7b_Compac Sol Castables [Compatibility Mode]

No Cement Castables a new family of sol-gel bonded castables

Cement

ICTM • R. Krischanitz • March 2011

What are Sol-Gel bonded castables?
The new product line named COMPAC SOL is based on a completely different bonding system, based on nano-particle silica.
This bonding system replaces the conventional cement as binder and its complex system of (hydrated) calcium-aluminate-phases.
The binder is delivered separately from the mix. This offers a variety of advantages:

2 36

RHI AG

Advantages
easy to dry, no specific pre-drying requirement.
Fast and easy heating-up procedure.
Reduced ambient temperature impact on final product properties.
Reduced sensitivity to incorrect dosing of the mixing fluid.
Easily adjusted to the desired setting time.
Higher refractoriness compared to equivalent cement-bonded products.
Improved chemical resistance (e.g., alkali as well as sulphur) compared to equivalent cement-bonded products.
Longer shelf life than low cement castables (LCC).

3 36

RHI AG

Difference cement-/ sol-gel bonded castables Sol-gel bonded castables:
The setting and hardening of the concrete (jellying) is based on the formation of Si-O-Si - bonding
NO chemically bonded water, no hydrate phases  easy drying and heating up

Disadvantages: separate binder, storage/processing only above + 5°C ! 4 36 RHI AG

Abdampfrate


NO chemical additives necessary in order to achieve a controlled and practice-oriented setting and hardening of LCC & ULCC

TGA - Abdampfrate / 1K/min / Ankocast SV90, Ankocast 341 + zementhältige Varianten

100 0 -100 0 -200 -300 -400 -500 -600 -700 -800 -900 -1000 -1100 -1200 -1300 -1400

50

100 150 200 250 300 350 400 450 500 550 600

Ankocast SV90 Ankocast 341 (0% Zement)

temperature [°C]

Characteristics, pore structure
mean pore size diameter is significantly smaller compared to cement bonded castables (1/10 compared to cement bonded castables)  lower infiltration tendency
very homogeneous pore structure, homogeneous pore size distribution
relative higher pore volume at low temperatures P oresizedistribution - Sol bonded vs cement bonded castable - easy heating up 70


only slight increase of porosity at higher temperatures
excellent thermal shock resistance

60

50

Cement

40

Sol-Gel 30


safe and fast heating up procedure (ready at 200 °C)

20

10

0 0,001

5 36

RHI AG

0,01

0,1

1

P o ]re s ize [ µm

10

100

1000

Drying and Heat Up of Sol-products - Heat-up Process The average pore size in Sol-mixes is significantly lower than for a LCC (lower risk of infiltration). Homogeneous pore-structure and (size) distribution (better heat up properties). In relation at low temperatures a higher pore-volume (better heat up), because you can use all the pores at very low temperatures. For cement bonded castables, a large amount of pores are created lately during the heat up. No increase of porosity at higher (>200°C) temperatures. Safe and very fast heat up that can be finished completely even below 200°C! 7 36

Properties, heating up Thermoelemente Steinschalung

Brenner

Abzug

1

2

Brenner

Versuchsblock ANKOCAST 341

Fasermatte 3mm

3

1 Versuchsaufbau 2 Mould and thermo elements 3 trial tundish 4 block after heating up

8 36

RHI AG

4

Properties, heating up Thermogravimetry of a sol-bonded 130 kg block 100

700

90 600 80 70 60

400

50 300

40

temperature in the furnace temperature on the surface of the block

200

30

temperature in the middle of the block

20

emitted water

100 10 0

0 0

9 36

RHI AG

2

4

6

8

10

12

14

16

18

time [h]

20

22

24

26

28

30

32

34

dehydration [%]

temperature [°C]

500

Properties, heating up Heat Up Schedules of Low Cement and Compac / Carsit Sol Castbales 800 700

Temperature (°C)

600 500 400 LCC Sol

300 200 100 0 0

10 36

RHI AG

10

20

30

40 Time [h]

50

60

70

Properties, refractoriness sol bonded vs. cement bonded concretes based on Bauxite / Refractoriness under load

Increased RuL due to sol-gel-bonding

2

Cement Sol-Gel

Espansion [lin% ]

1

Temperature

0

0

100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700

approx. 90°C -1

higher! -2

-3

Cement T0: 1403°C T0,5: 1464°C T1: 1482°C T2: 1506°C

Sol-Gel T0: 1501°C T0,5: 1549°C T1: 1565°C T2: 1588°C

-4

Temperature [°C]

11 36

RHI AG

Alkali Resistance Sol Gel Mixes

Crucible test with DIDURIT 160 after 3 cycles (a) and COMPAC SOL 160 after 7 cycles (b).

12 36

RHI AG

Product Range Sol Gel Grade

Al2O3

SiO2 Fe2O3

SiC

CCS

TE

TC

110°C

1000°C

1000°C

400°C

800°C

1200°C

ATL

AR

SL

Raw Material

%

%

%

%

N/mm2

N/mm2

%

W/m K

W/m K

W/m K

°C

cm3

months

COMPAC SOL F53-6

52,5

44,0

0,8

-

70

110

0,55

1,50

1,60

1,80

1600

9,0

12

Dense fire clay, low iron

COMPAC SOL M64-6

64,0

32,0

0,9

-

70

115

0,55

1,80

1,75

1,95

1700

7,0

12

Mullite

COMPAC SOL B87-6

85,0

9,5

1,5

-

70

140

0,60

2,20

2,30

2,40

1700

7,0

12

Bauxite

CARSIT SOL F30-6

39,0

29,5

0,6

29

70

105

0,55

2,70

2,68

2,62

1550

8,5

12

Dense fire clay, low iron / SiC

CARSIT SOL M10-6

58,0

28,0

0,8

10

70

120

0,55

1,84

1,77

2,13

1650

12

Mullite / SIC

CARSIT SOL S30-6

46,5

22,0

0,5

30

70

110

0,55

2,75

2,72

2,81

1580

12

Andalusite / SiC

29,0

1,2

10

50

80

0,55

1,84

1,77

2,13

1650

12

Mullite / SIC

Castables

8,0

Available from Calsil, India CARSIT SOL M10-05 V 13 36 RHI AG

57,0

Product Range Sol Gel Grade

Al2O3

SiO2 Fe2O3

SiC

CCS

TE

TC

110°C

1000°C

1000°C

400°C

800°C

1200°C

W/m K

W/m K

W/m K

ATL

AR

SL

°C

cm3

months

Raw Material

%

%

%

%

N/mm2

N/mm2

%

COMPAC SOL F53G-6

50,0

47,0

0,7

-

45

45

0,55

1570

12

Dense fire clay, low iron

COMPAC SOL M64G-6

61,0

34,0

0,7

-

55

65

0,55

1670

12

Mullite

COMPAC SOL S64G-6

63,0

36,0

0,5

-

55

60

0,55

1670

12

Andalusite

CARSIT SOL F10G-6

45,0

42,0

0,7

10

45

50

0,55

1550

12

Dense fire clay, low iron / SiC

CARSIT SOL F30G-6

38,0

31,0

0,7

30

45

45

0,55

1550

12

Dense fire clay, low iron / SiC

CARSIT SOL S10G-6

60,0

23,0

0,7

10

55

55

0,55

1650

12

Andalusite / SIC

CARSIT SOL S30G-6

44,0

22,0

0,7

30

55

55

0,55

1580

12

Andalusite / SIC

CARSIT SOL M10G-6

57,0

30,0

0,7

10

55

65

0,55

1650

12

Mullite / SIC

CARSIT SOL RHI M30G-6 14 36 AG

44,0

20,0

0,7

30

65

75

0,55

1580

12

Mullite / SIC

Gunning Mixes

1,70

1,60

2,00

References 1: outlet segments & 4,8m diameter SP kiln in Germany: Test field in nose ring lined with COMPAC SOL 155SIC in comparison to competitive cement bonded SIC castable. Competition

The castable lining was not dried before heating up. After 45 weeks in operation COMPAC SOL 155SIC shows an even surface without crack formation or spalling. The adjacent lining with an equivalent LC castable type already shows clear signs of crack formation and spalling.

15 36

RHI AG

COMPAC SOL 155SIC

References 2: Horse shoe Horseshoe installation, Feb. 2010: COMPAC SOL 155SIC showed excellent processing conditions at ambient temperatures around and slightly below 0°C. As the castable was stored correctly it was possible to keep the temperature of the mix at about 10°C. The castable was easy to pour into the moulds and also easy to vibrate and deaerate. The appearance of the fields were very homogeneous without formation of cavities. 16 36

RHI AG

References 2: horse Shoe Horseshoe installation, after one year in operation: The area has not been predried and also not heated up with auxiliary burners.

17 36

RHI AG

References 3: inlet cone Inlet cone installation, Feb. 2010: About 5 t of Compac Sol 155SIC and 5t Compac Sol 123SiC were used for an installation of an inlet cone. The ambient temperature was about +5°C. Dry materials and binder were both around +10°C. The mould out times were adjusted down to 4 hours using an accelerator. 10t of Compac Sol 123SiC were used in the same plant for repair work in the cooler side wall. 18 36

RHI AG

References 4: planetary cooler Planetary cooler, intermediate segments: Ambient temperature Mix temperature Setting time:

19 36

RHI AG

2,5 hrs

+5°C +12 °C

References 4: planetary cooler Planetary cooler, intermediate segments: and after after 6 months 1 year in in operation operation

20 36

RHI AG

References 5: calciner Compac Sol 123SiC 0-6 / Carsit Sol F30-6 Ambient temperature: Mix temperature: Setting time:

installation 21 36 RHI AG

+6 °C +1 °C 5-6 hrs

after one year

References 6: burner Especially for the burner pipe the advantages of Sol castables are of particular interest, such as: • No need for heating up • Higher refractoriness compared to cement bonded castables.

Comparison of a burner pipe from an Egyptian customer lined with high alumina standard low-cement castable from a competitor and with CARSIT SOL M10-6.

installation 22 36 RHI AG

after one year

References 7: nose ring Another Egyptian customer use the material for casting a 15t nose ring, which had previously less than two months life time. In this case one of the main reasons for choosing a sol-bonded material was, that the flexibility of the material is better than the more brittle behaviour of a conventional castable but still having a high strength. Furthermore nose ring areas cant be heated up correctly because their proximity to the main burner. After six month since the installation the lining still shows excellent appearance (see picture). Customer has already placed new orders for more sol-bonded castables. Total lifetime has been 12 months from original 2-3.

installation 23 36 RHI AG

after one year

References 7: nose ring

CARSIT SOL M10 nose ring installation (including outlet segments) in Egypt in March 2012. On the left side is 1 m of ANKRAL QF compound lining.

installation 24 36 RHI AG

Nose ring after 6 months in operation: No damages at all. Previously the nose ring lined with high alumina competitor castable was lasting less than 3 months. after one year

Reference 8: Clinker Bed Customer: Product: Performance:

NORCEM Brevik Heidelberg grp. CARSIT SOL M10-6

Life time could be increased from 7 to 12 months compared to previous installations of competitive materials. Further steps:

25 36

=> Sol-prefab-concept

References 9: gunning Gunning techniques (guniting or shotkasting) are popular installation methods for minimising turnaround times. RHI is proud to be the first in the market to offer its customers the advantages of sol products also for gunning installation. COMPAC / CARSIT SOL gunning materials can be installed using the common conventional or dense gunning equipment. The only special equipment needed is a simple pump for adding the liquid binder DIVASIL at the gunning nozzle. The first field trials using CARSIT SOL F10G-6 were conducted already in February and March 2011 at cooler sidewalls and roofs in cement plants in Germany. As these trials showed very promising results in the last winter repair period 2011/2012 (fotos next page). More German cement customers ordered material for their stops. Pumping and shotkasting products are under development at the moment.

installation 26 36

after one year

References 9: gunning

CARSIT SOL F10G-6 in cooler sidewall and roof.

installation 27 36 RHI AG

after one year

References 9: gunning Feb. 2013

CARSIT SOL F10G-6 Even after 2 years lining is still in perfect shape.

installation 28 36 RHI AG

after one year

Reference 10: Cooler Roof Customer:

Portland Zement Otterbein

Material:

CARSIT SOL F10G-6

Area:

Cooler sidewall and roof

CARSIT SOL F10G-6 after one year 29 36

Reference 10: Cooler Roof.......and after 2 years Customer:

Portland Zement Otterbein

Material:

CARSIT SOL F10G-6

Area:

Cooler sidewall and roof

30 36

Reference 11: Burner lance

31 36

Brand:

CARSIT SOL M10 – 5 V

Customer

Golden Bay Cement, Whangerai, New Zealand

Unit

Burner lance (tip)

Service life

7 months +

Previous castable

high alumina castable

Previous service live

4 months

Reference 11: Burner lance CARSIT SOL M10 - 5 V Burner lance was removed from service only due to the degradation of the castable further along the burner

36

REFERENCE LIST

Zlatna Panega cement, Zlatna Panega




CZECH REPUBLIC

Lafarge Cement, Cizkovice




DENMARK

AALBORG PORTLAND CEMENTFABRIK, Aalborg




EGYPT EGYPT

Alexandria Portland Cement, Alexandria Beni Suef Cement S.A.E., Beni Suef

FRANCE

Ciments Calcia, Chateau la Valliere Ciments Calcia, Cruas

Casting

GERMANY

33 36

RHI AG

Cemex OstZement, Rüdersdorf Dykerhoff Zement, Lengerich HeidelbergCement Burglengenfeld HeidelbergCement Hannover HeidelbergCement Schelklingen Holcim (Deutschland), Lägerdorf Holcim (Deutschland), Sehnde Krupp Polysius AG, Beckum Liapor GmbH&Co., Hallerndorf-Pautzfeld Phönix Zementwerke, Beckum Portlandzementwerk Dotternhausen Portlandzementwerk Wittekind, Erwitte Schwenk Zement, Allmendingen Schwenk Zement, Heidenheim Spenner Zement, Erwitte Zement und Kalkwerk Otterbein

CARSIT SOL M30G-6

BULGARIA

CARSIT SOL M10G-6

CUSTOMER

CARSIT SOL F30G-6

COUNTRY

CARSIT SOL F10G-6

CARSIT SOL S30-6

CARSIT SOL F30-6

CARSIT SOL M10-6

COMPAC SOL B87-6

COMPAC SOL F53-6

SOL bonded castables

Gunning











































REFERENCE LIST

ITALY

Colacem, Gubbio Colacem, Modica Colacem, Ragusa




34 36

Gunning





LUXEMBOURG

Cimalux Rumelange




MEXICO

Cementos Apasco Ramos Arizpe, Saltillo Cementos Apasco, Hermosillo, Sonora





NAMIBIA

Ohorongo Cement LTD, Windhoek




NORWAY

Norcem AS, Brevik




SLOVAKIA

VSH - Východoslovenské Stavebné, Turna nad Bodvou




SPAIN

Cementos Cosmos, Oural/Lugo

TURKEY

Baticim - Bati Anadolu Cimento, Izmir Batisoeke Soeke Cimento, Bornova, Izmir Mardin Cimento Sanyii ve Ticaret A, Mardin




UGANDA

Tororo Cement, Tororo




UNITED KINGDOM

Tarmac LTD (Tunstead Maerz Kiln), Buxton Lafarge Cement UK, Stoke on Trent Zambezi Portland Cement LTD, Ndola















RHI AG ZAMBIA







CARSIT SOL M30G-6




Casting

CARSIT SOL M10G-6

Irish Cement LTD, County Louth

CARSIT SOL F30G-6

IRELAND

CARSIT SOL F10G-6

CUSTOMER

CARSIT SOL S30-6

COUNTRY

CARSIT SOL F30-6

CARSIT SOL M10-6

COMPAC SOL B87-6

COMPAC SOL F53-6

SOL bonded castables

Conclusions All the applications so far have proved:
No need of pre-drying and easy heating up: Although the castables have not been pre-dried and where heated up with the same heating up curve as applied to basic bricks, there was no spalling or pre-damage of the castables.
Perfect workability and setting also under extreme winter conditions.
All customers rated the workability as good or very good.

35 36

RHI AG

Thank you for your attention!

www.rhi-ag.com

36 36

RHI AG