No Cement Castables

a new family of sol-gel bonded castables

Cement

ICTM R. Krischanitz March 2011

What are Sol-Gel bonded castables?

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 and its complex system of (hydrated) calcium-aluminate-phases. The binder is delivered separately from the mix.
This offers a variety of advantages:

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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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Difference cement-/ sol-gel bonded castables

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 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 + 5C ! 4 36 RHI AG
Abdampfrate
TGA - Abdampfrate / 1K/min / Ankocast SV90, Ankocast 341 + zementhltige Varianten

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

Ankocast SV90 Ankocast 341 (0% Zement)

temperature [C]

Characteristics, pore structure

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 relative higher pore volume at low temperatures P oresizedistribution - Sol bonded vs cement bonded castable - easy heating up
70

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

0 0,001 0,01 0,1 1 10 100 1000

P o] m re s ize [

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). 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 (>200C) temperatures. Safe and very fast heat up that can be finished completely even below 200C!
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Properties, heating up
Thermoelemente Steinschalung

Brenner

Abzug

Brenner

Versuchsblock ANKOCAST 341

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

Increased RuL due to sol-gel-bonding

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

Cement T0: 1403C T0,5: 1464C T1: 1482C T2: 1506C

Sol-Gel T0: 1501C T0,5: 1549C T1: 1565C T2: 1588C

Temperature [C]

-4

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Alkali Resistance Sol Gel Mixes

Crucible test with DIDURIT 160 after 3 cycles (a) and COMPAC SOL 160 after 7 cycles (b).

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Product Range Sol Gel

Grade Al2O3 SiO2 Fe2O3 SiC CCS
110C % % % % N/mm2 1000C N/mm2

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

Product Range Sol Gel

Grade Al2O3 SiO2 Fe2O3 SiC CCS
110C % % % % N/mm2 1000C N/mm2

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

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

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.

COMPAC SOL 155SIC

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References 2: Horse shoe

Horseshoe installation, Feb. 2010: COMPAC SOL 155SIC showed excellent processing conditions at ambient temperatures around and slightly below 0C. As the castable was stored correctly it was possible to keep the temperature of the mix at about 10C. 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.
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References 2: horse Shoe

Horseshoe installation, after one year in operation: The area has not been predried and also not heated up with auxiliary burners.

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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. The ambient temperature was about +5C. Dry materials and binder were both around +10C. 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.
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References 4: planetary cooler

Planetary cooler, intermediate segments: Ambient temperature Mix temperature Setting time:
2,5 hrs

+5C +12 C

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References 4: planetary cooler

Planetary cooler, intermediate segments: and after after 6 months 1 year in in operation operation

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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

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after one year

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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after one year

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. 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.

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after one year

References 7: nose ring

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

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Reference 8: Clinker Bed

Customer: Product: Performance: NORCEM Brevik Heidelberg grp. CARSIT SOL M10-6

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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after one year

References 9: gunning

CARSIT SOL F10G-6 in cooler sidewall and roof.

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after one year

References 9: gunning
Feb. 2013
CARSIT SOL F10G-6 Even after 2 years lining is still in perfect shape.

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after one year

Reference 10: Cooler Roof

Customer: Material: Area: Portland Zement Otterbein CARSIT SOL F10G-6 Cooler sidewall and roof

CARSIT SOL F10G-6 after one year

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Reference 10: Cooler Roof.......and after 2 years

Customer: Material: Area: Portland Zement Otterbein CARSIT SOL F10G-6 Cooler sidewall and roof

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Reference 11: Burner lance

Brand: CARSIT SOL M10 5 V Golden Bay Cement, Whangerai, New Zealand Burner lance (tip) 7 months + high alumina castable 4 months

Customer Unit Service life Previous castable Previous service live

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Reference 11: Burner lance

CARSIT SOL M10 - 5 V Burner lance was removed from service only due to the degradation of the castable further along the burner

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REFERENCE LIST
SOL bonded castables
CARSIT SOL M10G-6 CARSIT SOL M30G-6

CARSIT SOL F10G-6

COMPAC SOL B87-6

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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CARSIT SOL F30G-6

COMPAC SOL F53-6

CARSIT SOL M10-6

CARSIT SOL F30-6

CARSIT SOL S30-6

Gunning

REFERENCE LIST
SOL bonded castables
CARSIT SOL M10G-6 CARSIT SOL M30G-6

CARSIT SOL F10G-6

COMPAC SOL B87-6

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

NAMIBIA NORWAY SLOVAKIA SPAIN TURKEY

UGANDA UNITED KINGDOM

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ZAMBIA

CARSIT SOL F30G-6

COMPAC SOL F53-6

CARSIT SOL M10-6

CARSIT SOL F30-6

CARSIT SOL S30-6

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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Thank you for your attention!

www.rhi-ag.com

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