Insulation of refractory linings

Mark Filippich
 Expect the best.

Concrete concepts – main targets

Heat insulation

preheater:
thermally graduated alkali resistance
medium weight technology
heat insulation
preheater - calciner - kiln hood - cooler
high grade (Low cement castables)
high grade + flexible (Mixcrete)
high grade + fast (MCG - LCG - JETCAST®)

nosering - cooler
lower stress/crack sensitivity
 Expect the best.

Aspects of insulation

Aspects of high temperature insulation in the cement industry

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Aspects of insulation – physical aspects

conductivity radiation

Physical aspects
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Aspects of insulation – physical aspects

Physical aspects

Ideal insulation at ~ 85% porosity

Ideal density at ~ 400

 Expect the best.

Aspects of insulation – physical aspects

Physical aspects
temperature / °C
0 100 700 800 900 1000 1100 1200 1300
100
CaSi (95 %)
90
open porosity / %

RLE 20 G minimum
80 (85 %) 0.17 0.20 0.23 W/m·K
TC
70
RLE 30 G (65 %)
60 0.25 0.30 W/m·K
50 RLE 32 G (55 %)
0.30 0.35 W/m·K
40 RLE 40 G (40 %)
0.40 0.50 W/m·K
30

thermalalkali resistance 1100 °C heat

conductivity / K2CO
radiation
3
 Expect the best.

Aspects of insulation – thermal & thermochemical aspects

Heat insulation - thermal and thermochemical resistance

temperature gradient
1200 °C

alkali attack
KAS4 / KAS6 K2SO4

embrittlement
1000 °C KAS2

sigma phase
Na2SO4

shrinkage
K2SO4·CaSO4
hot surface

800 °C
NaCl

kiln shell
600 °C
hot gas

corrosion
KCl

wet
3K2SO4·Na2SO4 corrosion
400 °C

H2SO4
200 °C
HCl
wear layer insulation
 Expect the best.

Aspects of insulation – thermal & thermochemical aspects

Heat insulation - thermal and thermochemical resistance

higher higher
process temperature share of alternative fuels

standard insulating materials (“CaSi”)

- shrinkage - alkali attack

<135 °C

1200 °C - brittleness - sulphate attack

acid
expansion joint
channel formation

- increased thermal conductivity

- metal anchor corrosion
- kiln shell corrosion
 Expect the best.

Aspects of insulation – thermal & thermochemical aspects

Heat insulation - thermal and thermochemical resistance

CaSi
700 °C 1000 °C 1100 °C 1200 °C

RLE 30 G
RLE 20 G

RLE 30 G RLE 40 G
 Expect the best.

Aspects of insulation – thermal & thermochemical aspects

Heat insulation - thermal and thermochemical resistance

 Expect the best.

Insulation options - comparison

Heat insulation and medium weight technology

insulation medium weight
0.25 0.50 1.00 1.50 2.00 g/cm³

CaSi RLE RLE RLE RLE RT

20 G 30 G 32 G 40 G 150

0.15 0.20 0.25 0.30 0.40 0.60 W/m·K

95 80 63 55 37 30 %
0.5-1 0.5 1 6 10 20 N/mm²
1000 950 1200 1150 1250 1350 °C

(the bulk density and porosity were determined at 900 or 1000 °C respectively the CCS and thermal conductivity at 600 or 700 °C)
 Expect the best.

Insulation options – technical comparison

Thermal Conductivity Calculations

30 150 mm 180 mm
350 °C 350 °C
Upper Cyclone
(T inside: 350 °C 238
118
T outside: 20 °C 72
wind speed 0 m/s) 75
RT 800 RCY 25 RLE 40 G
250 SP MCG

70 150 mm 70 150 mm 220 mm

900 °C 900 °C 900 °C
Lower cyclone
757 691 358
(T inside: 900 °C
T outside: 20 °C 110
91 106
wind speed 0 m/s)
RT 800 RCY 25 RLE RCY 25 RLE 40 G
250 SP MCG 20 G MCG
 Expect the best.

Insulation options – price comparison

Thermal Conductivity Calculations (comparison material costs EUR/m³)

30 150 mm 180 mm
350 °C 350 °C
Upper Cyclone
(T inside: 350 °C 238
93 % 118 100 %
T outside: 20 °C 72
wind speed 0 m/s) 75
RT 800 RCY 25 RLE 40 G
250 SP MCG

70 150 mm 70 150 mm 220 mm

900 °C 900 °C 900 °C
Lower cyclone
757 691
(T inside: 900 °C 85 % 81 % 358 100 %
T outside: 20 °C 110
91 106
wind speed 0 m/s)
RT 800 RCY 25 RLE RCY 25 RLE 40 G
250 SP MCG 20 G MCG
 Expect the best.

Insulation options - comparison

Heat insulation: REFRALITE® 20 G Calcium silicate board

• Installation technology dry gunning cutting and gluing

• Bulk density 0.45 g/cm³ at 900 °C 0.25 g/cm³ at 1000 °C

• Apparent porosity 80 % at 900 °C 95 % at 1000 °C
• Thermal conductivity 0.20 W/m·K at 700 °C 0.17 W/m·K at 800 °C

• Kiln shell temperature 112 °C 97 °C

(900 °C inside, 114 +100 mm
working/insulation layer)

• Time factor installation (h/t) lower, factor 1 higher, at least (!) factor 2-2.5
 Expect the best.
Installation of Calcium Silicate Board…good
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Installation of Calcium Silicate Board…not so good
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Installation of Calcium Silicate Board…not so good
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Installation REFRALITE® by gunning
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Installation REFRALITE® casted or gunned behind bricks
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Installation REFRALITE®40 and 40G as one layer lining
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Installation REFRALITE®40G as one layer lining…drastic example
 Expect the best.
Application areas REFRALITE®

All system components can be isolated with REFRALITE products

Advantage:

Installation speed up to 5x faster than CaSi

Less loss of material by cutting
Even quality of insulation
As an overall concept (material and installation) more economic