Technically and economically-developed monolithic

refractory concrete concepts for the cement industry

Kai Beimdiek
Presented by Dirk Basten
Technico-economic refractory concrete concepts
for the cement industry
Topics

Technico-economic refractory concrete concepts for the cement industry

• Part 1: Introduction, workability and installation

• Part 2: Product philosophy for the application in the preheater and calciner

• Part 3: Product philosophy for the application in the kiln hood and cooler
Topics

Technico-economic refractory concrete concepts for the cement industry

• Part 1: Introduction, workability and installation

• Classification
• Storage - workability properties - dry out/heating-up
• Installation technologies vibration vs. dry and wet gunning
• Cold repair technology (veneering)
Classification refractory products:
raw material - bonding system - installation technology
refractory products

magnesia corundum bauxite mullite andalusite fireclay silica zirconia SiC light weight

final semi final

brick external - cement plant - monolithic
product product
internal process temperature - gradient
ceramic hydraulic chemical
regular cement medium cement low cement ultra low cement no cement
burned
>2.5 % CaO >2.5 % CaO ≤2.5 - 1.0 % CaO ≤2.5 - 0.2 % CaO < 0.2 % CaO
tempered
special
internal pre-cast deflocculated
additives
(mortar) castable gunning

brickwork vibration self-cast wet gunning dry gunning

dense or insulation layer // single or double layer

Classification refractory products –
raw materials

Highest thermal resistance:

•andalusite, corundum
REFRAMULLITE 63 …, REFRACORUND 95 …
Highest mechanical resistance:
•mullite, bauxite, corundum
REFRAMULLITE 60 …, REFRABAUXITE 75 …
REFRABAUXITE 85 …, REFRACORUND 95 …
Highest alkali resistance:
• quartz, acid fireclay, fireclay, SiC/zircon
REFRACLAY 25 …, REFRAZIRKON …,
REFRA-SiC…, or products with abbr. AR or Z AR
Classification refractory products –
bonding system
Parameter RCC - fireclay concrete LCC - fireclay concrete
CaO content (%) 7.5-13 1.1-2.4
Water addition (%) 10-12 6-7
Bulk density (g/cm³) 2.05 2.25
Apparent porosity (%) 20-22 14-15
CCS (N/mm²) 35-45 90-110
Abrasion loss (cm³) 19-20 5-7
Application temperature (oC) 1320 1500
Alkali resistance
Workability properties – storage

influence:
- higher water demand
- longer mixing time
- retarded setting process
- lower green strength
suboptimal delivery
optimal date 6 months 1st year 2nd year
influence: influence:
- setting time <10 oC - slightly higher water demand
- retarded setting time <20 oC
- lower green strength
Workability properties – storage

New paper bag technology [25 kg]

Features:
• no perforation
• only one air outlet valve
• filling hole closed by ultrasonic gluing

Extended shelf life: 12 - 18 months

 higher product quality

 higher transport and storage flexibility
Workability properties – mixing process

suboptimal
optimum
- recommended capacity: 100 kg batch
- easy dosage with a water tank: up to 18 litre
- 3 mixing blades for intensive mixing process
Workability properties – water addition

too dry consistency optimum consistency too wet consistency

Workability properties – installation equipment –
performance

optimum equipment insufficient equipment

and densification and densification
Workability properties –
lower and higher ambient temperature

1000
Setting time [min]

100

Low working temperatures: Higher working temperatures:

10 1. preheat bags (in heated rooms) 1. cool bags (shadow)
2. add hot water (max. 50 oC) 2. add cool water/ice
3. preheat air (radial burner) 3. quick processing
4. add accelerators 4. add retarder
1
0 5 10 15 20 25 30 35
Working temperature [oC]
Recommendation for dry out and heating-up

cement-containing
Installation technologies

high grade, fast and flexible

Different installation technologies

Vibration Dry gunning REFRA JETCRETE® (Wet gunning)

≤1 t/h ≤3 t/h ≤10 t/h

Dry gunning – setup of the equipment

- separate air compressor 

high water
- compressed air pipe-network X
pressure pump
(60 - 90 bar)
6-8 bar and 8-12 m³/min
G, MCG RLE: 0.5-1.5 (3.5) bar
- sufficient power
LCG or EDG G/MCG: 2.0-3.5 bar
- enough standby - reduced water content LCG: 2.0-4.5 bar
- homogeneous water EDG: 3.0-4.5 bar
injection to the core
- without dust development
- with reduced rebound
upper
- homogeneous microstructure
lower

20-100 m - increased reaction time,

- continuous flow, homogeneous mixing
without interruptions
Dry gunning – one standard setup

Insulation / high cement Medium cement Low cement (dense gunning) No cement (dense gunning)

REFRALITE® 20 G REFRACLAY 25 MCG REFRAZIRCON LCG Z AR REFRAMULLITE 60 EDG Z AR

REFRALITE® 30 G REFRACLAY 40 MCG AR REFRACLAY 40 LCG
REFRALITE® 32 G REFRACLAY 50 MCG REFRACLAY 40 LCG Z AR
REFRALITE® 40 G REFRAMULLITE 63 MCG AR REFRAMULLITE 60 LCG
REFRACLAY 40 G REFRA-SiC 50 MCG AR REFRAMULLITE 60 LCG Z AR
REFRACLAY 50 G REFRA-SiC MCG AR REFRAMULLITE 63 LCG
REFRABAUXITE 80 LCG

+ +
Dry gunning – trend of development

Properties G MCG LCG EDG JC LCC

dry gunning wet vibration

gunning

Water addition high reduced low low 6.0-9.0 4.0-7.5

Rebound loss (%) 15-20 10-15 5-10 5-10 ≤5 no
Dust development high no no no no no
Heat-up/adherence slow / … slow / … fast / ++ fast / +++ slow / ++ slow / …
Porosity (%) 30-35 22-28 18-25 20-25 15-22 12-20
CCS (MPa) 15-25 40-60 50-90 40-60 60-110 70-200
Application temp. (max.) ≤1400 1400-1500 1450-1600 1500 1500-1650 1500-1750

Alkali resistance
(1100 oC / K2CO3)
Practical experience in the cement industry –
REFRAMULLITE 60 LCG Z AR
Area: cooler shaft, side wall Area: cooler shaft,
Capacity: 2000 t/d side wall

after 8 months after 5 months

Dry gunning technology –
application recommendation (G - MCG - LCG - EDG)

REFRACLAY 25 MCG
REFRALITE® 32 G

REFRACLAY 40 LCG
REFRACLAY 40 LCG
REFRACLAY 25 MCG REFRACLAY 40 LCG Z AR
REFRALITE® 40 G
REFRAMULLITE 60 LCG
REFRAMULLITE 60 LCG Z AR REFRABAUXITE 80 LCG
REFRAMULLITE 60 EDG Z AR
REFRAZIRKON LCG Z AR
REFRAZIRKON LCG Z AR REFRAMULLITE 60 LCG Z AR
REFRA-SiC 50 MCG AR REFRAMULLITE 60 EDG Z AR
REFRAMULLITE 60 EDG Z AR

REFRACLAY 40 LCG
REFRACLAY 25 MCG
Application of the cold repair technology (veneering)

Relining on worn surface:

• mainly in static areas

• safe gunning and setting

• very good adherence
• fast heating-up
• optimum performance

• focus EDG / ED JC
• focus LCG
Practical aspects for the cold repair technology (veneering)

• Type of bonding (optimum adherence, strength of the compound layer)

• Alumina on alumina or basic on basic
• Thickness (≥30 mm and ≤120 mm)
• Self-supporting or additional anchors (stud welding, pins or special anchor shape)?
• Expansion or working joints necessary?
• Necessary preparatory activities?
 surface cleaning and preparation by air, sandblasting, pre-wetting or extra adhesive layer
• Maintenance
 concept with permanent lining, time calculation, shutdown frequency, endless lining
Characteristics of REFRAMULLITE 60 EDG Z AR

• No cement technology - chemical bonding

• All-rounder properties for different application areas (balanced properties)

• Very good adherence and bonding strength, also on worn surfaces
• Safe gunning and setting behavior, also at temperatures below 5 °C
• Fast dry out and heating-up
Alkali resistance
• Good mechanical properties (1100 °C, K2CO3)

• Good refractoriness
• Very good alkali resistance
Practical experience
with the cold repair technology (veneering)
RME 60 EDG Z AR Contact/interface area Example: RBE 85 ED JC AR

new old
lining lining
1000 °C
7.5 MPa
old JC
surface new EDG
surface (03.17 - 02.18)

Installation without Form and forced closure, Cooler curbs (≤10 cm), with
additional anchors measured by the MOR lengthening of the anchors
Practical experience
with the cold repair technology (veneering)
RME 60 EDG Z AR RME 60 EDG Z AR RME 60 EDG Z AR

Installation with Installation with and without Installation without

additional anchors additional anchors additional anchors
Application recommendations
of the cold repair technology (veneering)
 REFRAMULLITE 60 EDG Z AR  Calciner
 REFRAMULLITE 60 LCG Z AR  Riser duct
 Inlet chamber
 Cold repair “veneering” only with a  Inlet cone
alumina based refractory concrete
on a worn alumina brick or
concrete surface

 Kiln hood
 Safety zone  Bullnose
 Cooler
Topics

Technico-economic refractory concrete concepts for the cement industry

• Part 2: Product philosophy for the application in the preheater and calciner

• Insulation – medium weight technology (single layer construction with

RLE 32 G, RLE 40 G, RME 25 MCG)
• Thermally graduated alkali resistance (SiO2 / SiC / SiC + ZrO2)
• Reduced coating (RZN Z AR / RZN LCG Z AR)
Heat insulation and medium weight technology

preheater:
- medium weight technology
- heat insulation
Heat insulation and medium weight technology

insulation medium weight dense

0.25 0.50 1.00 1.50 1.85 2.00 2.25 g/cm³

CaSi RLE RLE RLE RCY RCY RCY

20 G 32 G 40 G 25 MCG 25 40 LCC

0.15 0.19 0.3 0.4 1.0 1.1 1.7 W/m·K

95 80 55 35 27 22 17 %
1 0.5 3-6 15 20 45 80 N/mm²
1000 950 1150 1250 1200 1200 1500 °C

destroyed good good good very good good

Engineering aspects – medium weight technology

30 150 mm
Upper cyclone 350 oC
180 mm
350 oC
180 mm
350 oC
180 mm
350 oC
o
T inside 350 C 238
T outside 20 oC 111 119 146
64 73 107
Wind speed 0 m/s 75
RT 800 RCY 25 RLE 32 G RLE 40 G RCY 25 MCG
250 SP MCG

70 150 mm 220 mm 220 mm 220 mm

Lower cyclone 900 oC 900 oC 900 oC 900 oC
T inside 900 oC 757 358 371 426
T outside 20 oC 104 122 183
wind speed 0 m/s 91
RT 800 RCY 25 RLE 32 G RLE 40 G RCY 25 MCG
250 SP MCG
Practical experience in the cement industry –
REFRALITE® 32 G
Area: top cyclone
Installation: dry gunning
Engineering: single layer / 80 mm

after 12 months in use

Practical experience in the cement industry –
REFRALITE® 32 G
Area: top cyclone
Installation: dry gunning
Engineering: single layer / 96 - 110 mm

after 24 months in use

Practical experience in the cement industry –
REFRACLAY 25
Area: lowest cyclone C6, d 5.20 m
Installation: vibration
Engineering: single layer / 114 - 250 mm

Calculation:
- T inside/outside 900/20 oC
- wind speed 0 m/s
- shell temperature 180 oC

Practice:
shell temperature 150-185 oC

after 24 months in use

Practical experience in the cement industry –
REFRACLAY 25 MCG
Area: lowest cyclone
Installation: dry gunning
Engineering: single layer

after 12 months in use

Thermally graduated alkali resistance

preheater:
thermally graduated alkali resistance
Alkali-sulphate-chloride circle in a cement plant

3K2SO4·Na2SO4
K2SO4·CaSO4
secondary burner
Na2SO4
for pre-calcination high alumina, high cement-containing
NaCl concrete, apparent porosity >20 %
KCl

alkalis
main burner
alkali circle
for clinker burning process
sulphate circle
chloride circle
Thermally graduated alkali resistance
Thermally graduated alkali resistance (600-1100 oC)
REFRACLAY 25 (MCG) (JC)
REFRACLAY 25 MCG • very low Al2O3/SiO2-ratio (SiO2-surplus)
Raw material basis fireclay • in theory only formation of SiO2-rich feldspar
(e.g. sanidine K2O∙Al2O3∙6SiO2 (∆volume: 0.1 %)
Al2O3 25-29 % • no volume increase
SiO2 59-63 % • no destroyed microstructure

Max. application temperature 1200 oC

no
o
Properties at 1000 C volume
increase
- Bulk density 1.85 g/cm³
- Cold crushing strength 20 MPa
- Thermal expansion 0.50 %
- Permanent linear change -0.5 % cup test (1100 oC/K2CO3)
Thermally graduated alkali resistance (900-1300 oC)
AR-products (alkali resistant)
unprotected
Product philosophy SiC-containing
SiC 5-72 %

Excellent thermochemical resistance

- SiC + 2O2 = SiO2 + CO2
- SiO2-surplus ≥900 oC
- silicatic protective layer leucite/kalsilite
- lower Al2O3/SiO2-ratio
- no volume increase no
- no destruction of microstructure volume
increase
Permanent linear change (higher SiC contents)
1200 oC typical -0.1 up to +0.5 %
1400 oC typical +0.6 up to +2.5 % cup test (1100 oC/K2CO3)
Thermally graduated alkali resistance (900-1500 oC)
REFRACLAY 40 Z AR
Product philosophy SiC + zircon • High thermal resistance
- lower SiC content/unproblematic SiC oxidation
SiC 9-13 % - thermal stabilisation by ZrO2 compounds
ZrO2 3-7 % • Excellent thermochemical resistance
- SiO2-surplus 900-1300 oC (protective layer)
Max. application temperature 1500 oC SiC + 2O2 = SiO2 + CO2
Cold crushing strength [1000 oC] 100 MPa 1200-1550 oC
ZrSiO4 = ZrO2 + SiO2
Thermal expansion [1000 oC] 0.60 %
no
Permanent linear change volume
1200 oC -0.30 % increase
1400 oC -0.20 %
1500 oC 0.5 %
cup test (1300 oC/K2CO3, K2SO4,KCl, CaSO4)
Thermally graduated alkali resistance (900-1500 oC)
REFRZIRCON Z AR
Product philosophy SiC + ZrO2 Excellent thermochemical/-mechanical resistance
• Silicatic protective layer
SiC 7-11 % • Lower Al2O3/SiO2 ratio (SiO2-surplus)
ZrO2 16-20 % • Excellent chemical resistance of ZrO2-component
• Reduced coating formation
Max. application temperature 1550 oC • High mechanical and abrasive resistance
Cold crushing strength [1000 oC] 100 MPa
Abrasion resistance [1000 oC] 5-6 cm³
no
Thermal expansion [1000 oC] 0.60 % volume
increase
Permanent linear change
1200 oC 0.00 %
1400 oC 0.20 %
cup test (1100 oC/K2CO3)
Practical experience in the cement industry –
REFRAZIRCON Z AR
Area: inlet chamber
Installation: vibration
Performance: without coating formation and alkali attack

after installation after 6 months in use

Alkali resistant AR- and Z AR-technology

SiC zircon
12.5 12.5

Alkali cup test

1100 oC/K2CO3
25 25

SiC + zircon
50
R-SiC 50 AR

RCY 40 Z AR

Z AR-technology RZN Z AR
Thermally graduated alkali resistance –
application recommendation (RLE – SiO2 – AR – Z AR)
REFRALITE® 32 G (as single layer)
REFRACLAY 25 / MCG (also as single layer)

REFRACLAY 25 / 25 ED

REFRALITE® 40 G (as single layer) REFRACLAY 25 / (MCG) / (JC) / (ED JC)

REFRACLAY 25 / MCG / JC / ED JC (also single layer) REFRACLAY 40 LCC / (LCG)
REFRACLAY 40 LCC / LCG / JC REFRACLAY 40 Z AR / (LCG Z AR)

REFRACLAY 40 Z AR / (LCG Z AR)

REFRACLAY 40 Z AR / LCG Z AR REFRACLAY 40 JC Z AR / (40 ED JC Z AR)
REFRAMULLITE 60 LCG Z AR / (60 EDG Z AR)
REFRAZIRKON Z AR / (LCG Z AR)
REFRACLAY 40 JC Z AR / ED JC Z AR
REFRAZIRKON Z AR / LCG Z AR
REFRA-SiC 50 AR / 50 MCG AR
Topics

Technico-economic refractory concrete concepts for the cement industry

• Part 3: Product philosophy for the application in the kiln hood and cooler

• Lower stress/cracking sensitivity

• Adjusted thermomechanical properties (AR / Mixcrete / ED)
• Adjusted thermal/thermochemical properties
(basic concretes for the static areas).
Stress reducing concepts from
kiln outlet to the wear benches

Nose ring - cooler:

- fast heating-up and dry-out
- lower stress/crack sensitivity
- excellent thermal shock resistance
- very good thermochemical resistance
SiC-free SiC-containing No cement Basic concretes

Load: Load: Load: Load:

thermomechanical thermomechanical dry-out + thermochemical +
+ thermochemical structural tension thermal overload

RCD 95 LCC AR/ZAR-technology ED-technology REFRA-MgO …

refractoriness conductivity hydrate water refractoriness

thermal expansion temp. gradient gas permeability melting phase
property gradient vapour pressure alkali resistance
hot strength
ratio CCS / E
structural elasticity (cold crushing strength / elastic modulus)
AR / Z AR-technology

SiC-containing

• higher thermal conductivity (SiC)

• lower temperature gradient
• lower difference in properties
• lower microstructural tensions without cracks
• lower cracking sensitivity
• very good alkali resistance

with cracks
AR- and Z AR-Mixcrete concept

AR-Mixcrete Z AR-Mixcrete
RBE 85 LCC 3:1 / 2:1 / 1:1 RBE 85 LCC 1:1
RBE 75 LCC 3:1 / 2:1 / 1:1 RBE 75 LCC 1:1
RME 63 LCC 3:1 / 2:1 / 1:1 R-SiC 50 AR RME 63 LCC 1:1 RZN Z AR
RME 60 LCC 3:1 / 2:1 / 1:1 RME 60 LCC 1:1
RCY 40 LCC 3:1 / 2:1 / 1:1 RCY 40 LCC 1:1

higher thermal conductivity higher quotient of CCS/E-modulus

lower temperature gradient higher thermomechanical resistance
higher alkali resistance higher thermochemical resistance

like REFRACLAY 40 LCC AR like REFRACLAY 40 Z AR (9 % SiC / 5 % ZrO2)

or REFRABAUXITE 85 LCC AR
AR- and Z AR-Mixcrete concept

• modular/flexible installation AR-Mixcrete:

• flexible use of standard products product combination ratio Al 2O3 SiO2 Si C
• graduated SiC contents/concepts [wt.-%] [wt.-%] [wt .-%]
• zonally adapted product properties REFRACLAY 40 LCC + 3 1 38 45 12
REFRA-SiC 50 AR 2 1 36 43 17
1 1 32 39 25
• standardised product range REFRAMULLITE 60 LCC + 3 1 44 36 16
• smaller number of products REFRA-SiC 50 AR 2 1 42 35 20
• simplified storage 1 1 36 33 27
• minimised storage times REFRAMULLITE 63 LCC + 3 1 48 36 13
REFRA-SiC 50 AR 2 1 45 35 17
• reduced warehousing costs 1 1 39 33 25
REFRABAUXITE 75 LCC + 3 1 52 27 16
• mixing bag by bag REFRA-SiC 50 AR 2 1 48 27 20
• easy application 1 1 41 27 27
REFRABAUXITE 85 LCC + 3 1 61 17 16
• mixing batches: 3:1 / 1:1 = 100 kg REFRA-SiC 50 AR 2 1 56 18 20
2:1 = 75 / 150 kg 1 1 47 20 27
Mixing of REFRABAUXITE 85 LCC + REFRA-SiC 50 AR

after 5 months
RBE 85 LCC

ratio 3:1 ratio 2:1 ratio 1:1

R-SiC 50 AR
Practical experience in the cement industry –
Mixcrete
Area: wear benches
Installation: Mixcrete - vibration
Performance: without significant cracking

after 6 months, after 4 months,

>12 months in use >12 months in use
Steam explosions causing damages to
cement-containing refractory concrete linings
 Recommended drying of cement-containing
refractory concretes
700 3rd phase
1st phase 2nd phase
600 temperature-dependent
500 °C water vapour pressure
temperature / °C

500 in closed pores

400 210
370 °C
bar

300 300 °C 85.8

bar
15.5 CAC: Calcium Aluminate
200 °C
200 bar Cement containing refractory
150 °C 4.8
bar
concretes
100 0.02
20 °C bar
0
min. 24 hrs
-24 0 24 48 72
setting time time after setting/hrs
Comparison of physically and chemically bonded water
amounts in dependency of the cement content

chemically bonded
(150-1000 °C)

physically bonded,
evaporation (20 °C),
drying (100-150 °C)
Easy Dry – faster drying

• no cement technology

• alkali-activated binding phase

• less hydrate water

• higher permeability

• lower water vapour pressure

Optimised microstructure of Easy Dry
refractory concretes for faster and safe drying
specially adapted microstructure binding phase technology

permeability pore size distribution proportion of chemically bonded

[.10-13 / nPm] [ratio %] hydrate water [LECO intensity]

large amount
of hydrate water
low amount of
hydrate water
Comparison of binding phase technologies
during setting, drying and heating-up

chemically bonded
(150-1000 °C)
drying and firing losses
[%] / CCS [MPa]

physically bonded,
drying (100-150 °C)

CCS: cold crushing strength

LC ED Sol-Gel
(low cement content) (no cement content) (no cement content)
 Recommended drying of no cement
(ED) refractory concretes
temperature / °C

ED (≤ 200 mm)

ED (> 200 mm)

CAC

time after setting/hrs

Comparison of cement-free geopolymer and
low cement hydraulic bonding technologies
cold crushing strength (CCS) elastic modulus (E) ratio CCS/E (flexibility)

higher quotient,
lower cracking sensitivity

high microstructural strengths

higher microstructural elasticity

cement-free cement-free cement-free

(ED: Easy Dry) (ED: Easy Dry) (ED: Easy Dry)
Practical experience in the cement industry –
REFRABAUXITE 85 ED JC AR
Area: nose-ring (left), inlet chute (right)
Installation: wet gunning (REFRA JETCRETE®)
Performance: without significant tensions and cracking

lining after 7 months, lining after 6 months,

lifetime > 12 months lifetime > 12 months
Practical experience in the cement industry –
REFRABAUXITE 85 ED AR
Area: nose-ring
Installation: vibration
Performance: without significant tensions and cracking

lining after 7 months,

lifetime > 12 months
Easy Dry –
faster drying and stress reduced performance

• no cement technology

• easy installation

• faster drying

• higher structural elasticity

• tailor-made for the cement industry

Practical experience in the cement industry –
alumosilica containing refractory concretes
Area: kiln hood, bullnose, cooler
Performance: after 8-12 months thermochemically overloaded
Characterisation of basic refractory concretes

REFRA-MgO 88 M (static areas)

Raw material basis magnesia • reduced spinel content
• higher alkali/thermochemical
MgO 86-90 % resistance
Al2O3 2- 6 % • no volume increase
SiO2 5- 9 % • no destroyed microstructure

Max. application temperature 1650 oC

Properties at 1000 oC
- Bulk density 2.80 g/cm³
- Cold crushing strength 50 MPa
- Thermal expansion 1.20 %
- Permanent linear change +0.20 % cup test (1340 oC/K2CO3)
Practical experience in the cement industry –
REFRA-MgO 88 M
Area: bullnose and kiln hood
Installation: vibration (at 5 °C)
Performance: without melting phase formation

lining after 4 months,

current lifetime >12 months
Basic refractory concretes –
application recommendation (REFRA-MgO ...)

REFRA-MgO 88 M:
-calciner
-riser duct
-inlet chamber
-bypass REFRA-MgO 88 M / REFRA-MgO 85 M:
- kiln hood
(calculated shell temp. with - burner
RLE 40 G: 170-180 °C) - bull-nose
- cooler side wall + roof
Many thanks for your attention!

Refratechnik Cement GmbH

Rudolf-Winkel-Strasse 1
37079 Göttingen · Germany
Tel. +49 5 51-6 94 10 · Fax +49 5 51-69 41-104
refra@refra.com · www.refra.com