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P.I. Poyo de Reva C/ Poniente, 6 1A bajo 46190 Ribarroja del Turia (Valencia), Spain comercial@refracta.net
Content:
I. Introduction II. Products III. Applications IV. Advantages & Savings V. Experience
I. Introduction:
Company: 1940: Foundation of Refractarios Especiales, S.A. - Refracta 1993: Focus on cement industry R&D on special qualities 1997: New generation of qualities obtained 2005: Refracta stops making traditional refractories, to produce only special qualities 2006: Company moves to a new plant
II. Products:
1. Bricks: R-2000 Superior raw material, special manufacturing process Ta > 1600 C Low Porosity 12-14 % Excellent Chemical Attack Resistance Extremely Abrasion resistant High Crushing strength Thermal Shock resistance AF Ready
II. Products:
2. Castable: PF-97-H Ultra Low Cement Castable Superior performance, does not crack Ta > 1600 C High Degree of Chemical Attack Resistance Extremely Abrasion resistant AF Ready
II. Products:
Advantages: Very long service life (2-3x more) Alkali, chemical attack protection Spalling protection Shell corrosion protection: less thickness loss and maintainence Nose ring protection (longer service life of mechanical parts) Solution for Rings, build ups and snowman
Result of: chemical reaction between brick and alkalis Consequences: formation of cracks within the brick and destruction lower lifetime kiln shell corrosion: infiltration of the alkalis penetrates to the kiln shell reacting with H2O to corrosive acids Uneven (spalled) Surface leading to ring formation
Result:
Consequences:
cristalisation of salts (up to 30 % more volume!) Cracks on refractory kiln shell corrosion: infiltration of the alkalis goes to the kiln shell and reacts with H2O to create corrosive acids
Result:
No infiltration of alkalis, no cracks No chemical reaction Consequences: - much longer lifetime - better protection of the kiln shell against corrosion - quick transport of material through the kiln (better process control)
II. Products:
Advantages: No Rings, No Buildups, No Spalling, Long Service Life
II. Products:
no rings or build ups
No Coating R2000 forms a glassy layer reducing porosity and protecting from infiltration Advantages: No Rings No Buildups No Spalling Long Service Life
II. Products:
No Rings, No Buildups, No Spalling, Long Service Life
No infiltration of alkalis No chemical reaction Consequences: - longer lifetime - minimized sticky substance formation
Tests realized under reducing conditions at CSIRO labs, Australia. Result after 96 h.
II. Products:
Advantages: Smooth Surface, No Infiltration, No Spalling, Long Service Life
III. Applications R2000 Nose ring Outlet zone, retaining ring UTZ up to kiln inlet Grate and planetary cooler Inlet chamber Tertiary air duct/damper area PF97H Nose ring Riser / Calciner Cyclone roofs Inlet chamber / Cone Cooler / Bullnose Tertiary air duct / Damper area Burner (except tip)
R-2000 and/or PF-97-H R-2000 R-2000 and/or PF-97-H R-2000 and/or PF97-H
Holcim Prahovice
Holcim Prahovice
Holcim Prahovice
Holcim Prahovice
Italcementi Rezzato
30-35 m / 98-115 kiln with grate cooler: R-2000 from 30-35 m - inlet
45-50 m
Holcim Orizaba Aug. 2003: position 42,6 - 47,8 mts (5,2 mts)
K1 11/02/2003 4.6m dia, 4800tpd, nsp, 3.3 rpm. 2 Rings in area 40-50 m
Ring 1
Ring 2
K1 08/05/2003
Ring 2
Kiln 1 14/11/2003
Kiln 1 08/06/2007
3. Grate cooler
Lining with R2000 in combination with castable PF97H: longer lifetime no build ups or snowmen anchored bricks to wall no cut bricks. Fill in with castables
Planetary Coolers
Anneliese Ennigerloh
Planetary Coolers
Anneliese Ennigerloh : 3 years later. TOTAL 5 YEARS
4. Other Areas
4. Other Areas
Real Infiltration resistance, chemical attack protection Very high abrasion and impact resistance Encapsulation installation: insulation and anchor protection Long service life in excellent conditions Easier Cleaning
4. Other Areas
Italcimenti Hood
4. Other Areas
IV. Plant savings and advantages: Lower refractory cost per ton of clinker Less risk of kiln stops due to refractory failures Higher productivity / less & shorter outages Savings on shutdown costs Better process control due to ring elimination Savings on more petcoke replacing coal Savings on shell replacements Capacity optimisation Environmental benefit: less waste and handling