Castables

Castables are refractory concretes that are made with calcium aluminate (CA) cements and various
refractory aggregates. They are used in different areas of a COB. The service capability of a castable is
dependent on the purity level of the CA cement as well as of the aggregate. Usually there are three purity
levels of CA cement namely low purity, medium purity and high purity. The aggregates can range from
calcined clays to high purity tabular alumina. Size grading of castable aggregates can also vary
considerably.
Castables are used in COB include low and medium purity castables. In addition to regular cement
castables, low cement and ultra low cement castables are used. Low purity castables are used to line the
waste heat tunnels and flues. They can be formed up and cast in place or it can be gunited. The gunniting
application is faster and less costly.
Low purity castables are also applicable to areas in the battery top, for example it is used as a filler
material in the parapet area. Low purity castables used in COB construction or repairs is generally
specified to satisfy strength requirements and carbon monoxide resistance. Medium purity castables are
used for the higher temperature areas in a battery to which castables are applicable, for example door plug
refractories and standpipe lining.