REFRATECHNIK
New Developments in Monolithic ProductsNew Developments in Monolithic Products
For the Portland Cement Industry
Mark Weidhaas
Senior Sales Manager
Director of Monolithics
Refratechnik North America, Inc.
I t d ti
Content
Introduction
Cement Bonded Cement Bonded Monolithics
MixMix--CreteCrete Cement Bonded Monolithics
•• ARAR Mix-Crete
•• ZZ--ARAR Mix-Crete
Chemically Bonded Chemically Bonded Monolithics
NanobondNanobond No-Cement Monolithics
EZ EZ Dry Dry No-Cement Monolithics
Conclusions
Consumption of Monolithic Refractory Material
Cement Industry: Areas of Application
The image cannot be displayed. Your computer may not have enough memory to open the image, or the image may have been corrupted. Restart your computer, and then open the file again. If the red x still appears, you may have to delete the image and then insert it again.
Cement Bonded MonolithicsCement Bonded Monolithics
CALCIUM – ALUMINATE Cement Bonded Monolithics
• REGULAR Cement CA > 4%
• MEDIUM Cement 2% < CA < 4%
• LOW Cement 1% < CA < 2%
• ULTRA – LOW Cement CA < 1%
M t i l ClMaterial Classes
VIBRATION Castables
SELF LEVELING Castables SELF-LEVELING Castables
PUMPABLE Castables
DRY GUNNITES
SHOTCRETES (Wet Gunning)
MixMix--CreteCrete MonolithicsMonolithics
AR MixAR Mix--Crete Crete Monolithics
AR Products - Riser Duct (after approximately 1 year)( pp y y )
reaction zoneili t i h t ti lsilicate-rich protective layer
unaffected microstructure
Improved Alkali Resistance
high
formation of
protective layer
Al2O
3alkali cu
87 %
bauxite
A up test / 1100 °C /
60 %
andalusite
K2 C
O3
coating-
repellent
40 %
fireclay
low
REFRACLAY 40 JC
25 %
fireclay
SiC 50 % 20–30 % 0 % 5–10 %
fireclay
REFRACLAY 25 JC
AR-Mixcrete Conceptp
The Mixcrete Concept: 6 refractory concretes
for the whole kiln line (static sections of the kiln line)
product combination Al2O3
[wt.-%]SiO2
[wt.-%]SiC
[wt.-%]ratio
( )
• modular / flexible installation
• flexible use of standard products
• graduated SiC contents/concepts [ ] [ ]REFRACLAY 40 LCC + 3 1 38 45 12REFRA-SiC 50 AR 2 1 36 43 17
1 1 32 39 25REFRAMULLITE 60 LCC + 3 1 44 36 16REFRA SiC50AR 2 1 42 35 20
graduated SiC contents/concepts
• zonally adapted product properties
• standardized product range
• smaller number of products REFRA-SiC 50 AR 2 1 42 35 201 1 36 33 27
REFRAMULLITE 63 LCC + 3 1 48 36 13REFRA-SiC 50 AR 2 1 45 35 17
1 1 39 33 25
smaller number of products
• simplified storage
• minimized storage times
• reduced warehousing costs1 1 39 33 25
REFRABAUXITE 75 LCC + 3 1 52 27 16REFRA-SiC 50 AR 2 1 48 27 20
1 1 41 27 27REFRABAUXITE 85 LCC + 3 1 61 17 16
• mixing bag by bag
• easy application
• mixing batches:
3:1 / 1:1 = 100 kgsREFRA-SiC 50 AR 2 1 56 18 20
1 1 47 20 27
3:1 / 1:1 100 kgs
2:1 = 75 / 150 kgs
Alkali Cup Test p
REFRACLAY 40 LCC + REFRA-SiC 50 AR
RCY 40 LCCRCY 40 LCC
3 1 2 13:1 1:12:1
R-SiC 50 AR
Alkali Cup Test p
REFRAMULLITE 60 LCC + REFRA-SiC 50 AR
RME 60 LCC
3 1 2 13:1 1:12:1
R-SiC 50 AR
Alkali cup test p
REFRAMULLITE 63 LCC + REFRA-SiC 50 AR
RME 63 LCC
3 1 2 13:1 1:12:1
R-SiC 50 AR
Alkali Cup Test p
REFRABAUXITE 75 LCC + REFRA-SiC 50 AR
RBE 75 LCC
3 1 2 13:1 1:12:1
R-SiC 50 AR
Alkali Cup Test REFRABAUXITE 85 LCC + REFRA-SiC 50 AR
RBE 85 LCC
3 1 2 13:1 1:12:1
R-SiC 50 AR
AR-Mixcrete – Clinker Cooler Curbs
REFRABAUXITE 85 LCC + REFRA-SiC 50 AR (1:1) REFRABAUXITE 85 LCC + REFRA-SiC 50 AR (1:1)
Cooler Curbs after 6 months Cooler Curbs after 4 months
AR-Mixcrete – Kiln Nose Ring
AR-Mixcrete
nose-ring after 12 months
Z Z AR MixAR Mix--Crete Crete Monolithics
Z AR-Mixcrete Concept
The Mixcrete concept: 6 refractory concretes
for the whole kiln line (static sections of the kiln line)
• modular / flexible installation
• flexible use of standard products
• graduated SiC contents/concepts
product combination Al2O3
[wt.-%]SiO2
[wt.-%]SiC
[wt.-%]ZrO2
[wt.-%]REFRACLAY40LCC+
ratio
• zonally adapted product properties
• standardized product range
• smaller number of products
REFRACLAY 40 LCC + REFRAZIRCON Z AR 1 1 45 37 5 9
REFRAMULLITE 60 LCC +REFRAZIRCON Z AR 1 1 49 30 7 9
• simplified storage
• minimized storage times
• reduced warehousing costs
REFRAMULLITE 63 LCC +REFRAZIRCON Z AR 1 1 52 31 5 9
REFRABAUXITE 75 LCC +• mixing bag by bag
• easy application
• mixing batches:
1:1 = 100 kgs
REFRAZIRCON Z AR 1 1 53 25 7 9
REFRABAUXITE 85 LCC +REFRAZIRCON Z AR 1 1 60 18 7 9
Z AR-Mixcrete: REFRACLAY 40 LCC + REFRAZIRCON Z AR
RCY 40 LCC
1:1
RZN Z AR
Z AR-Mixcrete: REFRAMULLITE 60 LCC + REFRAZIRCON Z AR
RME 60 LCC
1:1
RZN Z AR
Z AR-Mixcrete: REFRAMULLITE 63 LCC + REFRAZIRCON Z AR
RME 63 LCC
1:1
RZN Z AR
Chemically Bonded Chemically Bonded MonolithicsMonolithics
Chemically Bonded Monolithics
Phosphate Bonded
Alumino – Orthophosphate (AlPO4) Bond
• H S T °C ( °F)• Heat Setting T > 500 °C (930 °F)
Plastics
Ramming MixesRamming Mixes
2 Component Castables / Dry Gunning Mixes
NANOBONDNANOBOND (Sol-Gel) System
EASY EASY DRY DRY Bond Systemy
NANOBONDNANOBOND MonolithicsMonolithics
NANOBOND Content
Introduction
Performance Characteristics
• Storage, curing and drying
• CCS, CMOR, PLC
• Sticking properties
• Acid resistance
Product Groups
• VIBRATION CASTABLE
• SELF LEVELING CASTABLE (P bl )• SELF-LEVELING CASTABLE (Pumpable)
• DRY GUNITE
• SHOTCRETE (Pumpable)
Introduction
Nanobond name derived from the chemical Liquid Binder No.1
• Aqueous colloid dispersion / suspensions of amorphous SiOAqueous colloid dispersion / suspensions of amorphous SiO2
• Uncured spherical particles 5 – 75 nm
• S l h d ff l l d b d l d h d ff• Solutions with different particle size, particle distribution and solid phase content different reactivity
Introduction
Sol-gel reaction / polymerization
• S t t i t • System contains one or more components cause gelling and hardening
• Gelification: colloidal Silica 3- dimensional
network Si-O-Si bonds water solvent
• Formation of Si-O-Si binding system
• thermal drying
• changing the pH value
• addition of ion soluble salts
• Sol Gel Bond• Sol-Gel-Bond
Performance characteristics
Storage, curing and drying
• 2 3 t k i (d & t) t t 24 th (CA 12 th )• 2 or 3 component packaging (dry & wet) storage up to 24 months (CA < 12 months)
• Short & controllable curing / hardening time no exothermic reaction !• CA takes longer to form complete CAH-phases
• Less sensitive to ambient installation temperatures than CA bonded materials
• Liquid component water content is not part of bonding chemical reactionsLiquid component water content is not part of bonding chemical reactions
• CA bonded systems can trap water in C-A-hydrate phases
• NB easy water evaporation <150°C / 302°F
• NB Dry out schedules with heating rates up to 100°C / hr (212°F / hr)
°• CA: 3 to max. 50°C / hr
• Easy water evaporation helps avoid explosive steam spalling during hot repair or initial heat up
Performance characteristics
Initial heat-up of a 250 mm thick lining
22 Hour Savings
Performance Characteristics
>100°C>100 C
Nanobond
Hydraulic bond (CA)
Performance characteristics
CCS, CMOR, PLCcold crushing strength
140
coldmodulusof rupture 406080
100120140
ccs [
N/m
m²]
cold modulus of rupture
10
15
20
N/m
m²]
020
110 800 1000 1200 1400 1500
temperature [°C]REFRAJETCAST Nanobond F-60 AR/R REFRAJETCAST LC F-60 AR/R
0
5
10
110 800 1000 1200 1400 1500
cmor
[N
permanent linear change
0,0
temperature [°C]REFRAJETCAST Nanobond F-60 AR/R REFRAJETCAST LC F-60 AR/R
-0,4
-0,3
-0,2
-0,1plc
[%]
-0,5110 800 1000 1200 1400 1500
temperature [°C]REFRAJETCAST Nanobond F-60 AR/R REFRAJETCAST LC F-60 AR/R
Performance characteristics
Sticking properties to other surfaces, MACARBON brick
RSC NB S-60 R
carbon brick
B k MACARBON b i k i h
carbon brick
Broken MACARBON brick with
rough, dusty surface
RSC NB S 60 RRSC NB S-60 R• Treatment: thermal shock: 10 x 1200°C (200°C/h)
• Both materials still joinedNo cracks
carbon brick
Performance characteristics
Sticking properties to other surfaces, high alumina castable surface
EN Norm 1402-5, Type A (230x114x64 mm)
Casting No.1 (bottom):
REFRACAST MC B-83 AL
Casting No.2 (on top):
REFRACAST Nanobond B-90 AL
Treatment: 5 x 1000°C (200°C/h)!Treatment: 5 x 1000 C (200 C/h)!
Performance characteristics
Sticking properties to other surfaces, high alumina castable surface
after temperature treatment:
MOR (N/mm2), test regarding “sticking strength”
MOR = 21,7 N/mm2
Failure not in the contact area MCC – Nanobond
k h b dNo cracks in the bond area
REFRATECHNIKDrake Cement – Cyclone 4 (Nov 2013)
6 MT - RJC NB F-60AR Vernier Repairs
Performance characteristics
Acid attack on refractory castables
• Boiled in 70% sulphuric acid
cube 50 mm in sul. acid 70 wt.% at 20°C after 1 minute
f hafter 2 hours
Nanobond Product TypesNanobond Product Types
Material Types & Installation Methods
• Vibration Cast Activator in Dry ComponentVibration Cast Activator in Dry Component
• Self-Leveling Castable Activator in Dry Component
• Dry Gunite Activator in Dry Component
• P C t D A ti t dd d i Mi• Pump Cast Dry Activator added in Mixer
• Shotcrete Liquid Activator added at Nozzle
REFRATECHNIK
EASY EASY –– DRY DRY MonolithicsMonolithics
REFRATECHNIK
Easy Dry: Concept
Product Philosophy:Product Philosophy:
• no cement technology (<0.2 % CaO)• only one component-system for castables
1300 °C + K2CO3, K2SO4, KCl, CaSO4
y p y• only two component-system for JETCAST®-applications • easy installation with water comparable to CAC containing refractory concretes• storage and installation comparable to LC-refractory concretes storage and installation comparable to LC refractory concretes
- reduced water addition of 5.5 - 7.5 %- typical wet mixing time of 3 - 5 min for vibration and JETCAST®-applicationsh i ll ti t d b di• chemically activated bonding
• safe and faster dry out and heating up-procedure• physical properties comparable to LC-refractory concretes • refractoriness comparable to LC-refractory concretes • alkali resistance comparable to LC-refractory concretes
REFRATECHNIK
Easy Dry: Systems Comparison
Application cement industry: Easy Dry Low cement Nanobond
Temperature sensitivity storage + installation (water) (water) (silica sol
≥ 5 °C)
Drying out and heating-up safety
pp y y y
Apparent porosity / alkali resistance
Permanent linear change
Microstructural strength / abrasion resistance
Microstructural elasticity / TSR
Ratio microstructural strength/elasticity
Refractoriness / hot modulus of rupture
comparable respectively
high level of propertiesimproved worse
REFRATECHNIKDrying Out and Heating-Up
Recommendation
Installation Details
Installation Details
Cement Bonded Monolithics:
• Potable Water for Mixing
• Mix 5 Minutes Minimum
• Water Range
• Material & Water Temp > 50 F
h h lf f• 6 – 12 Month Shelf Life
Installation Details
Nanobond No Cement Monolithics:
• Liquid Binder No. 1 - Translucent liquid
• Used for All Nanobonds
• Mixing Ratio Range
• Storage > 5°C / 41°F (Do Not Freeze)
• 12 24 M th Sh lf Lif• 12 – 24 Month Shelf Life
Shipping “Freeze Watch” Indicators
Material OK Material Frozen in TransportMaterial OK Material Frozen in Transport
Liquid Binder No 1 – The Numbers
DensityDensity
1000 - 1350 Kg / M3
1.0 - 1.35 Kg / Liter
2 20 2 98 Lb / Lit 2.20 - 2.98 Lb / Liter
8.33 – 11.28 Lb / Gal
9.81 Lbs / Gal (Avg)
Liquid Binder No 1 - Mixing Examples
For REFRAREFRACASTCAST Nanobond F-60 AR :
150 Kg Batch (6 x 25 Kg / 55 Lb Sacks) 800 Kg Batch (1764 Lb Sack) 150 Kg Batch (6 x 25 Kg / 55 Lb Sacks)
1.74 – 1.93 Gal : 100 Kg (Mixing Ratio)
1.84 Gal : 100 Kg (Avg)
2.75 Gal : 150 Kg (6 x 25 Kg sacks)
800 Kg Batch (1764 Lb Sack)
1.74 – 1.93 Gal : 100 Kg (Mixing Ratio)
1.84 Gal : 100 Kg (Avg)
14.68 Gal : 800 Kg
Using 9.81 Lbs / Gal Density
27.0 Lbs LB#1 : 150 Kg Dry Mix
Using 9.81 Lbs / Gal Density
144.0 Lbs LB#1 : 800 Kg Dry Mix
Liquid Binder No 1 – Health Concerns
Nanobond Accelerant Details
Shotcrete Materials:
• Wet mix with Liquid Binder No 1
Vibration Casting Materials
• Dry Accelerant included in dry mix• Wet mix with Liquid Binder No 1
• Wet mix pumped to installation site
• Liquid Accelerator added to high pressure air at the nozzle
Dry-Gunning Materials
• Dry Accelerant included in dry mix
Pump Casting Materials:
• Li ht b l d d
q g p
(~0.7 wt% to Dry Mix)
• Frost free storage! > 5°C / 41°F• Light-brown colored powder
• Addition of 0.1 - 0.2 wt% to Dry Mix
• Initial set within 60 minutes at 70 °F
• Gelling within seconds plastic material on the surface
• NO addition of Powder Accelerator or additional water!
Initial set within 60 minutes at 70 F
• Without accelerator very long setting time (~days)
!
• Without addition of any Accelerator very long setting
time (days)!
Other Nanobond Considerations
• Less No 1 Liquid Binder amount shorter setting time
• More No 1 Liquid Binder amount longer setting time
• A bi t t h littl ff t tti ti• Ambient temps have little effect on setting times
• Mixing and Transport Equipment must be clean (No CA!)• Mixing and Transport Equipment must be clean (No CA!)
• Application Temp > 1500 FApplication Temp > 1500 F
Installation Details
EZ Dry No Cement Monolithics:
• Potable Water for Mixing
• Mix 5 Minutes Minimum
• Water Range
• Material & Water Temp > 50 F
h h lf f• 6 Month Shelf Life
REFRATECHNIK
ConclusionsConclusions
Cement Bonded Cement Bonded Monolithics Conclusions
High Initial Strengths at Room Temperature
Single Component Castable Mixes – Just add Potable Water
Two Component Jetcast Mixes Two Component Jetcast Mixes
6-12 Month Shelf Life
Long Dry-Outs (Temp Holds at 500, 1000 & 1500 °F)
Material Temp > 50 °F to Install Properly
Can be Difficult to Install at Low Temps
Need to Add SiC / Zirconia / AZS to increase Alkali Resistance
NanobondNanobond Conclusion
Two Component Material: Dry Mix + Liquid Binder Extended Shelf Life
A il bl i 50 E i ti Q liti V Sh t Ti f S i l D l t Available in > 50 Existing Qualities Very Short Time for Special Developments
Short Setting Time Hardening Time Start Heating Up
No Chemical Bonded Water Very Easy Dry Out Up to 100°C /Hr Heatups
Same CCS and CMOR like CA-Bonded Materials > 800°C (1500 °F)
Less Problems with Difficult Application Conditions (humidity, temperature)
Excellent Sticking Properties to Other Refractory Materials Hot and Cold Repair
Storage of Liquidbinder No.1 Always > 5°C!
Wet mixing with Liquidbinder No. 1 NO Additional WaterWet g w t qu db de No. NO dd t o a Wate
Different Accelerators as Activators for Different Installation Methods
EZ Dry EZ Dry Monolithics Conclusions
High Initial Strengths at Room Temperature
Single Component Castable Mixes Just add Potable Water Single Component Castable Mixes – Just add Potable Water
Two Component Jetcast Mixes
6 Month Shelf Life
Short Dry-Out Schedules
Chemically Activated Bonding
Physical Properties Comparable to LC-Refractory Concretes
Refractoriness Comparable to LC-Refractory Concretes
Alkali Resistance Comparable to LC-Refractory Concretesp y
Thank YouThank You