Carbon Black 2017 MagAl Spinel – Zirconia Vs. Alumina - Zirconia Refractory for Hard Black Reactor Ravikumar N, Ranjan Dey, Eswaran V T, Rajagopalan R CARBORUNDUM UNIVERSAL LIMITED
Carbon Black 2017
MagAl Spinel – Zirconia Vs. Alumina - Zirconia Refractory
for Hard Black Reactor
Ravikumar N, Ranjan Dey, Eswaran V T, Rajagopalan R
CARBORUNDUM UNIVERSAL LIMITED
Carbon Black 2017
Contents :
Refractory Application in Carbon Black Reactor
Issues in Hard Black Reactor
Issues in Soft Black Reactor
Addressing the issues w.r.t hot face refractory
Study on Alumina – Zirconia and Spinel – Zirconia Composite
Conclusion & Recommendation
Product recommendation for various application areas
Installation Service
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Refractory Application in Carbon Black Reactor
Hard Black Reactor
Soft Black Reactor
Inlet Box
Drier Combustor
Rotary Drier
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Exposure on Refractories in Hard Black Reactor
Extreme Temperature Thermal spalling Higher refractory wear in the restriction zone Temperature fluctuations due to grade changes Reaction between refractory and impurities in CBFS and with
Chemical Additives
Exposure on Refractories in Soft Black Reactor
High Temperature Thermal spalling Reaction between refractory and impurities in CBFS and with
Chemical Additives Localised combustion Localised heating due to improper burner alignment
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Alumina -
Zirconia
99.5%
Alumina
Zirconia
Different Refractory Materials used for Venturi in Hard Black Reactors
Alumina-
Chrome
MagAl Spinel -
Zirconia
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Operating temperatures in hard black reactors are going beyond 1900 Deg.C to improve the operating efficiencies.
We developed Alumina – Zirconia composite for evaluating at high temperature applications. Which is proven to be good upto 1850 Deg.C.
Presently, we are evaluating Mag – Al Spinel + Zirconia composite as a next level to Alumina – Zirconia Composite.
Issues towards Hot Face Refractory….
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Comparison of Phase Diagram : Alumina – Silica Vs Magnesia - Alumina
Alumina – Silica Phase Diagram Alumina – Magnesia Phase Diagram
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Two types of samples were taken for the study. Alumina – Zirconia and
Spinel – Zirconia Composite
Sample # Description Raw Material Base Firing Temperature
Sample A 95% Alumina Alumina + Zirconia
1750oC
Sample B 25% MgO Spinel Spinel + Zirconia 1750oC
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Thermal Shock Resistance [TSR] to determine the effect of
repeated heating and cooling.
Pyrometric Cone Equivalent : To Determine the refractoriness
Scanning Electron Microscopy [SEM] – EDAX Analysis: To
identify the phase morphology
Tests carried out :
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Results of Thermal Shock Resistance [TSR] at 1000 Deg C
Sample # Air Quenching (Cycle) Water Quenching (Cycle)
Sample A + 150 19
Sample B + 150 22
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Scanning Electron Microscopy [SEM] – Sample A
Homogeneous distribution of Zirconia in Matrix
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004
004
1.0 mm1.0 mm1.0 mm1.0 mm1.0 mm
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00
keV
004
0
40
80
120
160
200
240
280
320
360
400
Co
un
ts
OK
a
MgK
aA
lKa
Scanning Electron Microscopy [SEM] – EDAX
Analaysis Sample B
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002002 1.0 mm1.0 mm1.0 mm1.0 mm1.0 mm
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00
keV
002
0
100
200
300
400
500
600
700
800
900
1000
Co
un
ts
OK
a
MgK
aA
lKa
ZrL
lZ
rLa
Scanning Electron Microscopy [SEM] – EDAX
Analaysis Sample B
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High Resolution Optical Micrography Sample B
Zirconia Particle Distribution in matrix
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From the Scanning Electron Microscopy [SEM] study, Uniform Zirconia
distribution in matrix in sample A.
SEM – EDAX study on Spinel – Zirconia, Observed uniform distribution of
zirconia in matrix in Sample B.
Both Alumina – Zirconia and Spinel – Zirconia refractoriness observed to
be Orton Cone 38+. At present we are unable to do refractoriness test at
2000 Deg.C. In future, we are planning to do refractoriness test at 2000
Deg.C for both Sample A and Sample B.
Thermal Shock Resistance of Spinel – Zirconia observed to be superior
when compared with Alumina – Zirconia.
Inference of the Study
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From the study, it is found that sample A [CUMILOX 95AZ SPL] is more
stable & suitable product for the severe application as hot face refractory
in hard black reactor for application temperatures below 1850 Deg.C
Sample B ( CUMILOX MA 26 ) to be analyzed for grain growth stability
studies in repeated cycles at elevated temperature.
Zirconia enhances the thermal shock resistance
Observed Spinel based refractory possesses better thermal shock
resistance compared to Alumina – Zirconia.
Conclusion
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APPLICATION AREA REFRACTORY
HARD BLACK HIGH TEMPERATURE REACTOR TEMPERATURE 1700 oC -1850oC
HEAD SECTION - WORKING LINING CUMILOX 101 HB (99.5% ALUMINA DENSE SHAPE) / CUMILOX 95 AZ SPL
HEAD SECTION - BACK UP LINING CUMICRETE CA 66 (94% ALUMINA DENSE CASTABLE)
HEAD SECTION - INSULATION CUMICRETE CA 58 (94% ALUMINA INS. CASTABLE)
CHOKE SECTION - WORKING LINING CUMILOX 101 HB(99.5% ALUMINA DENSE SHAPE)
CHOKE SECTION - BACK UP LINING CUMICRETE CA 66(94% ALUMINA DENSE CASTABLE)
CHOKE SECTION - INSULATION CUMICRETE CA 58(94% ALUMINA INS. CASTABLE)
COOLER CUMILOX 101 HB(99.5% ALUMINA DENSE SHAPE)
BREACHING SECTION - WORKING LINING
CUMIHICAST EXTRA (80% ALUMINA LCC)
BREACHING SECTION - INSULATION CUMICRETE C9 G (30% ALUMINA VERMICULTE BASED INS. CASTABLE)
Refractory Application in Hard Black Reactor – Recommendation from CUMI
Carbon Black 2017
APPLICATION AREA REFRACTORY
HARD BLACK HIGH TEMPERATURE REACTOR TEMPERATURE (1900 - 2000 Deg.C)
HEAD SECTION - WORKING LINING Spinel Zirconia Composite
HEAD SECTION - BACK UP LINING CUMICRETE CA 66 (94% ALUMINA DENSE CASTABLE)
HEAD SECTION - INSULATION CUMICRETE CA 58 (94% ALUMINA INS. CASTABLE)
CHOKE SECTION - WORKING LINING CUMILOX 101 HB(99.5% ALUMINA DENSE SHAPE)
CHOKE SECTION - BACK UP LINING CUMICRETE CA 66(94% ALUMINA DENSE CASTABLE)
CHOKE SECTION - INSULATION CUMICRETE CA 58(94% ALUMINA INS. CASTABLE)
COOLER CUMILOX 101 HB(99.5% ALUMINA DENSE SHAPE)
BREACHING SECTION - WORKING LINING
CUMIHICAST EXTRA (80% ALUMINA LCC)
BREACHING SECTION - INSULATION CUMICRETE C9 G (30% ALUMINA VERMICULTE BASED INS. CASTABLE)
Refractory Application in Hard Black Reactor – Recommendation from CUMI
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APPLICATION AREA REFRACTORY
HARD BLACK CONVENTIONAL REACTOR TEMPERATURE 1650oC - 1700 oC
WORKING LINING CUMILOX 101 HB (99.5% ALUMINA DENSE SHAPE, CUMILOX 201HF / CUMILITE 90 (90% ALUMINA DENSE SHAPE)
QUENCH SECTION CUMILOX 201 HF(90% ALUMINA DENSE SHAPE)
BREACHING SECTION - WORKING LINING CUMIHICAST 70 (70% ALUMINA LCC)
BREACHING SECTION - BACK UP CUMIHICAST SUPER(45% ALUMINA LCC)
HARD BLACK CONVENTIONAL REACTOR TEMPERATURE 1600oC
WORKING LINING CUMILOX 201HF / CUMILITE 90, (90% ALUMINA DENSE SHAPE), CUMILITE WHF (FUSED MULLITE BASED 76% ALUMINA)
BACK UP LINING & END PORTION CUMICRETE CK 588 (60% ALUMINA HIGH PURITY DENSE CASTABLE), CUMICRETE CK14 (50% ALUMINA HIGH PURITY DENSE CASTABLE)
HARD BLACK CONVENTIONAL REACTOR TEMPERATURE 1550oC
WORKING LINING CUMILITE HF / WHF (FUSED MULLITE BASED 90 & 76% ALUMINA)
INSULATION BACK UP CUMICRETE CK14 (50% ALUMINA HIGH PURITY DENSE CASTABLE)
Refractory Application in Hard Black Reactor – Recommendation from CUMI
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REACTOR TYPE APPLICATION AREA REFRACTORY LINING
SOFT BLACK REACTOR TEMPERATURE 1600 - 1650oC
WORKING LINING CUMILOX 95 AZ / CUMILOX 101 HB (99.5% ALUMINA DENSE SHAPE / BRICK)
BACK UP LINING & END PORTION
CUMILITE WHF (FUSED MULLITE BASED BRICKS / SHAPES) & CUMILAG B101 (98% ALUMINA INS. BRICK / SHAPES)
SOFT BLACK REACTOR TEMPERATURE 1500 -1600oC
WORKING LINING CUMILITE HF / WHF ( FUSED ALUMINA BASED 90% AND 76% ALUMINA SHAPES)
BACK UP LINING & END PORTION
CUMICRETE CK 14 (50% ALUMINA HIGH PURITY DENSE CASTABLE)
Refractory Application in Soft Black Reactor – Recommendation from CUMI
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Alumina – Zirconia Composite : Choke
Assembly for Hard Black Reactor Spinel – Zirconia composite / Zirconia
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Thank You
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