7b_Compac Sol Castables [Compatibility Mode]

No Cement Castables

a new family of sol-gel bonded castables

Cement

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?

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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.

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

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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.

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

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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 0 100 0 50 100 150 200 250 300 350 400 450 500 550 600 temperature [°C] A b d a m p fr a te 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

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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)

P oresizedistribution - 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 re s ize [ 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 Brenner

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Properties,

heating up 36 8 RHI AG Fasermatte 3mm Versuchsblock ANKOCAST 341

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1 Versuchsaufbau

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2 Mould and thermo elements 3 trial tundish

Thermogravimetry of a sol-bonded 130 kg block 500 600 700 70 80 90 100

Properties,

heating up 36 9 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] te m p e ra tu re [ °C ] 0 10 20 30 40 50 60 70 d e h y d ra ti o n [ % ]

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 T e m p e ra tu re ( °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 36 11 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] E s p a n s io n [ li n % ] 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

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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 12 Dense fire clay,

low iron CCS TC 36 13 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 12 low 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 12 Dense 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

Product Range Sol Gel

Gunning Mixes

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

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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 12 Dense fire clay,

low iron / SiC

CARSIT SOL F30G-6 38,0 31,0 0,7 30 45 45 0,55 1550 12 Dense 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

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

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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

References 2: Horse shoe

Horseshoe installation, Feb. 2010:

COMPAC SOL 155SIC showed

excellent processing conditions at

ambient temperatures around and

slightly below 0°C.

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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

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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.

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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

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Mix temperature

+12 °C

Setting time:

2,5 hrs

References 4: planetary cooler

Planetary cooler, intermediate

segments:

after 6 months in operation

and after 1 year in operation

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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

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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

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installation _{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.

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installation _{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

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installation _{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:

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Life time could be increased from 7 to 12 months compared to previous installations of competitive materials.

Further steps: => Sol-prefab-concept

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.

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installation _{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.

References 9: gunning

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installation _{after one year}

References 9: gunning

CARSIT SOL F10G-6

Even after 2 years lining is still in perfect shape.

Feb. 2013

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Reference 10: Cooler Roof

Customer: Portland Zement Otterbein

Material: CARSIT SOL F10G-6

Area: Cooler sidewall and roof

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Area: Cooler sidewall and roof

CARSIT SOL F10G-6 after one year

Reference 10: Cooler Roof

...and after 2 years

Customer: Portland Zement Otterbein

Material: CARSIT SOL F10G-6

Area: Cooler sidewall and roof

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Area: Cooler sidewall and roof

Reference 11: Burner lance

Brand: CARSIT SOL M10 – 5 V

Customer Golden Bay Cement, Whangerai, New Zealand

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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

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REFERENCE LIST

COUNTRY CUSTOMER C O M P A C S O L F 5 3 -6 C O M P A C S O L B 8 7 -6 C A R S IT S O L M 1 0 -6 C A R S IT S O L F 3 0 -6 C A R S IT S O L S 3 0 -6 C A R S IT S O L F 1 0 G -6 C A R S IT S O L F 3 0 G -6 C A R S IT S O L M 1 0 G -6 C A R S IT S O L M 3 0 G -6

BULGARIA Zlatna Panega cement, Zlatna Panega

CZECH REPUBLIC Lafarge Cement, Cizkovice

DENMARK AALBORG PORTLAND CEMENTFABRIK, Aalborg

SOL bonded castables

Casting Gunning

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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

REFERENCE LIST

COUNTRY CUSTOMER C O M P A C S O L F 5 3 -6 C O M P A C S O L B 8 7 -6 C A R S IT S O L M 1 0 -6 C A R S IT S O L F 3 0 -6 C A R S IT S O L S 3 0 -6 C A R S IT S O L F 1 0 G -6 C A R S IT S O L F 3 0 G -6 C A R S IT S O L M 1 0 G -6 C A R S IT S O L M 3 0 G -6

SOL bonded castables

Casting Gunning

IRELAND Irish Cement LTD, County Louth

ITALY Colacem, Gubbio

Colacem, Modica

Colacem, Ragusa

LUXEMBOURG Cimalux Rumelange

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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

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

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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.

Thank you for your attention!

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