Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
at Refratechnik Cement
Holger Wirsing
Agenda
elastifier like
grain size distribution/densification spinel/chrome ore/
Thermal: hercynite/pleonaste/
++ Operation Temperature
Thermal Shock
Thermal Gradients
zirconia/forsterite
Refractories
Mechanical:
Chemical:
Weight Of The Lining
++ Kiln Feed
Atmosphere
Products of
Abrasion
Cyclic Stresses
++
Chemical Reactions
Influences on the properties of basic refractory bricks
Resistor
+
Modifier
+
Technology of the refractory producer
KRONEX ® 20 alkalis
KRONAL® 50 AR alkalis + thermal
KRONAL® 63 AR alkalis + thermal shock
+ abrasion
KRONAL® 60 AR alkalis + thermal shock
Use of alternative fuels
Alternative materials => increase of volatile compounds and increased thermal load
Problems to solve:
reinforcement of the alkali resistance
without decreasing the thermal resistance
without decreasing the flexibility
Basic bricks:
physical reinforcement = Refratechnik‘s AF-Technology
System of elastified basic brick grades
Magnesia +
X
Porosity + Elastifier mechanically sensitive
Magnesia + Porosity +
X
Elastifier mechanically sensitive
Parts of England spall off too....for almost the same reason...
Alkali-spalling of basic linings
Alkali-spalling of basic bricks
45
Risk of Spalling
Modulus of Elasticity (GPa)
30
13 15 17 19
Porosity (%)
Pore structure of magnesia spinel brick grades
150
Standarsized Properties [%]
100
50
0
Bulk Density Porosity Permeability CCS MOR Modulus of
Elasticity
AF Products Standard Products
Correlation between modulus of elasticity and porosity
Standard bricks and AF-Products
45
Risk of Spalling
Modulus of Elasticity (GPa)
30
AF-Products
13 15 17 19
Porosity (%)
Advanced performance of AF-products under increased alkali load
12
Risk of Spalling
10
Advance
8
Strength of AF-Products
Strength of
Mechanical Load
Standard Bricks
6
0
Area of Safe Operation
1 2 3 4 5 6 7 8 9
Increasing Alkali Saturation during Service Time
Compensation of increased mechanical loads
12
Risk of Spalling
10
Advance
Strength of AF-Products
8
Strength of
Standard Bricks
Mechanical Load
0
Area of Safe Operation
1 2 3 4 5 6 7 8 9
CCS: 96 MPa
G-modulus: 33 GPa CCS: 165 MPa
RTWB: 2.9*10-3 G-modulus: 54 GPa
RTWB: 3.1*10-3
CCS: 21 MPa
G-modulus: 15 GPa CCS: 45 MPa
RTWB: 1.3*10-3 G-modulus: 9 GPa
RTWB: 5.0*10-3
ALMAG® AF/TOPMAG® AF/REFRAMAG® AF
REFRATECHNIK
Refratechnik Cement GmbH
die nach oder in Anlehnung Rudolf-Winkel-Strasse 1
an DIN-Vorschriften an ma- D 37079 Göttingen
Physikalische Daten Physical properties schinengepressten Stan- Phone +49 551 69410
Rohdichte g/cm3 Bulk density g/cm3 2.95 - 3.10 dardformaten ermittelt
Fax +49 551 6941104
Optimized Elasticity
umseitigen Lagervorschrif-
Fe 2O3 ca. Fe 2O3 approx. 0.5 Segerkegel dance Pyrometric cone
with or with reference
Wärmeleitzahl Thermal conductivity
State 4/2002 to DIN equivalent
specifications.S.C. ten.
CaO ca. CaO approx. 1.0 W/m·K They > 42
W/m·K are typical standard values
SiO2 ca. SiO2 approx. 0.4
bei 300 °C at 300 °C 4.1 Wärmedehnung lin.-% which Thermal expansion lin.-%
cannot be considered
Stand 7/2003
bei 700 °C at 700 °C 3.1 bei 400 °C at 400
as binding °C
specifications. 0.4
bei 1000 °C at 1000 °C 2.9 bei 800 °C at 800published
All previously °C 0.9
Mörtel Mortar
% des Steingewichtes % weight of brick bei 1200 °C at 1200
technical data are°Creplaced 1.5
by the values stated herein The stated values are qua-
AG-R-Mörtel AG-R-Mortar 1.5 - 4
Chemische Analyse Chemical analysis Temperaturwechsel- Thermal
and thus become shock
invalid. resistance lity characteristics deter-
Gewicht % weight % mined for machine-pressed
beständigkeit 950 °C/Luft Kindly 950
follow°C/air
our storage 100
standard shapes in accor-
MgO MgO 84 - 88 instructions stated on
dance with or with reference
Al2O3 Al2O3 9 - Wärmeleitzahl
12 Thermal conductivity
reverse.
to DIN specifications. They
Fe 2O3 ca. Fe2O3 approx. 0.5 W/m·K W/m·K
are typical standard values
CaO ca. CaO approx. 1.1 bei 300 °C at 300 °C
State 3/2002 4.0
which cannot be considered
SiO2 ca. SiO2 approx. 0.5 bei 700 °C at 700 °C 3.0
as binding specifications.
bei 1000 °C at 1000 °C 2.8
All previously published
technical data are replaced
Mörtel Mortar by the values stated herein
% des Steingewichtes % weight of brick Chemische Analyse Chemical analysis
and thus become invalid.
Gewicht % weight %
AG-R-Mörtel AG-R-Mortar 1.5 - 4 Kindly follow our storage
MgO MgO 82 - 87
instructions stated on
Al2O3 Al2O3 11 - 14 reverse.
Fe 2O3 ca. Fe2O3 approx. 0.8
CaO ca. CaO approx. 1.4 State 7/2003
SiO2 ca. SiO2 approx. 0.9
Mörtel Mortar
% des Steingewichtes % weight of brick
AG-R-Mörtel AG-R-Mortar 1.5 - 4
thermal:
working temperature
AF-products - gradient of temperature
comparison
chemical: mechanical:
raw material weight of instalation
atmosphere abrasion
reaction products (rotation/ deformation/
ovality)
ALMAG® A1 / TOPMAG® A1
⇒ Demand for: a more elastic product with reduced thermal conductivity that still
shows all the AF properties
TOPMAG® A1
Concept
spinel ?
→ fused, sintered, in-situ, matrix, insitu-matrix, combinations ?
AF-Products TOPMAG® A1
Fields of application:
alkali load: tyre area in upper transition zones
fuel
raw materials
tyre area in lower transition and mechanically
stressed sintering zones subjected to normal
thermochemical load
PERILEX® CF
“Chrome-ore-free“ elastified brick for the central burning zone
Steps of PERILEX® CF development
PERILEX® 80 ALMAG® 85
alpine magnesia + chrome ore high purity magnesia + spinel
FERROMAG® 90 ALMAG® AF
pure magnesia + hercynite high purity magnesia + fused spinel
reinforced by AF-structure
FERROMAG® F1
pure magnesia + fused pleonaste
reinforced by AF-structure
Stable conditions and Instable conditions and No coating, the refractory has to
coating coating resist atmospherical conditions
without any protection
Resistor + Elastifier
alpine magnesia + fused pleonastic spinel
AF-Technology
Resulting from intensive sientific research about the ternary system MgO-Al2O3-FexOy
and the elastifying power of mineral phases from that system.
Types of wear in case of magnesia chromite bricks
X
Hot face clinker
melt infiltration X
Salt infiltration
X
Alkali chromate
formation (X)
Redox conditions
Physical properties of PERILEX CF and magnesia chromite Brick
Magnesia Chromite
PERILEX CF
PERILEX® CF
PERILEX® CF
alkali load:
fuel
raw materials
thermal load:
Magnesia hercynite process temperature
thermal shock
versus temperature gradients
PERILEX® CF
PERILEX® CF
alkali load:
fuel
raw materials
Extension to Refratechnik’s CF-Series
„Changing“ Refractoriness by changing the ratio of high purity magnesia : alpine sintered magnesia, all of the CF-products
are elastified with fused pleonaste
Extension to Refratechnik’s CF-Series
20 %-100 % alternative fuels => increase of volatile compounds and increased thermal load
Problems to solve:
reinforcement of the thermal resistance together with ...
... reinforcement of the alkali resistance
Basic bricks:
physical reinforced materials like Refratechnik‘s AF-products
Positive: Negative:
ability to form protective layers, sensible against oxygen,
high refractoriness, high thermal conductivity,
high thermal shock resistance, price!
high hot abrasion resistance
Conclusion:
Conventional SiC-containing materials (approx. > 40 % SiC) cannot be used extensively in
cement kilns because of their high thermal conductivity and from an economic point of view.
Question:
How much SiC is necessary to increase the alkali resistance of alumina materials?
Results of development
Alkali-crucible test according DIN 51069
dense layer
SiC
phase
transformation
3-6 % > 14 %
Products with properties very close Trouble shooters with high hot abrasion-,
to standard high alumina materials, alkali-, thermal shock and thermal resistance
but with additionally high alkali for special kiln zones,
resistance
increased thermal conductivity has to be
respected!
75% Al2O3
Lining installed in a kiln
outlet section next to
conventional bauxite
bricks.
KRONAL® 63 AR
75% Al2O3
Performance of KRONAL® 63 AR
75% Al2O3
Same installation after 10
month of service time.
KRONAL® 63 AR
Constant further development of main high alumina bricks
Safety Zone
Calcining Zone
Kiln Hood
Cooler
0
KRONEX® 20 - comparison with other products
K2O Al2O3
KRONEX® 20
reinforced fireclay product with increased alkali resistance