ANKRAL Q - Series

Cement

ICTM R. Krischanitz March 2013

Product Portfolio, Q Series:

Due to the success of the bricks based on the Q-concept, a complete product line has been implemented, based on this concept: top grade
special solutions

Q - Series

ANKRAL QF

top grade

ANKRAL Q1

high grade

ANKRAL Q2 (T2)

economic grade
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ANKRAL QE

Use of Q-concept Bricks Worldwide

Austria Belgium Brazil Bulgaria Canada China Costa Rica Croatia Cuba Czech Republic Denmark Ecuador Egypt Germany Greece Hungary Iran Iraq Ireland Israel Italy Jordan Kenya Lebanon Lithuania Luxembourg Mexico Nigeria Norway Peru Portugal Serbia Slovakia South Africa Spain Switzerland Togo Tunesia Turkey United Kingdom USA Venezuela

Innovation in Basic Bricks for Cement Rotary Kilns

Rebranding of all RHI CRK brands in ANKRAL Introduction of Q-series including ANKRAL Q1 and ANKRAL QE

Grant of the Hercynite patent 1994

Introduction of ANKRAL Z1

Introduction of ANKRAL QF

2003

2004

2005

2006

2007

2008

2009

2010

2000

2001

1995

1996

2002

1997

First installations of ANKRAL ZE (R63)

1994

1998

1999

Introduction of ANKRAL ZC into the Chinese market

Development of Q-concept

Introduction of ANKRAL Q2 (T2)

2012

2011

The Q-Concept

The Q-concept bricks:

own raw material

Qflexibilizing concept

Excellent price/ performance ratio

Sintered magnesia, mainly of own resources Q-concept flexibilizing for optimized performance

excellent price performance ratio

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Own Raw Material Production Sites

Austria: Breitenau Hochfilzen Radenthein Italy: Marone Turkey: Eskisehir Norway: SMA Mineral Ireland: PPL China: Dashiqiao South Africa: Isethebe
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Main Benefits of the Q Series:

Outstanding flexibility due to implementation of the Q-concept

Mechanical properties as CCS and HMOR are not sacrificed

Reduced loss of flexibility when infiltrated by alkaline salts Increased resistance to alkali salt infiltration due to implementation of Q-concept (hybrid spinel technology) Excellent price performance ratio
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Development Focus: Wear Mechanisms

thermal load
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Chemical Wear
Chemical wear is characterized by two effects:

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Dynamic E-Modul Increased Flexibility

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Diagram showing the development of E-modul during heating up and cooling down. There is a reduction in flexibility (increase in E-modul) during cooling down at around 1100C. This effect can be reduced significantly by use of the Q-concept technology, resulting in an overall higher flexibility.

E-modul Comparison

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ANKRAL Q2 shows even infiltrated a lower E-modul compared to conventional MA spinel brick of type e.g. ANKRAL R2, ALMAG 85 or MA11.

How to Combat thermo-chemical Attack? Change in Concepts

Kiln with easy operation conditions.
Max performeter 90%

80%

70%

thermochemical load

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How to Combat thermo-chemical Attack? Change in Concepts

Severe chemical attack: strong chemical attack causing reduced performance
Max performeter 90% 80% 70%

Q-concept: combined optimization of corrosion resistance + reduced loss of flexibility

Max performeter 90% 80% 70%

higher corrosion resistance

thermochemical load

higher corrosion resistance optimized flexibility

thermochemical load

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ANKRAL QF
Concept: top grade sintered magnesia Q-concept flexibilizing Properties: high refractoriness excellent resistance to chemical attack outstanding flexibility outstanding thermal shock resistance Low thermal conductivity Application: For special application and lining areas with severe thermo-chemical and especially in combination with high mechanical load (e.g. tyre sections)

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ANKRAL Q1
Concept: top grade sintered magnesia Q-concept flexibilizing Properties: high refractoriness excellent resistance to chemical attack outstanding flexibility outstanding thermal shock resistance low thermal conductivity Application: Transition zones of kilns with severe load due to use of alternative fuels (thermo-chemical, mechanical)

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ANKRAL Q2
Concept: high grade sintered magnesia Q-concept flexibilizing Properties: high refractoriness high resistance to chemical attack outstanding flexibility outstanding thermal shock resistance low thermal conductivity Application: Central burning and transition zones of kilns with increased load (thermo-chemical, mechanical)

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ANKRAL QE
Concept: natural alpine sintered magnesia Q-concept flexibilizing Properties: coating friendly high refractoriness outstanding flexibility outstanding thermal shock resistance low thermal conductivity Application: Central burning zone of kilns with moderate to severe load Transition zone of kiln with moderate load

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Lining Recommendation Conventional Q-concept

increased chemothermal load extreme conditions at use of AF

ANKRAL QE

ANKRAL QF in case of excessive thermo-chemical and/or mechanical load e.g. tyre, deformations, outlet!

ANKRAL Q2 ANKRAL Q1

Best of ANKRAL QF

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Plant A, Germany
Kiln: & 5,2 x 87m SP with satellite coolers, 2.500 tpd Lining area: UTZ tyre between rm 31,6 and 35,6 Tyre creep within campaign: about 40mm/rev
Fuels: Main burner: Inlet: Situation: The usual lining life until now has been limited to 4 months due to strong mechanical and chemical load in the tyre section.
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bituminous coal, plastics, solvents (AF approx 70%) tyre chips

Result after full campaign of 12 months

Brick shows nearly full residual thickness (205mm from original 220mm) with clear signs of severe chemo-thermal and mechanical load (scratch marks and damages on the cold face). Furthermore there are reducing operation conditions.
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Result after full campaign of 12 months

Severe chemical attack and mechanical load !! The colour is gone, but nothing serious happened.

Increase of life time from 4 to 12 months !

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Chemical investigation
Brick grade Area Sampling for chemical analyses
(distance from hot face)

ANKRAL QF A 5 - 25 mm
83,80 9,69 0,26 0,47 0,12 2,33 4,18 0,03 1,84 1,07 0,05 2,99

B 75 - 100 mm
80,40 9,73 0,25 0,74 0,12 2,97 7,09 0,60 3,24 1,88 0,08 5,80

C 130 - 155 mm
83,60 8,80 0,27 1,30 0,13 2,73 3,62 0,60 1,51 0,92 0,11 3,14

D 180 - 205 mm
86,8 9,26 0,26 0,76 0,12 2,71 -0,08 0,13 0,07 0,05 0,05 0,30

Technical data sheet

Chemical analysis (wt.%) MgO Al2O3 SiO2 CaO MnO Fe2O3 Loss on ignition SO3 Cl K2 O Na2O Cl + SO3 + K2O + Na2O 87 9,3 0,3 0,7

2,7

Despite severe chemical load no spalling or crack formation. 24 RHI AG

Molar alkali sulphur ratio (ASR) (K2O/94)+( Na2O/62)-(Cl/71) (SO3/80)

-43,92

-3,25

-1,30

0,23

Mineralogical investigation
Pore filling densification of the microstructure by alkaline salts. But bonding structure still present. Magnesia (1), potassium chloride (2), magnesia alumina spinel (4).

Detail showing the precipitation of periclase (3). Sample from area 3. Magnesia (1), potassium chloride (2).
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Mineralogical investigation

Microstructural detail from sampling area 2 showing severely densified brick structure but no corrosion or degeneration of hercynite. Formation of monticellite as corrosion product of dicalcium-silicate. Magnesia (1), potassium chloride (2), monticellite (3), hercynite (4), complex spinel (5).
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Plant B, Czech Republic

Kiln: & 5,6 x 90m SP 2.800 tpd Lining area: UTZ, rm 36 40, second trye Fuel: coal, 35-40% AF

Despite strong mechanical stresses in the tyre area (creep=30mm/rev) ANKRAL QF is the only brick which remains in place for a second campaign. Residual thickness after one campaign 150 170mm. Previous installations achieved only 1 campaign.
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Plant C, Slovakia
Kiln: & 5,0 x 78m PC (hot disc), 3.600 tpd Lining area: UTZ, rm 30 35 tyre section Approx. 60% alternative fuels
Situation: The usual lining life until now has been limited to 6 months due to strong mechanical load in the tyre section. Kiln had to be stopped usually for intermediate repair in summer. For a trial ANKRAL QF was installed in March 2009 in the UTZ tyre section.

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Plant C, Slovakia
ANKRAL QF was inspected in August 20th 2009 after 6 months in operation showing full residual thicknesses of 220mm . After a full campaign (10 months) bricks still show excellent performance without spalling and smooth surface (see pic). Bricks were in place until November 2011 (more than 2 years) and were replaced with res. Thicknesses of 180 200mm due to a change in kiln shell. The bricks clearly outperformed previous installations which did not reach more than 6 months.
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Plant D, Austria
Kiln: & 4,5 x 78m SP, 2.000 tpd Lining area: UTZ, rm 24 26 Content of AF used about 70% (plastics, tyres, sewage sludge, animal meal and solvents). During this campaign trials with 100%. Changes between different clinker types PC and Contra Gress. Lining in this area stayed in place for the first time for a second campaign (see pic). Kiln had to be stopped to to a hot spot in the neighbouring lining. ANKRAL QF still had residual thicknesses of 150-190 mm.
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Plant D, Austria

ANKRAL QF after about 18 months in operation. Despite severe chemical load and reducing operation conditions residual thicknesses of 150 180mm.
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Plant E, Italy
Kiln: & 4,6 x 60m SP, 2.300 tpd Lining area: UTZ, rm 19 24 Installation: March 2012 July 2013 still in service, thicknesses 160 170 mm (from original 200mm), no spalling even wear

Competition, AF product: Lining area: UTZ, rm 24 31 Installation: March/May 2012 July 2013 Residual thickness 30 40 mm Competitor product was replaced by ANKRAL QF.
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Best of ANKRAL Q2

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Plant A, UK
FLS, PC kiln, 2450 tpd 3,950 x 58 m 50% alternative fuels: pelletized sewage sludge tyre chips recycled liquid fuel with coal.

ANKRAL Q2 installed in Jan. 2011 1rm (23,8 - 24,8) trial field After a full campaign the brick was in most parts almost full depth although for part of the panel infiltration spall was noted. The customer is satisfied with performance and will install 5 metres of Q2 over the front tyre during this stop.
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Plant A, UK

ANKRAL Q2 after a full campaign in operation. The cut section shows severe infiltration by alkaline salts. The cold face shows also magnetic properties due to corrosion of the kiln shell. This outlines the strong chemo-thermal load within the lining area.

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General information
Customer Plant Aggregate Position Brand Sampling Lafarge Cauldon, UK Cement rotary kiln Upper transition zone ANKRAL T2 ANKRAL Q2 5-20 mm 145-165mm from the hot face from the hot face

Plant A, UK

ANKRAL T2 ANKRAL Q2 Technical data sheet

Chemical analyses
Wt.%
Loss on ignition (1050 C) (DIN 51081) 0.59 86.51 8.47 0.89 0.26 0.02 2.24 0.24

Wt.%
3.77 80.58 8.59 0.84 2.00 0.04 2.37 1.62

Wt.%

Determination by XRF1) (ISO 12677)

MgO Al2O3 SiO2 CaO MnO Fe2O3 86.3 9.0 0.8 1.6 2.3

Determination by titration 2)
Chloride

Determination by C-S elemental analysis2)

(DIN 51085)

Sulfur SO3

0.24 0.61 0.74 0.03 (K2O/94)+( Na2O/62)-(Cl/71) (SO3/80)

0.87 2.17 1.68 0.11

Determination by ICP-OES2)3) (ISO 26845)

K2 O Na2O

Alkali-sulfate ratio, molar 4)

0.66 -0.12
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Plant A, UK

The trial was only 1 running meter but was in the worst area and gives positive indications. The photo below shows the Q2 in position and spalls can be seen in the brickwork either side (competitor high grade brick). The brick top missing from the lower part was removed by the author to check for infiltrating salts. In comparison to the competitive high cost product ANKRAL Q2 shows an excellent 37 ANKRAL QF price performance ratio.

Plant B, UK
FLS, PC kiln, 2450 tpd 3,950 x 58 m 50% alternative fuels: pelletized sewage sludge tyre chips recycled liquid fuel with coal.

ANKRAL Q2 installed in Jan. 2012 in LTZ area of unstable coating Residual thickness after a full campaign about 150mm. Some spalling in the key area. Removed for safety reasons.

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Plant C, UK
4 m of ANKRAL Q2 were fitted last year from 5.8 to 9.8 metres between competitor AF brick at the front and competitor AF brick at the back. The interface of LTZ and CBZ is considered to be 8 metres from nose. There was no visible difference in thickness or condition. All bricks were removed after the campaign.

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rm 18

15

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Plant C, UK

Competition / ANKRAL Q2 (5.8 to 9.8) / Competition

outlet
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Plant D, Austria
Voest, PC kiln, 4.0 x 60 m Capacity 2400 tpd Fuels: coal, petcoke (3.5 sulphur), 25-30% mixture of plastic, animal meal & sunflower seeds Installation area: r.m. 3.2 - 6.2 Installation date: 09.03.2011 Inspection in Feb. 2012 stays in kiln for another year in kiln Total service life up to now: ~ 1 year Residual thickness: 180-190 mm Former installed product: ANKRAL ZE Total service life ZE: 1 year
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Plant D, Austria

ANKRAL Q2 after one full campaign in operation (LTZ rm. 3,2 - 6,2). 42 Residual thicknesses 180 190 mm. ANKRAL QF

Plant D, Austria

ANKRAL Q2 after two campaigns still under coating (LTZ rm. 3,2 43 6,2). Residual thicknesses about 140 mm. ANKRAL QF

Plant E, Portugal
PC kiln = 4,8 x 88 m, 3000tpd Fuels: Petcoke, animal meal, RDFs, biomass ANKRAL Q2 installed in UTZ between rm 20-22 Installed: Replaced: Total service life: Residual thickness: May 2011 May 2012 12 months 12-14cm, despite twisting of the lining ( also increased mechanical load)

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Plant E, Portugal, Result

Customer satisfied with price/performance ratio. ANKRAL Q2 achieved same result as more expensive competitive product.

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Plant F, Germany
Kiln details: Pol SP kiln, = 5,6 x 90m, 3200 tpd ANKRAL Q2 was installed at Schwenk Karlstadt in May 2011. After 6 months of operation ANKRAL Q2 shows a very good performance equal to ANKRAL R1 and competitor AF brick, installed in direct neighborhood in the upper transition zone. Secondary fuel rate about 90 % mainly consisting of sewage and plastics. Bricks removed in October 2012, together with ANKRAL R1 and competitor AF brick. The customer reordered 10 rm.

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Plant F, Germany

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ANKRAL Q2 vs. competitor AF brick res. thickness 220mm

Plant G, Austria
Kiln details: Pol PC kiln, = 3,4 x 48m, 900 tpd (tyres 4,2/20,5/39,4) ANKRAL Q2 installed in UTZ between rm 27,4 and 29,2 results after one full campaign in UTZ (see pic). Permal 5E, installed together with Q2 and adjacent to Q2 (rm 25,4 to 27,4), showed partly only 3 cm res. thickness and strong spalling.

Permal 5E

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Thank you for your attention!

www.rhi-ag.com

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