7b_Compac Sol Castables [Compatibility Mode]

No Cement Castablesa new family of sol-gel bonded castables

Cement

ICTM • R. Krischanitz • March 2011

� 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

What are Sol-Gel bonded castables?

362 RHI AG

� 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:

� 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.

Advantages

363 RHI AG

� 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).

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

Difference cement-/ sol-gel bonded castables

364 RHI AG

� NO chemically bonded water, no hydrate phases

� easy drying and

heating up

� NO chemical additives necessary

in order to achieve a controlled

and practice-oriented setting and

hardening of LCC & ULCC

Disadvantages: separate binder,

storage/processing only above

+ 5°C !

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

Varianten

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

0100

0 50 100 150 200 250 300 350 400 450 500 550 600

temperature [°C]

Abdampfrate

Ankocast SV90

Ankocast 341 (0% Zement)

� 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

Characteristics, pore structure

365 RHI AG

� very homogeneous pore structure, homogeneous pore size distribution

� relative higher pore volume at low temperatures

- easy heating up

� only slight increase of porosity at

higher temperatures

� excellent thermal shock resistance

� safe and fast heating up procedure

(ready at 200 °C)

Poresizedistribution - Sol bonded vs cement bonded castable

0

10

20

30

40

50

60

70

0,001 0,01 0,1 1 10 100 1000

P o resize [µm]

Cement

Sol-Gel

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).

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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!

Brenner Abzug

Thermoelemente

Steinschalung

Brenner1 2

Properties, heating up

368 RHI AG

Fasermatte 3mm

Versuchsblock ANKOCAST 341

3 41 Versuchsaufbau

2 Mould and thermo elements

3 trial tundish

4 block after heating up

Thermogravimetry of a sol-bonded 130 kg block

500

600

700

70

80

90

100

Properties, heating up

369 RHI AG

0

100

200

300

400

500

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34

time [h]

temperature [°C]

0

10

20

30

40

50

60

70

dehydration [%]

temperature in the furnace

temperature on the surface of the block

temperature in the middle of the block

emitted water

700

800

Heat Up Schedules of Low Cement and Compac / Carsit Sol Castbales

Properties, heating up

36

0

100

200

300

400

500

600

0 10 20 30 40 50 60 70

Temperature (°C)

Time [h]

LCC

Sol

10 RHI AG

Increased RuL due to

sol-gel-bonding sol bonded vs. cement bonded concretes based on Bauxite /

Refractoriness under load

1

2

Cement

Sol-Gel

Properties, refractoriness

3611 RHI AG

-4

-3

-2

-1

0

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700

Temperature [°C]

Espansion [lin%]

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

Temperature

approx. 90°C

higher!

Alkali Resistance Sol Gel Mixes

3612 RHI AG

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

160 after 7 cycles (b).

Product Range Sol Gel

Grade Al2O3 SiO2 Fe2O3 SiC TE ATL AR SL Raw Material

110°C 1000°C 1000°C 400°C 800°C 1200°C

% % % % N/mm2 N/mm2 % W/m K W/m K W/m K °C cm3 months

Castables

COMPAC SOL F53-6 52,5 44,0 0,8 - 70 110 0,55 1,50 1,60 1,80 1600 9,0 12Dense fire clay,

low iron

CCS TC

3613 RHI AG

COMPAC SOL F53-6 52,5 44,0 0,8 - 70 110 0,55 1,50 1,60 1,80 1600 9,0 12low 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 12Dense 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 8,0 12 Andalusite / SiC

CARSIT SOL M10-05 V 57,0 29,0 1,2 10 50 80 0,55 1,84 1,77 2,13 1650 12 Mullite / SIC

Available from Calsil, India

Product Range Sol Gel

Gunning Mixes

COMPAC SOL F53G-6 50,0 47,0 0,7 - 45 45 0,55 1570 12Dense fire clay,

low iron

COMPAC SOL M64G-6 61,0 34,0 0,7 - 55 65 0,55 1670 12 Mullite

Grade Al2O3 SiO2 Fe2O3 SiC TE ATL AR SL Raw Material

110°C 1000°C 1000°C 400°C 800°C 1200°C

% % % % N/mm2 N/mm2 % W/m K W/m K W/m K °C cm3 months

CCS TC

3614 RHI AG

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 12Dense fire clay,

low iron / SiC

CARSIT SOL F30G-6 38,0 31,0 0,7 30 45 45 0,55 1550 12Dense 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 1,70 1,60 2,00 1650 12 Mullite / SIC

CARSIT SOL M30G-6 44,0 20,0 0,7 30 65 75 0,55 1580 12 Mullite / SIC

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

3615 RHI AG

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. 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.

3616 RHI AG

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.

References 2: horse Shoe

Horseshoe installation, after one year in operation:

The area has not been pre-

3617 RHI AG

The area has not been pre-dried and also not heated up with auxiliary burners.

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.

3618 RHI AG

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.

References 4: planetary cooler

Planetary cooler, intermediate

segments:

Ambient temperature +5°C

Mix temperature +12 °C

3619 RHI AG

Mix temperature +12 °C

Setting time: 2,5 hrs

References 4: planetary cooler

Planetary cooler, intermediate

segments:

after 6 months in operationand after 1 year in operation

3620 RHI AG

References 5: calciner

Compac Sol 123SiC 0-6 / Carsit Sol F30-6

Ambient temperature: +6 °C

Mix temperature: +1 °C

Setting time: 5-6 hrs

3621 RHI AGinstallation 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

3622 RHI AGinstallation after one year

• 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.

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.

3623 RHI AGinstallation after one year

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.

References 7: nose ring

3624 RHI AGinstallation after one year

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.

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.

Reference 8: Clinker Bed

Customer: NORCEM Brevik

Heidelberg grp.

Product: CARSIT SOL M10-6

Performance:

36

Life time could be increased from 7 to 12

months compared to previous installations of

competitive materials.

Further steps: => Sol-prefab-concept

25

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.

3626installation after one year

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.

References 9: gunning

3627 RHI AGinstallation after one year

CARSIT SOL F10G-6 in cooler sidewall and roof.

References 9: gunning

CARSIT SOL F10G-6

Even after 2 years lining is still in

perfect shape.

Feb. 2013

3628 RHI AGinstallation after one year

Reference 10: Cooler Roof

Customer: Portland Zement Otterbein

Material: CARSIT SOL F10G-6

Area: Cooler sidewall and roof

36

Area: Cooler sidewall and roof

CARSIT SOL F10G-6 after one year

29

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

Customer: Portland Zement Otterbein

Material: CARSIT SOL F10G-6

Area: Cooler sidewall and roof

36

Area: Cooler sidewall and roof

30

Reference 11: Burner lance

Brand: CARSIT SOL M10 – 5 V

CustomerGolden Bay Cement, Whangerai, New

Zealand

3631

Unit Burner lance (tip)

Service life 7 months +

Previous castable high alumina castable

Previous service live 4 months

CARSIT SOL M10 - 5 V

Burner lance was removed from

service only due to the degradation

of the castable further along the

burner

Reference 11: Burner lance

36

burner

REFERENCE LIST

COUNTRY CUSTOMER

COMPAC SOL F53-6

COMPAC SOL B87-6

CARSIT SOL M10-6

CARSIT SOL F30-6

CARSIT SOL S30-6

CARSIT SOL F10G-6

CARSIT SOL F30G-6

CARSIT SOL M10G-6

CARSIT SOL M30G-6

BULGARIA Zlatna Panega cement, Zlatna Panega�

CZECH REPUBLIC Lafarge Cement, Cizkovice�

DENMARK AALBORG PORTLAND CEMENTFABRIK, Aalborg�

SOL bonded castables

Casting Gunning

3633 RHI AG

EGYPT Alexandria Portland Cement, Alexandria�

EGYPT Beni Suef Cement S.A.E., Beni Suef�

FRANCE Ciments Calcia, Chateau la Valliere�

Ciments Calcia, Cruas�

GERMANY 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�

REFERENCE LIST

COUNTRY CUSTOMER

COMPAC SOL F53-6

COMPAC SOL B87-6

CARSIT SOL M10-6

CARSIT SOL F30-6

CARSIT SOL S30-6

CARSIT SOL F10G-6

CARSIT SOL F30G-6

CARSIT SOL M10G-6

CARSIT SOL M30G-6

SOL bonded castables

Casting Gunning

IRELAND Irish Cement LTD, County Louth�

ITALY Colacem, Gubbio�

Colacem, Modica�

Colacem, Ragusa�

LUXEMBOURG Cimalux Rumelange� �

3634 RHI AG

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�

ZAMBIA Zambezi Portland Cement LTD, Ndola�

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

3635 RHI AG

Although the castables have not been pre-dried and where heated upwith the same heating up curve as applied to basic bricks, there wasno 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.

Thank you for your attention!

3636 RHI AG

www.rhi-ag.com