refracta presentation (refractory)

$: Refracta Presentation (Refractory)$
Refractory Solutions for Critical Areas in Cement Kilns

Refractarios Especiales, S.A.P.I. Poyo de Reva – C/ Poniente, 6 – 1A bajo46190 Ribarroja del Turia (Valencia), Spain

[email protected]

“In the name of Allah, the Beneficent, the Merciful”

Content:

I. Introduction

III. Applications

IV. Advantages & Savings

V. Experience

II. Products

1940: Foundation of Refractarios Especiales, S.A. - Refracta

Company:

1997: New generation of qualities obtained

1993: Focus on cement industry R&D on special qualities

2006: Company moves to a new plant

2005: Refracta stops making traditional refractories,

to produce only special qualities

I. Introduction:

• Superior raw material, special manufacturing process

• Ta > 1600 ºC

• Low Porosity 12-14 %

• Excellent Chemical Attack Resistance

• Extremely Abrasion resistant

• High Crushing strength

•Thermal Shock resistance

1. Bricks: R-2000

II. Products:

• AF Ready

2. Castable: PF-97-H

• Ultra Low Cement Castable

II. Products:

• Superior performance, does not crack

• Ta > 1600 ºC

• High Degree of Chemical Attack Resistance

• Extremely Abrasion resistant

• AF Ready

Advantages:

II. Products:

• Very long service life (2-3x more)

• Alkali, chemical attack protection

• Spalling protection

• Shell corrosion protection: less thickness loss and maintainence

• Nose ring protection (longer service life of mechanical parts)

• Solution for Rings, build ups and snowman

Alkali attack with a standard alumina brick

Result of:

chemical reaction between brick and

alkalis

Consequences:

• formation of cracks within the brick

and destruction lower lifetime

• kiln shell corrosion: infiltration of the alkalis penetrates

to the kiln shell

reacting with H2O to corrosive acids

II. Products:

• Uneven (spalled) Surface leading toring formation

Alkali attack with magnesia spinel bricks

Result:infiltration of alkalis through the brick.

Consequences:• cristalisation of salts (up to 30 % more

volume!) Cracks on refractory

• kiln shell corrosion: infiltration of the alka-

lis goes to the kiln shell and reacts with

H2O to create corrosive acids

II. Products:

Alkali attack with R2000

Result:No infiltration of alkalis, no cracks

No chemical reaction

Consequences:

- much longer lifetime

- better protection of the kiln shell

against corrosion

- quick transport of material through

the kiln (better process control)

II. Products:

UTZ up to kiln inlet

Advantages: No Rings, No Buildups, No Spalling, Long Service Life

II. Products:

no rings or build ups

II. Products:

• No Coating

• R2000 forms a glassy layer reducing

porosity and protecting from

infiltration

Advantages:

•No Rings

•No Buildups

•No Spalling

•Long Service Life

II. Products:

No Rings, No Buildups, No Spalling, Long Service Life

Alkali attack with PF-97-H

Tests realized under reducing conditions at CSIRO

labs, Australia. Result after 96 h.

Result:No infiltration of alkalis

No chemical reaction

Consequences:

- longer lifetime

- minimized sticky substance formation

II. Products:

II. Products: Castable performance:

Holcim Lorca Bullnose - 1 yr result. No cracksPF97H on bottom, competitor on top

II. Products:

Advantages: Smooth Surface, No Infiltration, No Spalling, Long Service Life

III. Applications

• Tertiary air duct / Damper area

• Nose ring• Outlet zone, retaining ring• UTZ up to kiln inlet• Grate and planetary cooler• Inlet chamber• Tertiary air duct/damper

area

R2000 PF97H

• Nose ring• Riser / Calciner• Cyclone roofs• Inlet chamber / Cone• Cooler / Bullnose

• Burner (except tip)

III A. Cement Kiln - Grate Cooler:

4. Other Areas: R-2000 and/or PF97-H

1. Outlet Zone : R-2000 and/or PF-97-H

2. UTZ up to kiln inlet: R-2000

3. Cooler: R-2000 and/or PF-97-H

1a. Nosering in PF-97H/R-2000:

Extremely good resistance against axial thrust from the other refractories

caused by thermal expansion and gravity thrust of bricks

Cemex Pertigalete (Venezuela) 1,5 years later

1b. Nosering in PF-97-H / R2000

Holcim Prahovice

1c. Typical Outlet Profiles

1. Typical


2. With Cone


3. All Bricks


4. ‘FLS’ Type

1d. Outlet Zone Samples in PF-97-H / R-2000

Italcementi Rezzato

1d. Nosering / Outlet Zone, plant trial

1d. Nosering / Outlet Zone - FLS type

BCSC (Blue Circle Southern Cement) - Sydney / 5.2 m kiln

1d. Holcim Lorca Outlet Zone Installed Jul’00

1d. Holcim Lorca Outlet Zone 1 yr result

1d. Lafarge Villaluenga Installed Jan ‘01

1d. Lafarge Villaluenga 9 mo. results

1d. Lafarge Villaluenga 1.5 yr results

1d. Cementir Spoletto Install

1d. Cementir Spoletto 1 yr result

1e. Lehigh Mason City, USA (Heidelberg)

kiln with grate cooler: R-2000 from 30-35 m - inlet

kiln with satelite cooler: R-2000 from 45-50 m - inlet

OZ LTZ BZ UTZ SZ CZ

0 30-35 m / 98´-115´

0 45-50 m

R2000 areas with chemical attack and kiln shell corrosion

2. UTZ up to kiln inlet


Holcim Orizaba Aug. 2003: position 42,6 - 47,8 mts (5,2 mts)


Holcim Orizaba Aug. 2003: position 47,8 - 52,8 mts (5 mts)


Holcim Orizabal 12 months later

Holcim Orizabal 4 years and 3 months later


K1 11/02/2003

Ring 1 Ring 2

2 Rings in area 40-50 m 4.6m dia, 4800tpd, nsp, 3.3 rpm.

K1 08/05/2003

Ring 2

R-2000 in area of Ring 1 only > 3 months

Kiln 1 14/11/2003 R-2000 in area of Ring 1 + 2 > 9months

Kiln 1 08/06/2007 > 4 years and 4 months later

Holcim Mason City Install


Holcim Mason City 1 yr results and extension


Holcim Mason City 1 yr results and extension, no height loss


Holcim Mason City 2 yr results and extension, no height loss


3. Grate cooler

Lining with R2000 in combination with castable PF97H:

• no cut bricks. Fill in with castables

• anchored bricks to wall

• no build ups or snowmen

• longer lifetime

Italcementi Vivo Valentia castable rebuild

Lafarge Villaluenga IKN Castable / Bricks Rebuild

Lafarge Villaluenga IKN Rebuild

Holcim Apasco Centro rebuild

IIIB. Cement kiln with planetary coolers:

3. Satellites:

1. Outlets/discharge ports:

2. Cooling zone:

5. UTZ up to kiln inlet:

4. Elbows:

R-2000

R-2000 and PF-97-H

R-2000

R-2000

R-2000 and PF-97-H

Outlets/discharge ports in R-2000 & PF-97-H

Planetary Cooling zone

Planetary Coolers

Anneliese Ennigerloh

Planetary Coolers

Anneliese Ennigerloh : 3 years later. TOTAL 5 YEARS

4. Other Areas

Lafarge Langkawi Inlet Cone Inlet Cone 1 yr results

4. Other Areas

Cemex Hidalgo Inlet Slide Cemex Monterrey Cooler Roof

4. Other areas: Riser / Duct

• Real Infiltration resistance, chemical attack protection• Very high abrasion and impact resistance • Encapsulation installation: insulation and anchor protection• Long service life in excellent conditions• Easier Cleaning

4. Other Areas

Italcimenti Hood

4. Other Areas

BCSC Sydney Kiln Door BCSC Sydney Kiln Door Frame

IV. Plant savings and advantages:

• Capacity optimisation

• Lower refractory cost per ton of clinker

• Less risk of kiln stops due to refractory failures

• Higher productivity / less & shorter outages

• Savings on shutdown costs

• Savings on shell replacements

• Better process control due to ring elimination• Savings on more petcoke replacing coal

• Environmental benefit: less waste and handling

V. Experience: Materials in 52 countries:

ArgentinaAustraliaAustriaBelgiumBeninCanadaCheck RepublicChinaCroatiaDominican RepublicDubaiEcuadorEgyptFranceGermanyGreeceIndiaIreland

Italy KoreaLatviaLebanonLuxembourgMalaysiaMexicoMoroccoMozambiqueNew ZealandNigeria NorwayPanamaPeruPhillippinesPolenPortugal

RumaniaSerbiaSlovakiaSouthafricaSpainSri LankaSwitzerland TanzaniaTunisiaTurkeyU.A.E.U.K.U.S.AVenezuelaVietnamZambiaZimbabwe

refracta presentation (refractory)

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