7b - Compac Sol Castables (Compatibility Mode)
7b - Compac Sol Castables (Compatibility Mode)
7b - Compac Sol Castables (Compatibility Mode)
Cement
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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. 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).
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100 0 -100 0 -200 -300 -400 -500 -600 -700 -800 -900 -1000 -1100 -1200 -1300 -1400
50
100 150 200 250 300 350 400 450 500 550 600
temperature [C]
only slight increase of porosity at higher temperatures excellent thermal shock resistance safe and fast heating up procedure (ready at 200 C)
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60
50
Cement Sol-Gel
40
30
20
10
P o] m re s ize [
Properties, heating up
Thermoelemente Steinschalung
Brenner
Abzug
Brenner
Fasermatte 3mm
1 Versuchsaufbau 2 Mould and thermo elements 3 trial tundish 4 block after heating up
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Properties, heating up
Thermogravimetry of a sol-bonded 130 kg block
700 100 90 600 80 500 70 60 50 300
temperature in the furnace temperature on the surface of the block temperature in the middle of the block emitted water
temperature [C]
400
40 30 20 10
200
100
0 0
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0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34
time [h]
dehydration [%]
Properties, heating up
Heat Up Schedules of Low Cement and Compac / Carsit Sol Castbales
800 700 600 Temperature (C) 500 400 LCC 300 200 100 0 0 10 36 RHI AG 10 20 30 Time [h] 40 50 60 70 Sol
Properties, refractoriness
sol bonded vs. cement bonded concretes based on Bauxite / Refractoriness under load
2
Cement Sol-Gel
Espansion [lin% ]
Temperature
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700
approx. 90C
-1
higher!
-2
-3
-4
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Crucible test with DIDURIT 160 after 3 cycles (a) and COMPAC SOL 160 after 7 cycles (b).
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TE
1000C % 400C W/m K
TC
800C W/m K 1200C W/m K
ATL
AR
SL
Raw Material
cm3
months
Castables COMPAC SOL F53-6 COMPAC SOL M64-6 COMPAC SOL B87-6 CARSIT SOL F30-6 CARSIT SOL M10-6 CARSIT SOL S30-6 52,5 64,0 85,0 39,0 58,0 46,5 44,0 32,0 9,5 29,5 28,0 22,0 0,8 0,9 1,5 0,6 0,8 0,5 29 10 30 70 70 70 70 70 70 110 115 140 105 120 110 0,55 0,55 0,60 0,55 0,55 0,55 1,50 1,80 2,20 2,70 1,84 2,75 1,60 1,75 2,30 2,68 1,77 2,72 1,80 1,95 2,40 2,62 2,13 2,81 1600 1700 1700 1550 1650 1580 8,0 9,0 7,0 7,0 8,5 12 12 12 12 12 12 Dense fire clay, low iron Mullite Bauxite Dense fire clay, low iron / SiC Mullite / SIC Andalusite / SiC
Available from Calsil, India CARSIT SOL M10-05 V 13 36 RHI AG 57,0 29,0 1,2 10 50 80 0,55 1,84 1,77 2,13 1650 12 Mullite / SIC
TE
1000C % 400C W/m K
TC
800C W/m K 1200C W/m K
ATL
AR
SL
Raw Material
cm3
months
Gunning Mixes COMPAC SOL F53G-6 COMPAC SOL M64G-6 COMPAC SOL S64G-6 CARSIT SOL F10G-6 CARSIT SOL F30G-6 CARSIT SOL S10G-6 CARSIT SOL S30G-6 CARSIT SOL M10G-6 CARSIT SOL RHI M30G-6 14 36 AG 50,0 61,0 63,0 45,0 38,0 60,0 44,0 57,0 44,0 47,0 34,0 36,0 42,0 31,0 23,0 22,0 30,0 20,0 0,7 0,7 0,5 0,7 0,7 0,7 0,7 0,7 0,7 10 30 10 30 10 30 45 55 55 45 45 55 55 55 65 45 65 60 50 45 55 55 65 75 0,55 0,55 0,55 0,55 0,55 0,55 0,55 0,55 0,55 1,70 1,60 2,00 1570 1670 1670 1550 1550 1650 1580 1650 1580 12 12 12 12 12 12 12 12 12 Dense fire clay, low iron Mullite Andalusite Dense fire clay, low iron / SiC Dense fire clay, low iron / SiC Andalusite / SIC Andalusite / SIC Mullite / SIC Mullite / SIC
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.
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+5C +12 C
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References 5: calciner
Compac Sol 123SiC 0-6 / Carsit Sol F30-6
Ambient temperature: Mix temperature: Setting time: +6 C +1 C 5-6 hrs
installation 21 36 RHI AG
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 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.
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installation 23 36 RHI AG
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. after one year
installation 24 36 RHI AG
Life time could be increased from 7 to 12 months compared to previous installations of competitive materials. Further steps: => Sol-prefab-concept
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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. 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.
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References 9: gunning
installation 27 36 RHI AG
References 9: gunning
Feb. 2013
CARSIT SOL F10G-6 Even after 2 years lining is still in perfect shape.
installation 28 36 RHI AG
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REFERENCE LIST
SOL bonded castables
CARSIT SOL M10G-6 CARSIT SOL M30G-6
COUNTRY
CUSTOMER
Casting BULGARIA CZECH REPUBLIC DENMARK EGYPT EGYPT FRANCE Zlatna Panega cement, Zlatna Panega Lafarge Cement, Cizkovice AALBORG PORTLAND CEMENTFABRIK, Aalborg Alexandria Portland Cement, Alexandria Beni Suef Cement S.A.E., Beni Suef Ciments Calcia, Chateau la Valliere Ciments Calcia, Cruas Cemex OstZement, Rdersdorf Dykerhoff Zement, Lengerich HeidelbergCement Burglengenfeld HeidelbergCement Hannover HeidelbergCement Schelklingen Holcim (Deutschland), Lgerdorf Holcim (Deutschland), Sehnde Krupp Polysius AG, Beckum Liapor GmbH&Co., Hallerndorf-Pautzfeld Phnix Zementwerke, Beckum Portlandzementwerk Dotternhausen Portlandzementwerk Wittekind, Erwitte Schwenk Zement, Allmendingen Schwenk Zement, Heidenheim Spenner Zement, Erwitte Zement und Kalkwerk Otterbein
GERMANY
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Gunning
REFERENCE LIST
SOL bonded castables
CARSIT SOL M10G-6 CARSIT SOL M30G-6
COUNTRY
CUSTOMER
Casting IRELAND ITALY Irish Cement LTD, County Louth Colacem, Gubbio Colacem, Modica Colacem, Ragusa Cimalux Rumelange Cementos Apasco Ramos Arizpe, Saltillo Cementos Apasco, Hermosillo, Sonora Ohorongo Cement LTD, Windhoek Norcem AS, Brevik VSH - Vchodoslovensk Stavebn, Turna nad Bodvou Cementos Cosmos, Oural/Lugo Baticim - Bati Anadolu Cimento, Izmir Batisoeke Soeke Cimento, Bornova, Izmir Mardin Cimento Sanyii ve Ticaret A, Mardin Tororo Cement, Tororo Tarmac LTD (Tunstead Maerz Kiln), Buxton Lafarge Cement UK, Stoke on Trent Zambezi Portland Cement LTD, Ndola
LUXEMBOURG MEXICO
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ZAMBIA
Gunning
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 with the same heating up curve as applied to basic bricks, there was no 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.
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