Birds fly...

Because they know, they can

We excel...
Because we know, we can

Hazira Refractory Works Pvt. Ltd.

Where Concept is Implemented
COMPANY PROFILE

Village Mora
Registered Office
Dist Surat (Gujarat State)

Company Registration No. U36999Gz2003PTC42086

Name of Promoters Adil B Patel (Director)

Authorised Capital Rs. 100 Lac

Small Scale Industries 24-022-12-06052

Registration No.

Plot Nos. 47,48,49 & 50

Location of Factory GIDC Ichhapore-Bhatpore
Dist Surat 395 005

Production Activities All type of Castable Refractories and Monolithic

Production Capacity 12000 MT per year.

Production Commenced April 2004

Management by Directors Adil B Patel

Technical Director S K Raut

Connected by Rail and National Highways to entire

Transport Facilities
Country. All type of transport very easily available

ISO 9001:2008 TUV SUD

 QUALITY POLICY

We at Hazira Refractory Works Pvt Ltd have pledged unto ourselves towards :

Continually improving and optimizing our processes, work ethos, productivity and

customer service by practicing rigid quality parameters.

Achieving excellence by exceeding expectations of customers.

Minimizing process waste.

Motivating and training the employees for awareness for work discipline.

Stronger ties with customers and suppliers.

Adil Patel
Director
 MANUFACTURING ACTIVITIES :
At we are producing all kind of Castable Refractories & monolithic.
The renge is as under :
Conventional Castables :
45 % Alumina Medium Purity: HR CRETE (N)
70 % Alumina Medium Purity: HR CRETE SUPER
Low temperature: HR CRETE (LT)
Dense Castables
50 % Alumina Low iron High Purity: HR WHYTE C
60 % Alumina Low iron High Purity: HR WHYTE K
90 % Alumina Low iron High Purity: HR WHYTE A
Low Cement Castables
45 % Alumina Low Cement: HR LC 45
60 % Alumina Low Cement: HR LC 60
70 % Alumina Low Cement: HR LC 70
70 % Alumina Low Cement low iron: HR LC 70 Li
80 % Alumina Low Cement: HR LC 80
90 % Alumina Low Cement: HR LC 90
Ultra Low cement Castables:
80 % Alumina ultra low cement HR ULC 80
90 % Alumina ultra low cement HR ULC 90
95 % Alumina ultra low cement HR ULC 95
Insulating Castables :
Low density Insulating Castable: HR INSULCAST 4, (POURABLE) HR INSULCAST 7
Medium density Insulating Castable: HR INSULCAST 11, HR INSULCAST 13, HR INSULCAST 15
Medium density low iron Castable : HR INSULCAST 11Li, HR INSULCAST 13Li, HR INSULCAST 11Liz
Low Density low iron Insulating Castable : HR INSULCAST 22 Li
Mortars :
45 %, 60 %, 70 % Alumina Mortars
High Strength Air Setting Mortars: HR AIRSET 50, HR AIRSET 50 (F)
Insulating Mortar, Chromium base : HR 90K Mortar
90 K Chromium added Mortar
Specially Developed Castables
90 % Alumina Spinal base Castables: HR WHYTE A (SP)
55 % Alumina low cement Gunning Castable: HR GUN 55
60 % Alumina low cement Andalusite Castable: HR LC 60 A
60 % Alumina low iron 3 mm granles Castable
80 % Alumina low iron 3 mm granles Castable
90 % Alumina Chrome Based LC Castable: HR SF LC 90CR
94 % Alumina high purity dense Castable: HR CAST 94 W
97 % Alumina high purity dense Castable: HR CAST 97 W
Bubble Alumina base high purity insulating Castable: HR CAST 97L
95 % Alumina Hot Patching Mass: HR 95 HPM
55 % Magnesite base self flow pumpable basic Castable: HR SF BC 55
Non-Shrink free flow cement grout: HR CG 700
Other Products :
We have been supplying Quality Refractory bricks from our business associates from Wankaner & China.
Recently we have entered into an agreement with an International company from ltaly for advanced 'micro
porous advanced castables' and pre-cast Pre-fired' (PCPF) shapes.
We procure selected best quality raw material.
We procure raw material from renowned manufacturers only.
We are committed to our customers for maintaining zero inventories at their place.
We always keep enough quantity of raw material so that our customers can get material as and when they need.
 FLOW CHART Start
Failed
Receive Input Raw Material
QA
Bauxite Lumps and Graded Check Reject
Refractory Binder
Additives Passed
Accepted Inputs to Be Taken For Use
Refractory Binder
Additives
Accepted Inputs to Be Taken For Use
Bauxite Lumps

Crushing Line
Primary & Secondary
Crusher
STORE
Mark
grades, SCREENING
Binders
& granules
BALL MILL for
Fines, when
CCIM MIXER required.
For blending of graded
granules, Fines, binders
and additives Magnetic
Separation if
required

Pack in bags
Sample
drawn DESPATCH THE PACKED BAGS
for test Passed the test

Rejection & disposal as END

Failed the test
per Procedure No. P/01
 TESTING FACILITY & EQUIPMENTS :
In House Testing Facilities And Testing Equipments

Test Method/Apparatus IS Code ASTM Ref. IS Code

Determination of Alumina EDTA titration 1527 - 1527
Determination of Fe2 O 3 Spectrophotometer 1527 - 1527
Determination of Titanium Spectrophotometer 1527 - 1527
Determination of Silica Gravimetric 1527 - 1527
Calcium and Magnesium EDTA titration 10570 - 1527
Sampling Coning & Quartering 10570 - -
Sieve Analysis Dry Sieving by Sieve Shaker/Manually 10570 C 92 -95 1528 XIV
Preparation of Specimens Vibration table 10570 C 862 -02 1528 VII
Determination of Pyrometric Cone PCE Furnace 10570 C 24 -01 15281
Bulk Density Direct Measurement 10570 C 134 -95 1528 XII
Modulus of Rupture Modulus of Rupture Testing Machine 10570 C 133 -97 1528V
Cold Crushing Strength CCS Testing Machine 10570 C 133 -97 1528 IV
Permanent Liner Change Permanent Linear Change Furnace 10570 C210 1528 VI
Thermal Conductivity Calorimeter T C Furnace 10570 C 417 -93 9490:1980
BALL IN HAND for Consistency Physically 10570 C 860 -00
Refractoriness Under Load Refractoriness Under Load Furnace 152811 C 832 -00 152811
Self flow and workable
Cone Mould Cup C 1446 -99
consistency
 INSTALLATION OF CASTABLE REFRACTORIES
v Castable Refractories are hydraulic setting material.
v They must be installed under controlled conditions to ensure that the resultant concrete has a low
permeability and better structure.
v To obtain best results from Castables, the following instructions must be followed:

Temperature
v In hot summer if casting done at higher ambient temperature - temperature of the dry material and the water
to be added should be around 20C.
v During cold season potable clean tap water is adequate.
v If the temperature is lower, the setting time longer-just as higher temperature acclerates setting time.

Anchoring
If anchoring is required, care must be taken to ensure that it is firmly welded in position according to the relevant
specification. Proper coating of the anchors must be ensured prior to casting.

Forms
These should be water tight and strong enough to remain rigid and undistorted during casting. Forms must be
treated in the following manner before fixing to make it water tight and to achieve easy release after curing.
v Coat all the forms required for casting with suitable mould oil.
v For preventing absorption of water, make porous working surface impervious.
v All form-works perferably made of MS with proper stiffeners.

Joints
Care must be taken to provide expansion / construction joints as per design requirements.

Mixing
Proper mixing of Castable Refractories is very much essential for getting optimum results. Utmost care is required
for mixing of Castable Refractories.

Water
v Use only potable tap water and maintain the water temperature as mentioned in beginning.
v Use the specified quantity of water. Excess water would lead Bleeding.
v Excess water also defoliates strength of Castable.
v Lesser quantity water world affect bonding of Castables
v Make sure that the Mixer is first washed and cleaned.
v Castable Refractories look very dry at the beginning but become fluid after mixing after giving sufficient time
for mixing, castable would develop workalbe consistency. So do not add more water but just wait for
achieving workable consistency.
v To determine the optimal quantity of water the best way is to vibrate the
contents using a small-improvised mould or alternatively a ball in a hand.

Mixer
Use Pan Type Mixer. Concrete mixer is not suitable. The speed of mixer may
according to type of Castables. Generally mixer with 28 to 36 rpm is suitable for
mixing the Castables

Consistency
Consistency could be checked to arrive at the correct moisture and flow ability.
The method is given below:

Make a 3” ball of mix in the hand and shake horizontally. If the mix is right it appears like an oily looking ball,
if too dry, it crumbles; and if too wet, it flatness and tends to flow out.
Placing :

v Castables are high performance product. Their placement must be effected with the use of high frequency
vibrator of a diameter 1-7/8” 21/2”(or approximately 40mm) working at around 14,000 VPM should be used.
v Movethe vidratpr slowly through the mix, withdrawing gently to prevent voids.
v Add batches of materials progressively, using vibrations until the design thickness is achieved.
v Placing of each batch should be done successively within 15 to 20 minutes and care should be taken not to
retum excess material to mix.
v The appearance of plain and shining surface indicated good densification.
v Also check the specific density from the ratio of quantity placed and the volume of the hardware in which it is
placed.
v LC Castables are recommended for placement by vibration not by hand due to the inherent thixotrpic nature of
the material.

Finishing
Trowel the surface only enough to make it level; avoid excessive trowel ling of the surface. The Castable surface
should never be towelled to slick finish.

Removal of Forms
Ensure the refractory Castable is thoroughly set before removing forms. The work should then be covered with
polyethylene sheets or by damped gunny bags / cloths.

Curing and Drying

Castable Refractories must be prevented from drying for at least 24 hours after the initial set. Covering with
polyethylene sheet best carries this out. Strength will continue to improve. On completion of curing, air dry for at least
24 hours, allowing free air circulation over the whole installation.

Initial Heat Up
The resultant concrete has a dense structure and care must be exercised during the initial heating. Listed below are
specific recommendations of heating rates for various thicknesses.

For lining less than 12” thick :

v Ralse temperature to 1100C, at 250C per hour
v Hold for 6 hours or until steaming ceases, whichever is longer,
v Raise temperature to 6000C at not more than 250C per hour and hold for 12 hours.
v Raise to 10000C at not more than 250C per hour and hold it for at least 6-8 hours and then raise it to working
temperature at the rate of 500C per hour

For lining over 12” thick :

As above, except that the increase in temperature above 6000C should not be exceed 250C per hour up to 10000C. For
lining over 20” thick or for installation of over 30MT weight, and on other questions related to placement, special
instructions will be provided on request.

AGENDA FOR FUTURE

1. CAC MANUFACTURING UNIT

2. PRECAST PREFIRED MANUFACTURING.

3. BASIC CASTABLES.
VALUED CUSTOMERS LIST
Sr. No. Name of Customers
1 ESSAR STEEL LTD, Hazira

2 Essar Oil Ltd, Vadinar

3 JSW Steel Ltd, Bellary

4 Reliance Industries Ltd, Hazira

5 L & T Ltd, Hazira

6 Kribhco Ltd, Hazira

7 Saint Gobain Ltd

8 Heatex Engineering Ltd, Palsana, SURAT

9 Hindalco Industries Ltd, Dahej (Presently Not Supply)

10 Industrial Boilers, Vapi

11 Sugar Plants in Gujarat

12 G I P C L, Nani Naroli,

13 Gujarat Narmada Valley Fertiliser Co Ltd, Bharuch

14 GEB, Ukai

15 Local Textiles Units in

16 Bharuch Enviro Infrastructure Ltd., Ankleshwar

17 Inductotherm India Limited, Ahmedabad

18 Porwal Auto Components Ltd, Pithampur.

19 Vishal Malleable, Ankleshwar

20 Gujtex Industries, Surat

21 Meghmani Finechem Ltd, Dahej

22 Lanco Infratech Ltd, Ukai & Bellary.

 HR SFBC 55 - SELF FLOW PUMPABLE CASTABLE
Stave Back Filling Mass For Corex And Blast Furnace.
Salient Features :
ª HR SFBC is self-flowing pumpable basic Castable.
ª The flow measured as per ASTM 1446 is achieved to 160%
ª It can be pumped to 30 meters height.
ª The Workable consistency is achieved with 8% water.
ª Pumpable flowability is achieved with 10.5 to12% water.
ª There will not be any segregation even after adding 10.5 to 11% water.
ª Flowable consistency lasts up to 60 minutes.
Description MgO Base Alumina Base IS Code for testing
Maximum Grain Size: mm ?3 ?3 IS 10570 Ref.1528 XIV
%MgO 55-59 ---
%SiO2 6-8 40.0 Max
IS 1527/12107
%Fe2O3 11-14 0.6 Max
%Al2O3 14-18 50.0 Min
0
Pyrometric Cone Equivalent (PCE) 32/1712 C 31/1683 0C IS 10570 Ref: IS 1528 Part I
Maximum Service Temperature 15500C 16000C
Water % for Pumpable consistency 10.5 12.0 IS 10570
After 1 Minute 160 165
After 30 Minute 135 140
ASTM :1446
After 60 Minute 95 110
Initial Setting Start min 60 60
Bulk Density @ 110 0C/24 hrs gm/cc 2.21 2.03 IS 10570 Ref: 1528 Part XII
Cold Crushing Strength
275 315 IS 10570 Ref: 1528 Part IV
@ 110 0C/24 hrs kg/cm2

Mixing Procedure:
ª Mixer: Pan mixer with 38 rpm.
ª Dry mixing: 1-2 minute.
ª Water: Mix 90.0 % at a time & balance 10% after 2 minutes.
ª Wet mixing time: 5 Minute.
ª Mixed material is to be stored in vessel covered with
ª Wet gunny bag to prevent evaporation.
ª At the time using: stirring with metal road.
ª Do not add any water once material is ready.
ª Do not mix again in mixer. This will lead to segregation.
Location
Plot No. 47, 48, and 49 and 50at Gujarat Industrial Development Corporation (GIDC)
Ichhapore Industrial Estate, Bhatha.
It is located opposite to ONGC and GAIL. The land area is appx 60,000 Sq. Ft.

Utr
Rander

Damka Surat
Bhatha
Suvali G U J
Salatapu

Dumas
Tapti
Bhimpur
Essar

CONSTRUCTION AREA
Total constructed area 8000 Sq ft

Hazira Refractory Works Pvt. Ltd.

47, GIDC, Ichchhapore, Dist. Surat - 395 005.
Website : www.hazirarefractory.com