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No Cement Castablesa new family of sol-gel bonded castables
Cement
ICTM • R. Krischanitz • March 2011
� 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?
362 RHI AG
� 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:
� 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
363 RHI AG
� 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).
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
364 RHI AG
� 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
0100
0 50 100 150 200 250 300 350 400 450 500 550 600
temperature [°C]
Abdampfrate
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
365 RHI AG
� 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)
Poresizedistribution - 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 resize [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).
367
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
Brenner1 2
Properties, heating up
368 RHI AG
Fasermatte 3mm
Versuchsblock ANKOCAST 341
3 41 Versuchsaufbau
2 Mould and thermo elements
3 trial tundish
4 block after heating up
Thermogravimetry of a sol-bonded 130 kg block
500
600
700
70
80
90
100
Properties, heating up
369 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]
temperature [°C]
0
10
20
30
40
50
60
70
dehydration [%]
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
Temperature (°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
3611 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]
Espansion [lin%]
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
3612 RHI AG
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 12Dense fire clay,
low iron
CCS TC
3613 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 12low 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 12Dense 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
Available from Calsil, India
Product Range Sol Gel
Gunning Mixes
COMPAC SOL F53G-6 50,0 47,0 0,7 - 45 45 0,55 1570 12Dense 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
3614 RHI AG
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 12Dense fire clay,
low iron / SiC
CARSIT SOL F30G-6 38,0 31,0 0,7 30 45 45 0,55 1550 12Dense 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
CARSIT SOL M30G-6 44,0 20,0 0,7 30 65 75 0,55 1580 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
3615 RHI AG
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
References 2: Horse shoe
Horseshoe installation, Feb. 2010:
COMPAC SOL 155SIC showed excellent processing conditions at ambient temperatures around and slightly below 0°C.
3616 RHI AG
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 pre-
3617 RHI AG
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.
3618 RHI AG
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
3619 RHI AG
Mix temperature +12 °C
Setting time: 2,5 hrs
References 4: planetary cooler
Planetary cooler, intermediate
segments:
after 6 months in operationand after 1 year in operation
3620 RHI AG
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
3621 RHI AGinstallation 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
3622 RHI AGinstallation 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.
3623 RHI AGinstallation 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
3624 RHI AGinstallation 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:
36
Life time could be increased from 7 to 12
months compared to previous installations of
competitive materials.
Further steps: => Sol-prefab-concept
25
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.
3626installation 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.
Pumping and shotkasting products are under development at the moment.
References 9: gunning
3627 RHI AGinstallation after one year
CARSIT SOL F10G-6 in cooler sidewall and roof.
References 9: gunning
CARSIT SOL F10G-6
Even after 2 years lining is still in
perfect shape.
Feb. 2013
3628 RHI AGinstallation after one year
Reference 10: Cooler Roof
Customer: Portland Zement Otterbein
Material: CARSIT SOL F10G-6
Area: Cooler sidewall and roof
36
Area: Cooler sidewall and roof
CARSIT SOL F10G-6 after one year
29
Reference 10: Cooler Roof.......and after 2 years
Customer: Portland Zement Otterbein
Material: CARSIT SOL F10G-6
Area: Cooler sidewall and roof
36
Area: Cooler sidewall and roof
30
Reference 11: Burner lance
Brand: CARSIT SOL M10 – 5 V
CustomerGolden Bay Cement, Whangerai, New
Zealand
3631
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
36
burner
REFERENCE LIST
COUNTRY CUSTOMER
COMPAC SOL F53-6
COMPAC SOL B87-6
CARSIT SOL M10-6
CARSIT SOL F30-6
CARSIT SOL S30-6
CARSIT SOL F10G-6
CARSIT SOL F30G-6
CARSIT SOL M10G-6
CARSIT SOL M30G-6
BULGARIA Zlatna Panega cement, Zlatna Panega�
CZECH REPUBLIC Lafarge Cement, Cizkovice�
DENMARK AALBORG PORTLAND CEMENTFABRIK, Aalborg�
SOL bonded castables
Casting Gunning
3633 RHI AG
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�
Zement und Kalkwerk Otterbein�
REFERENCE LIST
COUNTRY CUSTOMER
COMPAC SOL F53-6
COMPAC SOL B87-6
CARSIT SOL M10-6
CARSIT SOL F30-6
CARSIT SOL S30-6
CARSIT SOL F10G-6
CARSIT SOL F30G-6
CARSIT SOL M10G-6
CARSIT SOL M30G-6
SOL bonded castables
Casting Gunning
IRELAND Irish Cement LTD, County Louth�
ITALY Colacem, Gubbio�
Colacem, Modica�
Colacem, Ragusa�
LUXEMBOURG Cimalux Rumelange� �
3634 RHI AG
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�
ZAMBIA Zambezi Portland Cement LTD, Ndola�
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
3635 RHI AG
Although the castables have not been pre-dried and where heated upwith the same heating up curve as applied to basic bricks, there wasno 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.
Thank you for your attention!
3636 RHI AG
www.rhi-ag.com