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High Concentration of Zirconia Ceramic Refractory Coating

 Zircoat-HT with its high concentration of Zirconia, resists harsh chemical attacks at high and low temperatures. Around 3mm thick Zircoat coating can work wonders at ambient to 1800° C temperature.

Zircoat -HT prevents leakage of hot gases from heating chambers, thus maximum heat energy is preserved, wear and tear on the Zircoated surface is minimised and Zirconia Ceramic Refractory Coating lasts longer.

Zircoat-HT has unlimited applications and is used in the following areas where continuous and high temperature heating is found hazardous, specially in the heating chambers constructed with conventional materials.

Zirconia Ceramic Refractory Coating

  • Ceramics / Glass

  • Ferrous & brass and other nonferrous metals except aluminium

  • Chemicals and fertilizers

  • Pulp and paper

  • Natural and other gases

  • Petroleum and hydrocarbon

  • Iron and steel

  • Marine and shipping

  • Cement

  • Sugar

  • Coating of kiln furniture, graphite and carbon crucibles.

Zircoat-HT coating will be of great benefit to use in the above areas as well as in domestic boilers, induction furnaces, rotary kilns, chimneys, ducts, etc., where fuel oil, gas or electricity are used for heating purposes.

Use of Zircoat-HT in Induction Melting Furnace

The refractory brick lining between electric bobbins and silica ramming is the vital part of the induction melting system, and sensitive to thermal shock and physical wear.

Zircoat-HT is used to reinforce these refractory bricks by trowelling with 3 to 4mm thick coating on outside and 5 to 6mm thick coating on inside refractory brick walls. Coating has to be properly dried up to set it hard.

The brick wall is thus reinforced by Zircoat-HT and it becomes super resistant to wear and sudden break downs due to thermal shocks. After repeated usage of Zircoat-HT, service life of furnace can be increased multi folds

After proper setting of Zircoat-HT, silica sand has to be rammed in between the steel sleeve and 5mm thick asbestos or mica sheet to form an average silica wall thickness of 200mm. Melting of steel starts and the steel sleeve is allowed to melt away and get dissolved in the molten steel. After removing the molten metal from the trough, coating of pure silica is formed on top of the Zircoat-HT coating.

Guidelines to Use Zircoat-HT Efficiently

Precaution: After coating the area with Zircoat-HT the first firing should be carried out slowly to avoid development of any surface cracks or other defects due to the moisture content in the coating material. The applied Zirconia Ceramic Refractory Coating should be air dried for minimum 24 hours and then slowly raise the temperature to 600°C at 20 to 25°C / hr and then to operating temperature at around 50°C / hour. For large coating thickness adequate air dying is required to avoid cracks the Zircoat-HT coating

1. The surface to be coated with Zircoat-HT should be cleaned thoroughly.

2. Refractory surface should be cleaned with scraper or wire brush removing all loose pieces, particles etc.

3. Glossy surface should be roughened enough with an abrasive disc.

4. Before applying Zircoat-HT, the surfaces of refractories, castables etc. should be dampened with water.

5. Before mixing water to Zircoat-HT powder, it should be thoroughly dry-mixed. Then water should be added and mixed homogeneously for better adhesion. The pasty mass should be consumed within the stipulated pot life of 8 to 10 hours.

6. Mixing, applying, drying and first firing should be done strictly according to the procedures laid down in the brochure.

7. If coating beyond 2mm is applied, it should be in multiple layers for proper drying.

8. After consuming part quantity, the left out Zircoat-HT dry powder should be kept air tight to avoid absorption of outside moisture. This will ensure longer service life.

For More Information Please Visit us at: https://www.jyoticeramic.com/zircoat.php

Watch us: https://youtu.be/Ln-zV37d700
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Location: Mumbai, Maharashtra, India

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