Monolithic refractory system solutions for installation technologies and

linings of preheater and cooler in cement plants

Kai Beimdiek
Topics

• Classification
• Part 1: Storage - workability properties - dry out/heating-up
• Part 2: Installation technologies
• Part 3: REFRALITE® and medium weight technology
Thermally graduated alkali resistance
- SiO2-rich / AR / Z AR
Lower stress/crack sensitivity
- SiC/SiC-free / Mixcrete / Easy Dry-technology (ED)
Comparison concrete / Brick lining
Brick Lining (final product)
Advantage
• very good product properties
• constant + homogeneous product properties
• fabrication + adjustment product properties
at the refractory producer
• low risk of defects in lining
• self-supporting lining
• quick lining of flat or circular walls
• quick heating up possible
Disadvantage
• dependence on kiln size and construction
design in stationary areas
• adaptation/pre-cut is time-consuming
Concrete Lining (semi-final product)
Advantage
• very good product properties
• quick + easy lining method
− reduction of downtime
− lower costs in case of stoppage Solution
− higher plant efficiency Combination of
− high grade and fast brick/concrete lining
• in case of complicated geometry
− adaptation to kiln construction
Disadvantage
• adjustment product properties at the customer
• sensitivity of workability properties
• lower heating up of the concrete lining
Classification refractory products –
Raw materials / Bonding systems / Installation technology

refractory products
SiC
doloma magnesia corundum bauxite mullite andalusite fireclay silica zircon light weight

brick monolithic

ceramic organic hydraulic chemical

RC: >2.5 % CaO MC: >2.5 % CaO LC: 2.5-1 % CaO ULC: 1-0.2 % CaO NC: <0.2 % CaO
regular cement medium cement low cement ultra low cement no cement

deflocculated

mortar plastic ramming pre-cast castable gunning

brickwork self-cast vibration dry gunning wet gunning

dense product insulating product

Classification refractory products – Selection of raw materials

Highest thermal resistance

• andalusite, corundum: REFRAMULLITE 63 …
REFRACORUND 95 …

Highest mechanical resistance

• mullite, bauxite, corundum: REFRAMULLITE 60 …
REFRABAUXITE 75 …
REFRABAUXITE 85 …
REFRACORUND 95 …

Highest alkali resistance

• quartz, SiC, fireclay: REFRA-SiC …
REFRAZIRCON …
REFRA … AR or Z AR
REFRACLAY 40 …
Classification refractory products – Bonding system

Parameter RC vibratable fireclay concrete LC vibratable fireclay concrete

Cement content (wt%) 15-25 3-7

Water addition (wt%) 10-12 6-7
Bulk density (g/cm³) 2.05 2.25
Apparent porosity (%) 20-22 14-15
CCS (N/mm²) 35-45 90-110
Abrasion loss (cm³) 19-20 4-5
Application temperature (oC) 1320 1500

Alkali resistance
Trend of development – Product properties – Installation technique

RCC / MCC / LCC / ULC / NCC

part 3 part 1
high grade very good
specially adapted improvement
safe
product properties

- higher thermal, thermochemical 1955 workability

and thermomechanical loads to properties
2015
cement burning improvement
process installation technique

- modern preheater & precalciner systems - vibration / self-cast technology

- modern cooler systems - dry / wet gunning technology
- short downtime/stoppage part 2
- increase cement plant efficiency fast
- quick and easy lining technology
Workability properties – Storage

direct influence on reactive raw materials

influence:
- high water demand
- longer mixing time
- faster/slower setting process
- compaction behaviour/green strength

suboptimal delivery typical aging effects of the cement and additives (H2O + CO2)
optimal date 6 months 1 year 2 years

influence: influence:
- setting time <10 oC - slightly higher water demand
- setting time <20 oC
- green strength
Workability properties – Optimal/Suboptimal mixing process

suboptimal
optimal
- recommended capacity: 100 kg batch
- easy dosage with a water tank: up to 18 litre
- 3 mixing blades for intensive mixing process
Workability properties – Water addition for vibratable concretes

too dry consistency optimal consistency too wet consistency

Workability properties – Installation equipment – Performance

optimum equipment insufficient equipment

and densification and densification
Workability properties – Lower and higher ambient temperature

Higher working temperatures:

1. cool bags (shadow)
1000
2. add cool water/ice
3. quick processing
Setting time [min]

4. add retarder
100

Low working temperatures:

1. preheat bags (in heated rooms)
10
2. add hot water (max. 50 oC)
3. preheat air (radial burner)
4. add accelerators
1
0 5 10 15 20 25 30 35

Working temperature [oC]

Recommendation for dry out and heating-up

cement-containing cement-free
Too fast dry out and heating-up process
Trend of development – Product properties – Installation technique

RCC / MCC / LCC / ULC / NCC

part 3 part 1
high grade improvement very good
specially adapted product properties safe

- higher thermal, thermochemical 1955 workability

and thermomechanical loads to properties
2015
cement burning improvement
process installation technique

- modern preheater + precalciner systems - vibration / self-cast technology

- modern cooler systems - dry / wet gunning technology
- short downtime/stoppage part 2
- increase cement plant efficiency fast
- quick and easy lining technology
Installation technologies

preheater:
thermally graduated alkali resistance
medium weight technology
heat insulation
preheater - calciner - kiln hood - cooler
high grade (low cement castables)
high grade + flexible (Mixcrete)
high grade + fast (MCG - LCG - JETCAST®)

nose ring - cooler

lower stress/crack sensitivity
Installation technologies regarding economic and technical factors

Vibration Dry gunning JETCAST® (Wet gunning)

≤1 t/h ≤3 t/h ≤10 t/h

Trends in development of installation technologies

Source: Refratechnik Cement GmbH, cement industry, worldwide

Dry gunning technology – Setup dry gunning equipment

separate air compressor high water

compressed air pipe-network X pressure pump

8-12 m³/min
6-8 bar
G or MCG
or LCG
90 bar

upper
lower

20-100 m RLE: 0.5-1.5 bar

G/MCG: 2.0-3.5 bar
LCG: 3.0-4.0 bar
Dry gunning technology – Setup dry gunning equipment

indefinable,
higher/lower
water addition
- reaction time - gunning mix/water
- homogeneous mixing
- dust development and rebound loss

gunning nozzle
technology
20-110 cm
Dry gunning technology – One standard setup

Insulation G MCG LCG (dense gunning)

REFRALITE® 20 G REFRACLAY 40 G REFRACLAY 25 MCG REFRACLAY 40 LCG

REFRALITE® 30 G REFRACLAY 50 G REFRACLAY 40 MCG AR REFRAMULLITE 60 LCG
REFRALITE® 32 G REFRACLAY 50 MCG REFRAMULLITE 60 LCG Z AR
REFRALITE® 40 G REFRAMULLITE 63 MCG AR REFRAMULLITE 63 LCG
REFRA-SiC 50 MCG AR REFRABAUXITE 80 LCG
REFRA-SiC MCG AR

+ +
Dry gunning technology – One standard setup

Properties G MCG LCG JC LCC

dry gunning wet gunning vibration

Water addition high reduced low 6.0-9.0 4.0-7.5

Rebound loss (%) 15-20 10-15 5-10 ≤5 no
Dust development high no no no no
Porosity (%) 30-35 22-28 18-25 15-22 12-20
CCS (MPa) 15-25 40-60 50-90 60-110 70-200
Application temp. (max.) ≤1400 1400-1500 1450-1600 1500-1650 1500-1750

Alkali resistance
(1100 oC / K2CO3)

Trend of development
Practical experience with REFRAMULLITE 60 LCG Z AR in the cement industry

Area: cooler shaft, side wall Area: cooler shaft,

Capacity: 2000 t/d side wall

after 8 months after 5 months

Dry gunning technology – Application recommendation (MCG - LCG)
Wet gunning technology (JETCAST®)

high grade

low or no cement
REFRATECHNIK

technology
controllable mixing
and gunning process

compressed air

accelerator fast
Wet gunning technology (JETCAST®/JC)

Properties LCG LC / JC ED / JC LCC Projects JETCAST®

dry gunning wet gunning vibration

Water addition (%) low 6.0-9.0 6.5-7.5 4.0-7.5 Machine output

Rebound loss (%) 5-10 ≤5 ≤5 - up to 10 t/h

Porosity (%; 1200 oC) 18-25 15-22 17-22 12-20 Daily installation output
CCS (MPa; 1200 oC) 50-90 60-110 60-80 70-200 10-40 t/d
TSR (cycles; 1200 oC) >30 (no cracks) >30 (no cracks) >30 (no cracks) high/low
Application temp. (oC) 1450-1600 ≤1650 1500-1550 1500-1750 Calciner: 196 t/8 days
Kiln hood: 100 t/1 day
Nose ring: 7 t/1 day
Alkali resistance Inlet cone: 6 t/3 h
(1100 oC / K2CO3)
Application experience with REFRAMULLITE 63 JC

Area: kiln hood/cooler shaft

Installation: 110 t/1 week (incl. anchoring, insulation/wear layer)
Capacity: up to 1000 t/d
Firing: ~40 % coal and lignite / ~60 % alternative fuels
Operating time: 57 months

after installation after 7 months after 33 months

Application experience with REFRABAUXITE 85 JC AR

Area: rotary kiln/nose ring

Installation: without rotation of the kiln
Capacity: left figure: 3000 t/d (∅ 5.4 m)
right figure: 2200 t/d (∅ 3.6 m), 80 % AF

after 12 months after 12 months

>18 months in use >20 months in use
Trend of development – Product properties – Installation technique

RCC / MCC / LCC / ULC / NCC

part 3 part 1
high grade improvement very good
specially adapted product properties safe

- higher thermal, thermochemical 1955 workability

and thermomechanical loads to properties
2015
cement burning improvement
process installation technique

- modern preheater + precalciner systems - vibration / self-cast technology

- modern cooler systems - dry / wet gunning technology
- short downtime/stoppage part 2
- increase cement plant efficiency fast
- quick and easy lining technology
Heat insulation and medium weight technology

preheater:
thermally graduated alkali resistance
medium weight technology
heat insulation
preheater - calciner - kiln hood – cooler:
high grade (low cement castables)
high grade + flexible (mixcrete)
high grade + fast (MCG - LCG - JETCAST®)

nose ring – cooler:

lower stress/crack sensitivity
Heat insulation and medium weight technology

insulation medium weight higher density

0.25 0.50 1.00 1.50 2.00 2.50 g/cm³

CaSi RLE RLE RLE RLE RCY RCY RCY

20 G 30 G 32 G 40 G 25 MCG 25 40 LCC

0.15 0.19 0.25 0.3 0.4 1.0 1.1 1.7 W/m·K

95 80 60 55 35 %
1 0.5 2 3-6 15 20 45 80 N/mm²
1000 950 1200 1150 1250 1200 1200 1500 °C

(Bulk density, porosity and CCS were determined at 900 or 1000 oC respectively the thermal conductivity at 600 or 700 oC)
Technico-economic refractory concrete concepts

Medium weight technology REFRALITE® 40 G REFRACLAY 25 MCG

Installation technology Dry gunning Dry gunning

Bulk density (at 1000 oC) 1.40 g/cm³ 1.85 g/cm³

Apparent porosity (at 1000 oC) 37 % 30 %
Cold crushing strength (at 1000 oC) 10 MPa 20 MPa
Max. service temperature 1250 oC 1200 oC
Thermal conductivity (at 700 oC) 0.40 W/m·K 1.00 W/m·K
Al2O3/SiO2 41/40 % 27/61 %

Alkali resistance (1100 oC/K2CO3) good very good

Engineering and installation aspects – Medium weight concretes

30 150 mm 180 mm 180 mm

Upper cyclone 350 oC 350 oC 350 oC
o
T inside 350 C 238
T outside 20 oC 118 146
72 107
Wind speed 0 m/s 75
RT 800 RCY 25 RLE 40 G RCY 25 MCG
250 SP MCG

70 150 mm 220 mm 220 mm

Lower cyclone 900 oC 900 oC 900 oC
o
T inside 900 C 757 358 426
T outside 20 oC 110 183
wind speed 0 m/s 91
RT 800 RCY 25 RLE 40 G RCY 25 MCG
250 SP MCG
Single layer construction of REFRACLAY 25

Cement Plant, Germany

Lowest cyclone C6, d 5.20 m

T inside/outside 900/20 oC
wind speed 0 m/s

Calculation: after approx. 1 year

shell temperature 180 oC

Practice:
shell temperature 150-185 oC
Single layer construction of REFRACLAY 25 MCG

Cement Plant: Germany

Area: Side walls of the cold part of the cooler

after 5 months
Thermally graduated alkali resistance

preheater:
thermally graduated alkali resistance
medium weight technology
heat insulation
preheater - calciner - kiln hood – cooler:
high grade (low cement castables)
high grade + flexible (mixcrete)
high grade + fast (MCG - LCG - JETCAST®)

nose ring – cooler:

lower stress/crack sensitivity
Alkali-sulphate-chloride circle in a cement plant

3K2SO4·Na2SO4
K2SO4·CaSO4
secondary burner
Na2SO4
for pre-calcination high alumina, high cement-containing
NaCl concrete, apparent porosity >20 %
KCl

alkalis
main burner
alkali circle
for clinker burning process
sulphate circle
chloride circle
Thermally graduated alkali resistance
Thermally graduated alkali resistance (600-1100 oC)
REFRACLAY 25 (MCG) (JC)

REFRACLAY 25 MCG • very low Al2O3/SiO2-ratio (SiO2-surplus)

Raw material basis fireclay • in theory only formation of SiO2-rich feldspar
(e.g. sanidine K2O·Al2O3·6SiO2 (∆volume: 0.1 %)
Al2O3 25-29 % • no volume increase
SiO2 59-63 % • no destroyed microstructure

Max. application temperature 1200 oC

no
o
Properties at 1000 C volume
increase
- Bulk density 1.85 g/cm³
- Cold crushing strength 20 MPa
- Thermal expansion 0.50 %
- Permanent linear change -0.5 % cup test (1100 oC/K2CO3)
Thermally graduated alkali resistance (900-1300 oC)
AR-products (alkali resistant)
unprotected
Product philosophy SiC-containing
SiC 5-72 %

Excellent thermochemical resistance

- SiC + 2O2 = SiO2 + CO2
- SiO2-surplus ≥900 oC
- silicatic protective layer leucite/kalsilite
- lower Al2O3/SiO2-ratio
- no volume increase no
- no destruction of microstructure volume
increase
Permanent linear change (higher SiC contents)
1200 oC typical -0.1 up to +0.5 %
1400 oC typical +0.6 up to +2.5 % cup test (1100 oC/K2CO3)
Thermally graduated alkali resistance (900-1500 oC)
REFRACLAY 40 Z AR

Product philosophy SiC + zircon • High thermal resistance

- lower SiC content/unproblematic SiC oxidation
SiC 9-13 % - thermal stabilisation by ZrO2 compounds
ZrO2 3-7 % • Excellent thermochemical resistance
- SiO2-surplus 900-1300 oC (protective layer)
Max. application temperature 1500 oC SiC + 2O2 = SiO2 + CO2
Cold crushing strength [1000 oC] 100 MPa 1200-1550 oC
ZrSiO4 = ZrO2 + SiO2
Thermal expansion [1000 oC] 0.60 %
no
Permanent linear change volume
1200 oC -0.30 % increase
1400 oC -0.20 %
1500 oC 0.5 %
cup test (1300 oC/K2CO3, K2SO4,KCl, CaSO4)
Thermally graduated alkali resistance (900-1500 oC)
REFRACLAY 40 Z AR

Area: lower calciner

Installation: 100 t
Operating time: > 48 months

Further application areas: • calciner

• riser duct
• inlet chamber
• kiln hood
• cooler inlet
Thermally graduated alkali resistance (900-1500 oC)
REFRZIRCON Z AR

Product philosophy SiC + ZrO2 Excellent thermochemical/-mechanical resistance

• Silicatic protective layer
SiC 7-11 % • Lower Al2O3/SiO2 ratio (SiO2-surplus)
ZrO2 16-20 % • Excellent chemical resistance of ZrO2-component
• Reduced coating formation
Max. application temperature 1550 oC • High mechanical and abrasive resistance
Cold crushing strength [1000 oC] 100 MPa
Abrasion resistance [1000 oC] 5-6 cm³
no
Thermal expansion [1000 oC] 0.60 % volume
increase
Permanent linear change
1200 oC 0.00 %
1400 oC 0.20 %
cup test (1100 oC/K2CO3)
Alkali resistant AR- and Z AR-technology

SiC zircon

12.5 12.5

Alkali cup test

1100 oC/K2CO3
25 25

SiC + zircon

50
R-SiC 50 AR

RCY 40 Z AR

RZN Z AR

Z AR-technology
General application recommendation – Preheater and calciner

1th - 4th cyclone RCY 25 / MCG / JC, RLE 40 G

(also single layer)

5th cyclone RCY 25 / MCG / JC (also single layer)

RCY 40 LCC / LCG / JC
RCY 40 Z AR
calciner – cold part RCY 40 LCC / LCG, RCY 40 Z AR
calciner – hot part RCY 40 Z AR + RCY 40 ED JC Z AR
RME 60 LCG Z AR
RME 63 LCC (AR), RME 63 JC (AR)
RZN Z AR
riser duct RCY 40 Z AR + RCY 40 ED JC Z AR
inlet chamber RZN Z AR
R-SiC 50 AR (MCG AR)
Stress reducing concepts from kiln outlet to the wear benches

Preheater:
thermally graduated alkali resistance
medium weight technology
heat insulation
Preheater - Calciner - Kiln hood – Cooler:
high grade (low cement castables)
high grade + flexible (mixcrete)
high grade + fast (MCG - LCG - JETCAST®)

Nose ring – Cooler:

lower stress/crack sensitivity
Stress reducing concepts for excellent thermal shock resistance

SiC-free SiC-containing No cement technology

thermomechanical load thermomechanical + drying out process

thermochemical load

RCD 95 LCC RBE 85 LCC AR Easy Dry (ED)

from kiln outlet RME 72 LCC RBE 85 JC AR (85 ED JC AR)
Z AR-technology
to wear benches AR or Z AR-Mixcrete

refractoriness thermal conductivity CA-hydrate phases

thermal expansion temperature gradient gas permeability
hot strength difference in properties bending strength
structural elasticity
AR- and Z AR-Mixcrete concept

AR-Mixcrete Z AR-Mixcrete
RBE 85 LCC 3:1 / 2:1 / 1:1 RBE 85 LCC 1:1
RBE 75 LCC 3:1 / 2:1 / 1:1 RBE 75 LCC 1:1
RME 63 LCC 3:1 / 2:1 / 1:1 R-SiC 50 AR RME 63 LCC 1:1 RZN Z AR
RME 60 LCC 3:1 / 2:1 / 1:1 RME 60 LCC 1:1
RCY 40 LCC 3:1 / 2:1 / 1:1 RCY 40 LCC 1:1

higher thermal conductivity higher quotient of CCS/E-modulus

lower temperature gradient higher thermomechanical resistance
higher alkali resistance higher thermochemical resistance

like REFRACLAY 40 LCC AR like REFRACLAY 40 Z AR (9 % SiC / 5 % ZrO2)

or REFRABAUXITE 85 LCC AR
AR- and Z AR-Mixcrete concept

• modular/flexible installation AR-Mixcrete:

• flexible use of standard products product combination ratio Al 2O3 SiO2 Si C
• graduated SiC contents/concepts [wt.-%] [wt.-%] [wt .-%]
• zonally adapted product properties REFRACLAY 40 LCC + 3 1 38 45 12
REFRA-SiC 50 AR 2 1 36 43 17
1 1 32 39 25
• standardised product range REFRAMULLITE 60 LCC + 3 1 44 36 16
• smaller number of products REFRA-SiC 50 AR 2 1 42 35 20
• simplified storage 1 1 36 33 27
• minimised storage times REFRAMULLITE 63 LCC + 3 1 48 36 13
REFRA-SiC 50 AR 2 1 45 35 17
• reduced warehousing costs 1 1 39 33 25
REFRABAUXITE 75 LCC + 3 1 52 27 16
• mixing bag by bag REFRA-SiC 50 AR 2 1 48 27 20
• easy application 1 1 41 27 27
REFRABAUXITE 85 LCC + 3 1 61 17 16
• mixing batches: 3:1 / 1:1 = 100 kg REFRA-SiC 50 AR 2 1 56 18 20
2:1 = 75 / 150 kg 1 1 47 20 27
Mixing of REFRABAUXITE 85 LCC + REFRA-SiC 50 AR

after 5 months
RBE 85 LCC

ratio 3:1 ratio 2:1 ratio 1:1

R-SiC 50 AR
AR-Mixcrete – Practical experience in the cement industry

Cement plants: Russia

Area: cooler/wear benches

after 6 months after 4 months

>12 months in use >12 months in use
AR-Mixcrete – Processing instructions, data sheet
Easy Dry (ED) – Product philosophy

• No cement technology (<0.2 % CaO)

• Only one component system for castables
• Only two component-system for JETCAST® application
• Easy installation with water comparable to CAC containing 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®-application
• 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
Easy Dry – Product line
Easy Dry (ED) – Application in the cement industry

Easy Dry Low cement Sol-Gel

(water) (water) (silica sol ≥ 5 oC)
Temperature sensitivity storage + installation
Drying out and heating-up safety
Apparent porosity / alkali resistance
Permanent linear change
Microstructural strength / abrasion resistance
Microstructural elasticity / TSR
Ratio microstructural strength/elasticity
Refractoriness / hot modulus of rupture

excellent improved good sufficient

Easy Dry (ED) – Recommendation for drying out and heating-up
Practical experience with REFRABAUXITE 85 ED AR in the cement industry

Cement plants: Great Britain

Area: nose ring

after 4 months

after 5 months,
12 months in use
Practical experience with REFRABAUXITE 85 ED JC AR in the cement industry

Cement plants: Switzerland

Area: nose ring

after 3 months after 8 months,

>12 months in use
Many thanks for your attention!

Refratechnik Cement GmbH

Rudolf-Winkel-Strasse 1
37079 Göttingen · Germany
Tel. +49 5 51-6 94 10 · Fax +49 5 51-69 41-104
refra@refra.com · www.refra.com