Magnesita Refractory Optimization Model™ - ximang.vnximang.vn/Upload/48/Nam_2015/AFCM2015/9....

$Page 1: Magnesita Refractory Optimization Model™ - ximang.vnximang.vn/Upload/48/Nam_2015/AFCM2015/9. Magnesita - Optimization...Magnesita Refractory Optimization Model™ Process Audit Clinker$
Magnesita Refractory Optimization Model™

Eduardo Reis – AFCM Hanoi April 15

www.ximang.vn - www.cement.vn






Process Audit

Clinker analysisFuel & Alternative Fuels, FlameCoating area and its stability areaKBC - Kiln Brick Chart….

11



What is/are the wear mechanism phenomenon ?

Is it Thermal, Mechanical, Chemical or combination among them?

Cold FaceIntermediate Face

Hot faceCoating

Hot Face 1 Hot Face 2 Inter. Face Cold Face TDS

Distance from hot face mm 180-140 140-80 80-40 40-0

Apparent Porosity % 11,4 13,5 12,8 11,8 13-16

Bulk Density g/cm3 3,03 2,97 3,00 3,01 2,96-3,06

Elasticity Gpa 15 17,5 18,5 37

X-Ray Diffraction MgO, MA, K2SO4, C12A7

MgO, MA, βC2S MgO, MA, C12A7 MgO, MA, KCl,K2SO4,

MgO, MA,

ChemicalAnalysis

MgO % 83,1 85,8 83,3 81,6 83-87

Al2O3% 12,0 12,2 12,2 12,4 10,5-14,5

Na2O % 0,0 0,0 0,0 0,0 -

K2O % 0,16 0,04 0,09 0,28 -

SO3% 0,14 0,02 0,10 0,17 -

CaO % 2,8 0,9 2,6 3,4 < 0,9

Post Mortem Analysis22



Numerical simulation and finite element analysis

Thermal Mechanical Studies33



Complete modeling for full clinkerprocess and or separate equipments

in order to have total assertiveness on the calculated amount of materials.

As well as double checking on theequipments interconnection.

ComputerAided Design

44



Inlet kilnInlet kiln

Rotary Rotary KilnKiln

Detail Detail –– Inlet Inlet

kilnkiln

Rotary Rotary KilnKiln

CONECTION CONECTION DETAILDETAILComputer

Aided Design

44



Meedon Equation:

Ec = 3 . Ws . h . Me 4 R2

Ec : Compression force (N/mm2) –Limited by Refractory CCS

Ws : Kiln Ovality (mm)h : Lining thickness (mm)R : Kiln RadiusMe : Brick Elastic modulus (N/mm2)

Ovality Analysis55



Anticipating the near future and or planning the next shutdown,mainly on the equipments not

covered by on line system.

Comparative Table

Internal Temperature 1500 °C

Max. Temp. Thermograph 303,6 °C

Diagnostic Range

Critical 1500°C – 1050°C

Serious 1049°C – 600°C

Attention 599°C – 150°C

Normal 149°C - 0°C

Equipment Condition Attention

Thermo Graphics66



From which type of raw material ?

Basic Material : Magnesia-Spinel, Magnesia-Doloma, Doloma

Non basic Material : Alumina, Andaluzite, Silicon-Carbite, Bauxite.

Tailored Product Recommendation77

Which type of physical properties? Density Bulk, Apparent PorosityCold Crushing StrengthPermeability , ElasticityHot modulus of ruptureThermal conductivity…..

Which type of chemical properties?

Refractory Physical & Chemical Properties



Installation Services88

Kiln inspection

Supervision.

In house training.

Installation techniques.(Method & Equipments)




MAGKOR DB 1


Magnesita Refractory Optimization Model™ - Magkor DB1


Magnesita Refractory Optimization Model™ - Magkor DB1

Suitable for:Severe Thermal overloadHigh abrasion areaLow liquid phase viscosity.


MAGKOR S5


Magnesita Refractory Optimization Model™ - Magkor S5


Magnesita Refractory Optimization Model™ - Magkor S5

Magkor S5

Typical Mag-spinel brick

Stre

ss (

Mp

a)

Strain (%)

Pertinent Characteristics:

Very Low permeabilityHigh mechanical resistanceHigh abrasion resistanceLow porosityHigh refractorinessHigh Chemical resistance

Highly suitable for :

High mechanical stress areasNo protective coatingg area and unstable ones.Severe alkaline and salt infiltrationLow viscosity liquid phase of clinkerHigh abrasion in the outlet and lower transition zones


BRANDS MAGKOR DB1 MAGKOR S5

Technology AZT LPT

Chemical Analysis

MgO (%) 85,5 86,5

Al2O3 (%) 11,5 12,0

Fe2O3 (%) 0,5 0,5

SiO2 (%) 0,3 0,3

CaO (%) 0,8 0,8

ZrO2 (%) 1,7 -

Physical Properties

Bulk Density (g/cm3) 3,01 3,03

Apparent Porosity (%) 15,2 14,0

CCS (MPa) 68 85

Permeability (cD) - 15

Suitable for environment conditions such as:

Extreme Thermal overload and high abrasion areas

LP technology results in low infiltration deleterious gases, high abrasion areas,

Extreme mechanical stress

Magnesita Refractory Optimization Model™ - Product Details



Calcinations U.T.Z. C.Z.B. Z. L.T.Z.



There’s no kiln refractory performance that we can’t improve.

Give us the opportunity to go through our optimization model.

You’ll see the results. We’re up to the challenge.


Eduardo Reis

Global Technical Assistance Area

[email protected]

55 (31) 3368 1768 | 55 (31) 8646 1007

Thanks


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