zones
  - Floors
  - Bullnose
  - Stacks including ductwork
- Iron & Steel in reducing conditions

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Blazelite 25 HS AHP

Continuous use limit 2500^oF (1371^o C)

Low shrinkage, high strength, excellent insulator free of Alkaline Hydrolysis

APPLICATIONS

Petro Chemicals including fired heaters
- Areas requiring higher strength than Blazelite 2300 LI AHP
Iron & Steel in reducing conditions

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Blazelite 26 LI AHP

Continuous use limit 2600^oF (1427^o C)

Low shrinkage, high strength, excellent insulator free of Alkaline Hydrolysis

APPLICATIONS

Petro Chemicals including fired heaters
- Areas requiring high strength, low shrinkage, and good insulation
Iron & Steel
- Forge furnace doors and roofs
- Reheat furnace roofs, walls, sub-hearths

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Blazelite 28 LI AHP

Continuous use limit 2800^oF (1537^o C)

Low shrinkage, high strength, excellent insulator free of Alkaline Hydrolysis

APPLICATIONS

Iron & Steel
- Forge furnace doors and roofs
- Reheat furnace roofs, walls, sub-hearths

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Blazelite Insulating

Blazelite™ Insulating Castables

The unique aggregate used in BNZ Insulating Castables allows for the formulation of especially low density, thermally efficient products unsurpassed by other products.

Blazelite 2100
A general purpose lightweight castable for use as an exposed hot face refractory or as a very thermally efficient back-up to a dense refractory lining. Can be installed by casting, gunning or slap-troweling.

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Blazelite 2300
A lightweight, general purpose insulating castable. Can be used for back-up or exposed to furnace conditions. Used for one-shot linings, petrochemical heaters, combustion chambers and furnace doors and covers. Frequently used in those areas that would require a 2300°F (1260°C) Insulating Fire Brick.

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Blazelite 2300 LI and Blazelite 2300 VLI
Similar to Blazelite 2300 but suitable for those applications where reducing conditions might be encountered. These high purity, low iron products are specifically designed for both back-up and exposed to furnace combustion conditions.

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Blazelite 2500
An extremely strong insulating castable designed for general purpose use in those areas that require this combination of light weight and high strength, such as forge furnace doors and roofs, reheat furnace sub-hearths, petrochemical stills and heater linings, metal heating furnace hearths, cat-cracking units, reactor vessels, flue and duct linings and kiln car tops.

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Blazelite 2600 LI
A low iron, high purity castable for service to 2600°F (1427°C) in controlled atmosphere applications. Recommended for casting monolithic shapes and furnace linings.

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Blazelite 2000 G
Widely used for stack linings, heaters and vessels where a gunning mix with low rebound loss is required.

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Crystalline Silica Free Castables

Respirable Crystalline Silica has been determined to be a health hazard leading to potential silicosis and OSHA has put a limit of 50 μg/m³ (micrograms of silica per cubic meter of air), averaged over an 8-hour day. These extremely low PELs require complete dust control when installing castables into various Refinery, Petrochemical, or industrial furnaces to provide safe work conditions or using crystalline silica free castables during the installation of the refractories. BNZ Materials Inc, has developed and field tested these products listed below. This control of silica in our products provides good health and safety for our customers and the end users.

Blazelite 80

Blazelite 80 is a crystalline silica free castable designed for FCCU and Petrochemical regenerator and reactor linings including Exxon Mobil Flexicoker Fluidized Bed. Designed for continuous use at 2700^oF (1482^oC) having a fired density of 85 to 87 lbs/ft³ has much lower k values than products of the same density. Its excellent resistance to alkali/vanadium attack opens other applications where these environments are present.

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Blazelite 3000 Cast

Blazelite 3000 Cast is a crystalline silica free insulating castable designed for continuous operating temperatures of 3000^oF (1649^oC). It is designed for hot face and pre-cast applications. The low iron content also provides excellent performance in reducing conditions in Iron & Steel applications. The combination of lightweight, high strengths and excellent thermal insulation enable this product to be used in forge furnace door and roofs, reheat furnace walls and roofs and reheat furnace sub-hearths.

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Blazelite 3000 Gun

Blazelite 3000 Gun a crystalline silica free castable designed for continuous operating temperatures of 3000^oF (1649^oC). The combination of lightweight, high strength, low iron content, and excellent thermal insulation enable this product to be used reducing applications in forge furnace door and roofs, reheat furnace walls and roofs and reheat furnace sub-hearths. The excellent gunnibility provide low rebound, high strengths, and excellent thermal properties.

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Blazecrete Castables

Blazecrete™ Gunning Mixes

Blazecrete 3000 G
High alumina castable for service to 3000°F (1667°C). Used in building new and repairing old refractory linings, for gunning

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Blazecrete 2300 ARG
An alumina-silica castable with high strength and abrasion resistance. For service to 2300°F (1260°C). May be gunned or slap-troweled over Blazelite 2000G to obtain a high strength hot face with a good insulating back-up. Suitable for ash pits, dust collector flues and other areas where abrasive or erosive conditions exist.

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Blazecrete™ Castables

Blazecrete 3200
A high alumina castable for service to 3200°F (1778°C). It has good volume stability, extremely high modulus of rupture and crushing strength, and is of high purity for special furnace atmospheres. Designed for use in casting burner blocks, roof centers in electric arc furnaces, continuous casting tundish covers, incinerators, and other areas where these extremely high temperatures are encountered.

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Blazecrete 3000
A high alumina, high strength, general purpose castable for service to 3000°F (1667°C). Used for casting burner blocks, door linings, car tops, crucible furnace linings and special shapes. High purity for special furnace atmospheres.

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Blazecrete 2800
An economical, high alumina refractory for service to 2800°F (1556°C). Suitable for door linings, curbs and covers, pre-cast shapes, grey iron ladles, aluminum reverberatory furnace upper side walls and roofs.

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Blazecrete 2600
A general purpose castable for service to 2600°F (1427°C). It is especially effective in casting door linings, boiler walls, monolithic car tops, hearths, fire boxes, as well as safety linings in continuous casting tundishes.

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Blazecrete 2500 HS
A high-duty castable designed to withstand loads and resist normal abrasion and erosion at moderate temperatures to 2500°F (1371°C). Use with Blazelite 2100 for a dual component lining for combined high strength and insulation. Used for ash hoppers, incinerator floors, dust collector linings, cupola charging zones and fireplace sidewalls and hearths.

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Insulating Castables and Gunning Mixes

Properties

Blazelite
2000

Blazelite
2100

Blazelite
2300

Blazelite
2300 LI

Blazelite
2300 VLI

Blazelite
2500

Blazelite
2600 LI

Maximum Service Temperature, °F(°C)

2100 (1149)

2300 (1260)

2500 (1371)

2600 (1427)

Yield,

lbs dry mix required per cu. ft.
of construction without rebound (kg/m3)

62 (993)

60 (961)

64 (1025)

54 (865)

59 (945)

79 (1265)

74 (1185)

Density,

lb/ft3 (kg/m3)
Fired 5 hrs. at 1500°F (816°C)

64 (1025)

65 (1041)

70 (1121)

61 (977)

66 (1057)

78 (1249)

72 (1150)

Mixing Water Required,

(Approx)
U.S. qt/100 lb dry material
(Liter/100 kg dry material)

26
54

25
52

30
63

32
67

31
65

20
41

24
49

Modulus of Rupture,psi (kg/cm²)

(MPa) ASTM C 258

Dried at 220°F (104°C)

150 (1.03)

160 (1.10)

130 (0.90)

140 (0.97)

330 (2.78)

240 (1.65)

Fired at 1000°F (540°C)

70 (0.46)

120 (0.83)

70 (0.48)

150 (1.03)

80 (0.55)

160 (1.10)

1500°F (815°C)

90 (0.62)

150 (1.03)

80 (0.55)

60 (0.40)

90 (0.62)

140 (0.93)

110 (0.76)

2000°F (1095°C)

90 (0.62)

130 (0.90)

90 (0.62)

50 (0.34)

90 (0.62)

120 (0.83)

2300°F (1260°C)

200 (1.38)

90 (0.62)

140 (0.97)

200 (1.38)

100 (0.69)

2500°F (1371°C)

290 (2.00)

300 (2.07)

Cold Crushing Strength, psi (kg/cm²)

Dried at 220°F (104°C)

600 (4.13)

400 (2.75)

700 (4.82)

600 (4.13)

1500 (10.33)

700 (4.82)

Fired at 1000°F (540°C)

430 (2.96)

390 (2.69)

320 (2.21)

410 (2.82)

310 (2.14)

1200 (8.27)

1000 (6.89)

1500°F (815°C)

420 (2.90)

570 (3.93)

500 (3.45)

410 (2.82)

370 (2.55)

1200 (8.27)

700 (4.82)

2000°F (1095°C)

340 (2.34)

420 (2.84)

270 (1.86)

320 (2.20)

310 (2.19)

800 (5.51)

700 (4.82)

2300°F (1260°C)

550 (3.79)

430 (2.96)

550 (3.86)

1100 (7.58)

700 (4.82)

2500°F (1371°C)

1400 (9.65)

700 (4.82)

Permanent Linear Change, %

ASTM C 269

Fired at 1000°F (540°C)

– 0.1

– 0.2

– 0.1

– 0.2

1500°F (815°C)

– 0.2

– 0.1

– 0.2

2000°F (1095°C)

– 0.3

– 0.2

– 0.4

– 0.2

2300°F (1260°C)

– 0.9

– 1.0

– 0.7

– 0.5

2500°F (1371°C)

– 0.7

– 2.1

Chemical Analysis,%

fired basis per ASTM C 573

Alumina – Al2O3

34.0

35.3

43.9

41.3

47.8

43.6

51.0

Silica – SiO2

40.1

40.5

43.8

41.0

35.0

38.2

40.1

Ferric Oxide – Fe2O3

6.5

4.0

3.2

0.9

0.5

2.7

0.8

Titania – TiO2

1.9

1.7

1.8

1.6

1.0

1.2

Calcium Oxide – CaO

15.8

16.9

6.7

14.1

15.1

13.6

4.7

Magnesium Oxide – MgO

0.3

0.5

0.2

–

0.4

0.1

Alkalies, as Na2O & K2O

0.8

1.1

0.9

1.2

0.9

0.5

0.1

Others

2.0

ASTM Class C 64 & C 401

P

P & Q

O, P & Q

P & Q

Q

Thermal Conductivity

Dense Castables and Gunning Mixes

Properties

Blazecrete
2300 ARG

Blazecrete
3000 G

Blazecrete
2500 HS

Blazecrete
2600

Blazecrete
2800

Blazecrete
3000

Blazecrete
3200

Maximum Service Temperature, °F(°C)

2300 (1260)

3000 (1649)

2500 (1371)

2600 (1427)

2800 (1537)

3000 (1649)

3200 (1760)

Density,

lb/ft3 (kg/m3)
Fired 5 hrs. at 1500°F (816°C)

120 (1922)

130 (2082)

124 (1986)

130 (2082)

128 (2050)

135 (2162)

149 (2387)

Mixing Water Required,

(Approx)
U.S. qt/100 lb dry material
(Liter/100 kg dry material)

7
(15)

6
(12)

7
(15)

6
(12)

5
(10)

4
(8)

Modulus of Rupture,psi (MPa)

ASTM C 268

Dried at 220°F (104°C)

1100 (7.6)

200 (1.4)

1100 (7.6)

400 (2.8)

500 (3.4)

700 (4.8)

1000 (6.9)

Fired at 1000°F (540°C)

300 (2.1)

100 (0.7)

300 (2.1)

130 (0.9)

200 (1.4)

400 (2.8)

700 (4.8)

1500°F (815°C)

300 (2.1)

100 (0.7)

300 (2.1)

100 (0.7)

150 (1.0)

300 (2.1)

700 (4.8)

2000°F (1095°C)

200 (1.4)

130 (0.9)

200 (1.4)

100 (0.7)

200 (1.4)

300 (2.1)

700 (4.8)

2300°F (1260°C)

300 (2.1)

200 (1.4)

300 (2.1)

200 (1.4)

300 (2.1)

500 (3.4)

1200 (8.3)

2500°F (1371°C)

250 (1.7)

700 (4.8)

600 (4.1)

500 (3.4)

800 (5.5)

1400 (9.6)

At Use Limit

1000 (6.9)

700 (4.8)

900 (6.2)

1000 (6.9)

1200 (8.3)

Cold Crushing Strength, psi (MPa)

Dried at 220°F (104°C)

7100 (48.9)

1200 (8.3)

8000 (55.2)

2600 (17.9)

3000 (20.7)

4200 (28.9)

8400 (57.9)

Fired at 1000°F (540°C)

3200 (22.4)

1100 (7.6)

6400 (44.1)

2100 (14.5)

2200 (15.2)

4300 (29.6)

5300 (36.5)

1500°F (815°C)

3500 (24.1)

900 (6.2)

5600 (38.6)

1800 (12.4)

2500 (17.2)

3700 (25.5)

6100 (42.0)

2000°F (1095°C)

2400 (16.5)

900 (6.2)

2700 (18.6)

1000 (6.9)

1300 (9.0)

2700 (18.6)

4300 (29.6)

2300°F (1260°C)

2600 (17.9)

1200 (8.3)

3400 (23.4)

2100 (14.5)

2200 (15.2)

3100 (21.4)

3900 (26.9)

2500°F (1371°C)

1500 (10.3)

5200 (35.8)

4000 (27.6)

5100 (35.1)

7100 (49.0)

5500 (37.9)

At Use Limit

5000 (34.5)

7000 (48.8)

9200 (63.4)

7800 (53.8)

Permanent Linear Change, %

ASTM C 269

Fired at 200°F (104°C)

– 0.1

0.0

1000°F (540°C)

– 0.2

– 0.1

0.0

-0.1

– 0.1

1500°F (815°C)

– 0.3

– 0.1

0.0

– 0.1

2000°F (1095°C)

– 0.3

– 0.2

– 0.1

2300°F (1260°C)

– 1.1

– 0.5

– 0.8

– 0.2

0.0

– 0.4

2500°F (1371°C)

– 0.9

+ 0.2

+ 1.8

+ 1.0

– 0.7

– 0.4

At Use Limit

+ 1.0

+ 2.9

+ 0.1

+ 0.9

Chemical Analysis,%

fired basis per ASTM C 573

Alumina – Al2O3

33.4

53.9

42.9

45.5

47.6

53.0

65.3

Silica – SiO2

40.2

38.0

41.0

43.1

44.0

39.9

27.4

Ferric Oxide – Fe2O3

7.9

1.7

5.5

3.4

1.8

0.6

1.1

Calcium Oxide – CaO

13.6

2.0

8.4

5.6

4.8

2.7

3.4

Magnesium Oxide – MgO

0.2

0.1

0.2

0.1

Alkalies, as Na2O & K2O

0.2

0.3

0.4

0.1

Others, TiO2 etc

1.0

2.6

1.7

1.9

1.3

1.5

2.3

* Use this density for yield; approximate lbs/cu ft of dry material required for construction.

The physical and chemical properties of BNZ’s Insulating and Dense Castables and Gunning Mixes represent values obtained in accordance with accepted test methods and are subject to normal manufacturing variations. They are supplied as a technical service and are subject to change without notice. Results should not be used for specification purposes.

Disclaimer:

BNZ Materials warrants that its products are manufactured in accordance with its applicable material specifications and are free from defects in workmanship and materials using BNZ’s specifications as a standard. Every claim under this warranty shall be deemed waived unless in writing and received by BNZ within thirty (30) days of the date the defect was discovered and within one (1) year of the date of the shipment of the product.