ANH Refractories Refractory 101

ANH Refractories
Refractories 101
January 18-19, 2012
A.P. Green, Harbison-Walker and NARCO are part of the ANH

Refractories family of companies
1
Refractory Defined
According to Ceramic Engineers

• “Inorganic, non-metallic, Solid materials that
can withstand high temperatures and be
resistant to the chemical and mechanical
conditions of furnace operations”
2
Refractory Defined
3
Refractory Characteristics
• Resists High Temperature

• Contains Flame & Heat
• Resists Chemical Alteration
• Brittle, Not Flexible
• Maybe “Softer” at Elevated Temperature
• Not Metallic, but a Chemical Oxide in most cases
– SiO2 = silicon dioxide, or silica
– Al2O3 = aluminum trioxide, or alumina
4
Refractories:
Aggregate & Matrix
•Aggregate = the
rocks or large
particles in a brick,
castable, plastic, etc.
•Matrix = the fine

particles that surround
the aggregate. The
strength and durability
of the product is
primarily due to the
composition of the
matrix.
5
Refractory Types
• Dense Brick
• Insulating Brick
• Mortar
• Castables
• Gunning Mixes
• Shotcrete Mixes
• Plastics
• Ceramic Fiber
6
Major Product Families
Brick
Plastic
Castable
7
Major Installation Methods
Plastic Gunning Brick & Mortar
Pumping
Precast
Dry Gunning
8
Measurable Properties
• Chemical Analysis
• Density
• Porosity
• Compressive & Tensile Strength
• Expansion – Reversible & PLC
• Thermal Conductivity
• High-Temperature Strength
• Misc.
9
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What is this and where do we use it?
Product Chemistry
How was the sample prepared?
Be careful not to design for this temp
How much mat‟l? Need to calc volume
Pertinent material physical properties
Be sure to understand “At” vs. “After”
10
10
Chemical Composition
• Chemical Analysis
– Primary Oxides -- Typically Al2O3 & SiO2
– Other Oxides -- CaO, MgO
– Alkalies/Impurities -- Na2O, K2O, TiO2, Fe2O3
Chemistry of CLIPPER DP brick
Al2O3
SiO2
Fe2O3
TiO2
CaO
MgO
Na2O+K2O
11
11
Density & Porosity
• Density
– weight per unit volume
– pounds per cubic foot
– grams per cubic centimeter
• Porosity
– % of “open space”
– 12% to 20% for dense brick
– 60% to 80% for I.F.B.
12
12
Cold Crushing Strength
Crushing
Force
C.C.S.
Based on vertical
loading of sample
Refractory materials are

much stronger in
Specimen fails compression than in
in compression
tension
13
13
Modulus of Rupture
This is a
M.O.R.
Bending
measure of
Force
tensile strength
Based on 3-point
loading/bending
MOR is typically Specimen fails

15-25% of CCS in tension along
the bottom surface
14
14
Refractoriness: High
Temperature Performance
15
15
Hot Modulus of Rupture
H.M.O.R.
Bending
Force
..but run
inside a hot
furnace
at a pre-
determined
temperature
Same as Specimen fails

MOR... in tension along
the bottom surface
16
16
Hot Load
Loading
Force
Calculate
Original percent
height subsidence
from original
height
Heated
Original Specimen
Specimen hot load furnace
has squatted,
is now shorter
at a predetermined
than original
temperature
height
17
17
Creep
Moderate
load on
Electric sample
Transducer similar to
measures real-life
specimen loading
height on a
continuous
basis while
it is being
If variables are
heated
chosen properly,
Creep furnace
height change
following a
predetermined during test is very
heatup schedule low -- 1 or 2%
18
18
Expansion Under Load & Creep
19
19
Thermal Expansion
20
20
Thermal Conductivity
21
21
Permanent Linear Change
P.L.C.
Measure original length of
brick before heating
Heat brick to predetermined

temperature, and then cool
Measure new length of brick,

and determine % change -- may
be expansion or contraction
22
22
Permanent Linear Change
23
23
Prism Spalling Test
2200oF to Water Quench

24
24
Corrosion Tests
25
25
Destructive Factors:
• High or Excessive Temperature

• Thermal Shock, Rapid Temp Change
• Chemical Attack from Alkali
• Corrosion / Reaction with Molten Aluminum
• Abrasion and Erosion
• Mechanical Stress or Abuse
• Physical or Chemical Alteration
• Combined Effects
26
26
Temperature
• High Temperature is “first parameter” for

consideration
• Easy to deal with, as long as maximum
temperature is known
• Characteristics required….
– High Alumina Content
– High Firing Temperature
– High Degree of Mullite Formation
– Good values for Hot Load, Creep, RUL
27
27
Heat up & Cool Down
for Refractory Linings
-55°C/hr
+55°C/hr Maximum
Maximum Cool Down
Heat up Rate
Rate
28
28
Chemical Erosion & Spalling
Reacted Refractory
Refractory Furnace Atmosphere,

Metal, Slag
29
29
Alkali
• Effects of alkali are cumulative

• Dry reaction between 760C to 1200C
• Slagging (“wet”) reaction above 1200C
• Preferred refractory characteristics:
– Low Porosity
– High Chemical Purity
– Higher Alumina not necessarily better
– Look for ANH products with “AR” suffix
30
30
Alkali Tests
1200°C 1200°C
31
31
Abrasion & Erosion
• Abrasion due to solid-to-solid contact

• Erosion due to liquid-to-solid contact
– High Strength
– High Density
– Low Porosity
32
32
Mechanical Stress & Abuse
• Refractories are protective -- they are not

structural
• Expansion and shrinkage
• Suitable anchor system
• Hard use, especially during 3rd shift
– High strength
– Proper design and installation
33
33
Installation Method
• Each type of refractory construction has inherent

advantages
• Each type of refractory construction has inherent
disadvantages
• Careful comparison allows you to select the very
best method for each particular situation
34
34
Brick & Mortar Construction
•Advantages •Considerations
– Pre-fired & ceramic bonded – Requires good bricklayer
all the way through skills to install
– High hot strength – Longer lead time affects
– Good abrasion resistance availability
– Alkali and acid resistance – More joints in lining
– No free lime to react – Difficult to customize using
– Durable in hot/cold cycling standard shapes
– No special dryout required
– Lowest material cost on a
cubic-foot basis?
35
35
Castable Construction
– Engineering properties that – Must use forms to cast
rival brick – Castables are most
– Has become a high tech sensitive to installation
product in last 20 years variables
– Can be pumped, gunned, – Must cure before
sprayed, cast, etc. proceeding
– Good strength through entire – Must use controlled dryout
thickness to remove water
– Fewer joints – Will never be ceramic-
– Easy to vary & customize bonded clear through
thickness – Susceptible to chemical
attack
36
36
Plastic Construction
– Fewer joints – Not as strong as brick or
– Easy to vary thickness castable
– Easy to ram or gun – May laminate during ramming
– Easy to repair – Ramming is hard work
– No forming required – Gunning requires special
– Begin dryout as soon as equipment
installed – Not as durable in hot/cold
cycling
– Volume stable
– Phos-bonded plastics are
– Inherently resists thermal
hygroscopic
shock
– Bond is heat-evolved, varies
– Resists chemical attack
from front to back
37
37
Pre-Cast Construction
– Good, consistent physical – Need lifting equipment
properties – Need furnace interior access to
– Fewer joints install
– QC done by supplier – Long lead times
– Modular installation is very fast – More up-front design &
– Customize composition & engineering effort
features – Furnace shell distortion
– Dried or pre-fired off site for interferes with perfect fit
faster startup – Lining is not 100% precast, so
– Items can be replaced on the dryout may still be lengthy
fly – Subject to chemical attack -- no
different than castables
38
38
39
Monolithic Refractories 101
40
40
Outline
• Types of Monolithic Refractories
• Compositions and Binders
• Installation Considerations
• Curing and Dry out
41
41
Castable Types
Technology
Complexity
Viscosity
- • Hand Cast – Rod or Shovel Into Place

• Vibration Cast – Vibrate and Densify Into Place
• Pumpable – Pump into Forms
• Self-Flow – Flows Into Place on Its Own
42
Pumpables
43
43
Self-Flow Castable
•Even Though the

Amount of Water Used
for EXPRESS Castables
is Not Extremely High…
44
44
Self-Flow Castable
•Even Though the

45
45
Self-Flow Castable
•Even Though the

46
46
Shotcrete and Gunning
Shotcrete – Pump to Nozzle Wet, Add Accelerator

at Nozzle, Spray Into Place
Gunning – Air Feed to Nozzle Dry, Add Water at
Nozzle, Spray Into Place
47
47
Shotcrete Equipment
Double piston swing valve concrete pump
48
48
Shotcrete Equipment
Air
Set Activator
Nozzles for Shotcreting
49
49
Gunning Refractories
50
50
Plastic Refractories
Plastic / Ram/ Patch – Gunning Plastic –

air hammer installed spray into place
51
51
Rammed Plastic Refractories
52
• Clay Bonded
– Relatively Inexpensive
– Good Alkali Resistance
– Little Strength Development Below 1093oC
– Strength Varies Dramatically Throughout Lining
Thickness
53
53
• Phosphate Bonded
– “Dual Bond” Provides Strength Throughout Lining
– Good Thermal Shock Resistance
– Low Permeability of Bond Improves Alkali
Resistance
– Phos-Bond is Very Hygroscopic
• Rammed Plastics
– Installation Intensive
– Shelf Life
54
54
Gunning Plastics
• Extremely Rapid
• Hot Installations
are Possible
• Rebound can be
Reclaimed
• Phosphate
Chemistry
Source
55
55
Gunning Plastic
• Requires Special Equipment and Skilled Personnel

• Possibility of Trapping Rebound During Installation
• Phosphate or Clay Bonded Only
56
56
Castable Refractories
• Classification by Binder
Lime (CaO) Cement
Category
Level Level
Conventional > 2.5 % > 10%
Low Cement 1.0 – 2.5 % 4–8%
Ultra-Low Cement < 1.0 % <4%
Cement Free < 0.2 % No Cement

Chemical, Phosphate,
Silicate, Aluminum < 0.2% No Cement
Sulfate, Lignosulfonate
57
57
Example Castables
Cement CaO
Product (%) (%) Casting Method
KS-4 PLUS 16.5 6.7 Hand, Vibe
VERSAFLOW 45 PLUS 7.0 2.4 Vibe, Hand, Pump
ULTRA GREEN 45 3.5 1.2 Vibe
NOVACON 65 0.0 0.1 Vibe
Many Castable / Gunning / Shotcrete

Characteristics are Dependent on Binder
Type and Level
58
58
Ease of Use
% Cement ↑ User Friendliness ↑
Water Range Range as

Product (%) Gallons / 1000# Bag
KS-4 PLUS 12.0–14.5 14.4–17.4
VERSAFLOW 45 PLUS 6.0–7.0 7.2–8.4
ULTRA GREEN 45 4.9–5.5 5.9-6.6
NOVACON 65 4.7-5.3 5.6-6.3
Out of Range Water Will Lead to Degradation

in Strength and Density
59
59
Setting Reliability
% Cement ↑ Set Time Reliability ↑
Set Time Exotherm Heat

Product Range (hrs) Given Off (°F)
KS-4 PLUS 3-7 51
VERSAFLOW 45 PLUS 3-12 22
ULTRA GREEN 45 3-12 10
NOVACON 65 <24 0
Higher Cement Contents => More Predictable

Set / Less Temperature Sensitivity
60
60
Shelf Life
% Cement ↑ Shelf Life ↑

14
Storage Life (months)
12
10
8
6
4
2
0
KS-4 VERSAFLOW ULTRA GREEN NOVACON 65
45 45
High Tech Dispersants and Additives Reduce

Shelf Life of Products
61
61
Maximum Service Temperature
% Cement ↓ Refractoriness ↑
2000
Max Service Temp (°C)
1900
1800
1700
1600
1500
1400
1300
1200
1100
1000
KS-4 VERSAFLOW 45ULTRA GREEN 45 NOVACON 65
Cement is a Flux in the System
62
62
Hot Strength
% Cement ↓ HMOR ↑
3000
VERSAFLOW 45
2500 ULTRA GREEN 45
NOVACON 65
2000
HMOR (psi)
1500
1000
500 KS-4
0
800 900 1000 1100 1200 1300 1400 1500
Temperature (°C)
63
63
Installation of Monolithics
• Proper Installation Involves:
 Mixing
Placing
 Curing
 Drying
Optimum Properties
64
64
Mixing
• Use Clean Equipment
• Mix thoroughly (usually 5+ minutes)
–Need to Disperse Fines
–Need to Dissolve Additives
• Keep water and mix at acceptable
temperatures
–15-26°C
• Two Purposes for Adding Water
–Hydrate Cement
–Fluidity
65
65
Effect of Water Addition on Properties
VERSAFLOW 60 PLUS:
Casting Water (%) 5.5 6.5 7.5
110°C Density (pcf) 155.3 149.8 141.2
110°C MOR (psi) 1610 1270 990
Initial Set (hours) 5.4 6.0 19.7
Final Set (hours) 7.0 7.8 22.8
Be Careful with Water!
66
66
Placing
• Use clean equipment

• Use method and equipment appropriate to
product
• Place material before it begins to set
• Avoid laminations and cavities
• Densify and Knit Together Refractory to
Maximize Properties
67
67
Curing
• Begins with water addition

• Ends with the start of dry out
• Allows castable to set and strength to develop
• As a cement-bonded product sets, the cement
reacts with water to form hydrates
• Higher water content will slow this process.
• Lower temperatures will slow this process.
• This process releases heat → Exothermic.
• We measure this process with the Exothermic
Profile Measurement System.
68
68
Mix Fingerprints
41 EXPRESS 30
39
36
34 VERSAFLOW 60
Temperature (oC)
32
30
28
25
23
GREENKLEEN 60
21
19
17
2 4 6 8 10 12 14 16 18 20
Time (Hours)
69
69
Mathematically Derived Set Times
Final Set = 11.4 Hrs
31 EXPRESS 30 PLUS
30
28.8
27.7
Temperature (oC)
26.6
25.5
24.4
23.3
22.2
21.1
20 Initial Set = 9 Hrs
18.8
17.7
End Working Time = 4.1 Hrs
16.5
0 2 4 6 8 10 12 14 16 18 20 22 24
Time (Hours)
70
70
Set Time vs Temperature
VERSAFLOW 60 PLUS
105
86 F = 3.3 HRS
95
71 F = 6.3 HRS
Temperature (F)
85
53 F = 15.2 HRS
75
65
55
45
0 5 10 15 20 25
Time (hrs)
71
71
ON-LINE Set Time vs Temperature
ON-LINE 65 AL (4-6 hour set time target)
110
100
Temperature ( o F)
90
80
95 F = 2 HRS
70 75 F = 3.5 HRS
55 F = 8 HRS
60
50
0 2 4 6 8 10 12
Time (hrs)
72
72
Strength vs Curing Temperature
1400
1200
1000
MOR (psi)
800
600
Due to differences in
400 cement hydrate formation
200
30 40 50 60 70 80 90 100
Curing Temperature (F)
73
73
Permeability vs Curing Temperature
60
50
40
Permeability
30
20
10 Due to differences in
cement hydrate formation
0
30 40 50 60 70 80 90 100
Curing Temperature (F)
74
74
Temperature & Cement Hydrate Formation
CAH10 – Temp < 60 F C2AH8 – Temp > 60 F

(15.5 C)
CAH10 – Lower permeability and lower strength
From Lea’s Chemistry of Cement and Concrete. 4th
Ed. P.C. Hewlett, editor. 1998.
75
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Dry-Out
Water expands to 1600 times its volume when it

turns to steam.
How do we “diffuse” this situation?
1. High Cured Strength
2. High Permeability
3. Controlled Dry-Out
76
76
Controlled Dry Out
• Objective:
• Remove All Water
– Physical (Mechanical)
– Chemically Combined
• Minimize Steam Pressure Build Up
• Final Stage of Strength Development
77
77
Dry out Factors
MOR
Permeability
Refractory Castable
Dry out + Permeability => Internal Pressure (P)
IF P < MOR A Successful Dry out Will Result
78
78
Major Dehydration Points
400
350
Casting Water ("physical water")
Water Vapor (cm3/g)
300
250
200
150
Calcium Aluminate Phases ("chemical water")
100
50
0
212 440 540 1020
(100 C) (226 C) (282 C) (549 C)
Temperature of Dehydration (°F)
Source: D.L. Hipps and J.J.79

Brown
79
Moisture Release on Dry out
100
90
80
70
Moisture Loss (%)
60
50
40
30
20
10
0
0 100 200 300 400 500 600 700 800 900 1000
Temperature (°F)
Higher Temperature Leads to Higher Pressure (PV = nRT)
80
80
Steam Pressure vs Temperature
3500
3000
Pressure (psi)
2500
2000
1500
1000
500
0
0 200 400 600 800
Temperature (F)
(Worst Case Scenario – No Water Release
Allowed)
81
81
Dry out Procedures
• Allow For Water Removal

– Weep Holes - Unobstructed
• RCF Rope Wicking
• RCF Paper
• Exchange Air
– Once Every 2 Minutes
82
82
Dry Out Schedules
• Dry out schedules vary from job to job

• Dry out schedules depend on:
– Material selection
– Lining configuration/components
– Lining Thickness
83
83
Dry out Schedules
• Standard Schedules (~9”, single component)
– PLUS rated products
– Steady ramp to operation temperature
Temperature
Time
84
84
Dry out Schedules
• Standard Schedules (~9”, single component)
– ADTECH and other products
– Series of ramps and holds to operation temperature
Temperature
Time
85
85
Dry out Schedules
• Standard ALUMINUM Schedules
– Series of ramps and holds to operation temperature
– Typically lengthy due to lining thickness
Temperature
Time
86
86
Final Thoughts on Monolithics
• Several monolithic solutions to solve problems

• Many installation techniques for same materials
• Trade offs between time / manpower /
properties / job size / cost are key factors
• Final properties of lining are highly installation
dependent
• Pay close attention to water addition, cross
contamination, mixing, and curing conditions
• Installation isn‟t over „till dry out is over
87
87
88
Anchoring Refractories

89
Anchoring Refractories
• Selection Guidelines
– Refractory type being installed
– Lining thickness and # of lining components
– Method of refractory installation
– Process vessel geometry
– Max and continuous operating temps
– Vibration, structural stability of vessel shell
– Exterior insulation
– Operating atmosphere or process
90
90
Metallic Anchors For Castables
• Metallic Anchor length
– Typically extends 80% thru working lining
– Plastic tips may be placed onto anchors based on
customer specifications
– Anchor tips should not exceed temperature limits of
metallic anchor steel alloy
– 1600F (870C) for 304 alloy
– 1650F (890C) for 309 alloy
– 1700F (925C) for 310 alloy
91
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Metallic Anchors
• Castables and gunned linings

• Service temperatures do not exceed 2000F (1090C)
• Anchor spacing important and dependent on location
• Rotate anchor 90 degrees from neighboring anchors
• Solid fillet weld on both sides of anchor foot
• Check welds for ring
92
92
Wire Anchors
93
93
Wire Anchors
Welding detail
94
94
Anchor Spacing Pattern
95
95
Wire Anchor Spacing
96
96
Ceramic vs. Metallic Anchors
• Operating Temperature of Process
– >2000F (1090C) Use Ceramic Anchors
– <2000F (1090C) Ceramic or Metallic Anchor
97
97
Ceramic Anchors For Castables
• Ceramic Anchor length
– Never less than full thickness of working lining
– May extend thru hot face and backup linings
combined
• If interface between hot face lining and backup lining is
>1600F (870C)
• If lining vibration is present
98
98
Ceramic Anchors
99
99
Ceramic Anchors
100
100
Ceramic Anchors
101
101
Ceramic Anchors
102
102
Ceramic Anchors Qualities
• UFALA (60% Alumina)
• CORAL BP (85% Alumina + P205)

• Standard Stock Quality
• KORUNDAL XD (90% Alumina)
103
103
104
104
105
105
106
Refractory for Aluminum
Applications
107
Aluminum Applications
• Primary
• Secondary
108
108
Primary
• Pot Lines
– Electrolytic Cells
– Transfer Crucibles
• Carbon Bake Furnaces
• Cast House
– Reverbs
– Holders
– Transfer Trough/ Launder Systems
– Heat Treat Furnaces
109
109
Secondary
• Melting Furnaces
– Recycle Furnaces
– Round Top Charge
– Rotary
• Holding Furnaces
• Transfer Troughs/ Launder Systems
• Over Road Crucibles (OTR)
• Die Cast Furnaces
110
110
Primary- Pot Lines
• Electrolytic Cells
– Sodeberg vs Pre-Bake
• Operating Conditions
– Molten Metal and Cryolite Present
111
111
Pot Lines- Electrolytic Cells
• Refractory Used
– Insulation: Moler; Vermiculite; IFB
– Barrier Brick/ Mix: Semi-Silica; Fireclay
– Vapor Barrier Castable: Dense/Insulating
– Side Walls: Carbon/Graphite; Ni-bonded SiC
112
112
• Refractory Used
– Barrier Brick/ Mix: Semi-Silica; Fireclay
– Success in supplying mortar to lay these brick
• NO T-36 REFRACTORY CEMENT (wet, air setting,
~50% Al2O3)
• „SAIRBOND (dry, air setting, 40%Al2O3)
• ATMOSET (wet, air setting, 84% SiO2)
113
113
• Refractory Used
– Vapor Barrier Castable: Dense/Insulating
• KALAKAST AR
• KS-4/KS-4C (and variations)
• NARCOCAST 15R
• KAST-O-LITE 22
• INSWOOL MOLDABLE
114
114
Primary- Pot Lines
• Transfer Crucibles-
– Molten Metal Contact (from Pots)
– Short Residence Time
115
115
Pot Lines- Transfer Crucibles
• Refractory Used
– Brick- Fireclay; 45-50% Al2O3
• KALA
• CLIPPER DP/ KX-99
– ALCOR 60
– Monolithic
116
116
Primary- Carbon Bake Furnaces
• Pre-Bake Facilities…
– Furnace Design
– Reducing Atmosphere
– Thermal Cycling
– Hot Strength
– Refractoriness Under Load
117
117
• Refractory Used
– Flue and Head Wall
construction
• KALA
• CRYLA
– Mortar
• MEXI-KOMO
• „SAIRSET
118
118
• Refractory Used
– Fluewall Caps
• ULTRA-GREEN 45 (long history, good performer)
• ULTRA-GREEN 45 SR (improved resist. to cycling)
• EXPRESS 27 Plus (recently tested by ICAR, qualifies
for Pechiney spec 30.8)
• SENTINEL RC (low-cost alternative)
119
119
• Refractory Used
– Port blocks
• HPV-ESX (outstanding performer versus others)
– Cross over arches
• MC-28 L Plus (semi-insulating, coarse grain, proven
performer)
– Pre-cast shapes/small qty substitutes
• ULTRA-EXPRESS 45
120
120
• Refractory Used
– Insulating Firebrick
• Highly specification driven
• We have full line of GREENTHERM IFB and HS
products are available as well
121
121
Secondary Aluminum Applications
• Melting Furnaces
– Recycle Furnaces
– Round Top Charge
– Rotary
• Holding Furnaces
• Transfer Troughs/ Launder Systems
• Over Road Crucibles (OTR)
• Die Cast Furnaces
122
122
Secondary- Furnaces
• Reverb/ Melting/ Holding- Molten Aluminum;
Various Scrap Sources (UBC, Scrap Metal;
Sows/Rolls/Casting Scraps, Hot Metal)
• Side-well Melter
123
123
Refractory Selection
• Several Variables Present For Selecting Refractory
• Melting Practices
– Wear Mechanisms
– Fluxing/Alloying
– Scrap Charging
• Location in Furnace/Process
124
124
High Temperature Operation
• Higher Temperature to
Increase Production Rate
• Use of High BTU and Oxy
Fuel Combustion Systems
– Decrease Cycle Times
– Increase Melt Rates
• As Temperature Increases,
Degree of Corrosion and
Wear Increases
125
125
Higher Temperatures
• Increased Rate of Reaction

Rate of Reaction
Rate of Reaction Doubles with Every

100°F of Temperature Increase
Temperature
126
126
Chemical Attack: Corundum Formation
• Corundum is Aluminum
Oxide (Al203)
• Chemically the Same as
Alumina Used to
Manufacture Refractories
• Almost as Hard as
Diamonds
• Difficult to Remove From
Refractory Lining
127
127
Chemical Attack: Corundum Formation
Here is the reaction…..
4Al + 3O2 = 2Al2O3
– Taking Oxygen From
• Air
• Reducible Oxides
– Results
• Adherence
• Penetration
• Refractory Disruption
• Detrimental to Thermal Efficiency
• Mechanical Integrity of Furnace
128
128
Corundum- A Furnace Killer
Corundum
Buildup in
Corner of
Furnace
129
129
• Causes of Corundum Formation

– Operational Factors
• Increased Furnace & Metal Temperature
• Excess Oxygen, Negative Furnace Pressure
• Poor Burner Performance
• Dross & Dross Removal Practice
• Alloy & Percentage Of Magnesium, Zinc
• Flux Type (Salts, Na, KCl)
• Fluxing Practices
130
130
• Causes of Corundum Formation
– Refractory Factors
• Excess Free Silica
• Non-Wetting Capabilities, Resistance to Metal
Penetration and Reaction
• Porosity
131
131
Corundum-Resistant Materials
• Designed for extreme conditions (typically at belly
band)
– Zircon- very effective
• Can eventually dissociate when exposed to alkali flux
– Ultra-high alumina (pure alumina = corundum)
• Low silica (also beneficial to metal purity)
• Phos-bonded Plastics
132
132
• Belly Band Separate From Lower Side Wall
• Allows For Material Upgrade, Precast
Shape, Facilitate Repairs
133
133
Refractory Solutions, Design
• Contoured or Angled Corners Improve Metal
Flow And Facilitate Removal of Dross
134
134
Corundum
Questions?
135
135
Higher Temperatures
• Freeze Plane Calculations
– Depth of Metal Penetration
900
800
730 C Bath Temp
Temperature ( C)
700
600 660 C Freeze Plane

500
400
300
200
13½”
100 Aluminum Resistant 3”
Low Cement Castable Fireclay
0
Lining Depth 1½”
Mineral
Wool
136
136
Higher Temperatures
• Higher Temperatures
– Deeper Metal Penetration
900
790 C Bath Temp
800
Temperature ( C)
700

500
400
300
200
13½”
0
Lining Depth 1½”
Mineral
Wool
137
137
Over Insulation
• Over insulating linings can have profound effects
on freeze plane location
• Trade off between insulation/shell temperatures
and freeze plane locations
138
138
Broader Product Mix
• Multiple Base Alloys
– Zinc Based Alloys
• Increases Bath Fluidity
• Promotes Corundum Formation
– Magnesium Based Alloys
• Prone to Thermiting
• Leads to Corundum Formation
– Silicon Based Alloys
• Highly Fluid
139
139
Broader Product Mix
• Alloying Agents → Lower Solidus Temp
– Freeze Plane Location
900
800
730 C Bath Temp
Temperature ( C)
700

590 C Freeze Plane
500
400
300
200
13½”
0
Lining Depth 1½”
Mineral
Wool
140
140
Broader Product Mix
• Alloying Agents + Higher Temperature
– Freeze Plane Location
900
790 C Bath Temp
800
Temperature ( C)
700

590 C Freeze Plane
500
400
300
Through Hot
200
13½” Face
0
Lining Depth 1½”
Mineral
Wool
141
141
Broader Product Mix
• Freeze Plane Issues
• Alloying Agent Reactions
– Thermiting
– Sludge
142
142
Thermiting
• Oxidation of Metal Additives
• Very High Localized Temperature
– Magnesium ≥ 3000oF (1650 C)
• Results
– Accelerated Wear and Reactions
– Corundum Formation
143
143
Sludge
• Prone in Alloys with Fe, Mn & Cr

• High Density
• High Melting Points
• Results
– Adherence
– Penetration
– Refractory Disruption
144
144
Increased Scrap Utilization
• Increase Impurities Carried Over

• More Dross Build-up
– More Cleaning
– Prone to Corundum Growth
– Increased Melt Loss
145
145
sCRAP
146
146
Fluxing
• The Purpose of Metal Fluxing
– Lower the Melting Temperature
– Clean the Metal/Homogenize the Bath
• Remove Impurities
• Remove Hydrogen
• Remove Alkali Metals
147
147
Fluxing
• The Results of Metal Fluxing
– Increased Reactions at the Melt Line
– Combined with Al2O3 and SiO2 from Refractory 
Low Melting Phase
– Presence of Chlorine – reacts with CaO in cement
causing bond instability
148
148
Mechanical Abuse
• Mechanical Abuse
• Impact/Abrasion
• Thermal Shock
– Dross Skimming
– Charging
– Stirring
– Cold Cleaning
149
149
Mechanical Abuse
• Thermal Shock- Charging
Cold Ingot
Stress Plane
Working Lining
Sub Hearth
Can Lead to Thermal Spalling
150
150
151
151
Refractory Selection: Reverb/Holder
Metal Contact Zones
Hearth / Sub-Hearth
152
152
Metal Contact Zones
Ramp
Sub-Ramp
153
153
Metal Contact Zones
Lower Charge well walls

Side Wall (scrap well)
(LSW)
Hot-Wall
154
154
Refractory Selection: Metal Contact
• Wear Mechanisms
– Metal Contact
– Mechanical Abuse
• Stirring/Cleaning
• Charging
• Typical Selection Criteria
– Penetration Resistance
– High Strength
155
155
• Brick
– Phos bonded
• Burned
– DV-38
– CORAL BP
• Baked
– ALCOR 32
– ALCOR 60
– CORAL P
“LA” Spec. for Dimensional Tolerance of +0/-0.04”
156
156
• Castables
– “AL”- Aluminum Penetration Inhibitor Additives
– ARMORTECH 65AL
• New technology. Shows exceptional hot strengths and
the best AL resistance to date
– VERSAFLOW 65 AL
– ARMORKAST 65 AL
– ARMORKAST 80 AL C
– ULTRA-EXPRESS 70 AL
– GREENKLEEN 60 PLUS
157
157
Refractory Technology Brief
• EXPRESS Technology- Self-Leveling
– Mix to “vibe cast” consistency for enhanced
properties
158
158
Burners
Pre-Cast Blocks Set with
Tap Blocks / Drains
Phosphate Bonded Plastic
Inserts / Receivers
PLASTECH 50 P AL
159
159
• Back up Lining
• Hearth/Ramp Typically Castable for Level Surface
and/or Establishing Slope
– VERSAFLOW 45 AL
– H-W ES CASTABLE C AL
– KS-4
• LSW varies: brick or castable
• CLIPPER DP for a brick back up lining
160
160
• High Wear Applications

• Brick
– DV-38
– ALCOR 32
– Ni-Bonded SiC
• Castable
– THOR 60 ABR ADTECH
– VERSAFLOW 65 AL/C
– ARMORKAST 80 AL C
161
161
• Insulation
– Compressible Lightweight Material
– INSBLOK-19
– INSBOARD
– INSWOOL PAPER
INSBOARD
162
162
Metal Contact Zones
Belly Band
163
163
Refractory Selection: Belly Band
• Belly Band Zoning • Brick:
– High Localized
– ALCOR 32
Temperatures
– TUFLINE DM AL
– Alkali/Salt Resistance
– Corundum Resistance • Castable:
– AL Metal Contact – EXPRESS
ARMORKAST
• AL Resistant XPUR/AL
Brick/Castable – NARCON ZRAL
• Silica-Free Material- – EXPRESS
High Purity Al2O3; ARMORKAST 80AL
Harsh Conditions MAX
164
164
Upper
Non-Metal Contact
Side Wall Zones
(USW)
165
165
Roof
Non-Metal Contact
Zones
166
166
Non-Metal Contact
Zones
Flue
Lintel
Jamb
Sill
167
167
Refractory Selection: Above Metal
• Wear Mechanisms
– High Temperature
– Mechanical Abuse
• Cleaning/Stirring
– Atmosphere Considerations
• Typical Selection Criteria
– High Service Temperature
– Good Hot Strength
– Alkali/Salt Resistance
168
168
• Several Types of Materials

– Brick
– Castable
– Gun Mix
– Shot-Crete
– Plastic
169
169
• Brick
– DV-38, CORAP BP, ALCOR 60, ALCOR 32, CORAL
P
– KALA, KX-99, CLIPPER DP
• Castable
– VERSA-TECH 55 AR HS PLUS
• New technology- best combination of hot strength and
alkali resistance
– VERSAFLOW 55 AR ADTECH
– VERSAFLOW 57 A PLUS
– VERSAFLOW 60 PLUS
170
170
• Gun Mix/Shotcrete
– VERSAGUN 60
– SHOT-TEC 55 AR
– SHOT-TEC 60
• Phos-bonded Plastic
– PLASTECH 85P
– GREENGUN 85 P PLUS
• With inherent molten Al resistance phos-bonded plastics
are used in metal contact applications as well
171
171
Refractory Selection: Roof
• Pre-cast or Cast-In-Place
• Temp. and Alkali Resistance
– VERSA-TECH 55 AR HS PLUS
- VERSAFLOW 55 AR ADTECH
- VERSAFLOW 57 A PLUS
- VERSAFLOW 60 PLUS
- KAST-O-LITE 22 PLUS
-(insulation)
172
172
• Flue
• High Temp and Hot
Gasses
• Non-Metal Contact
– VERSAFLOW 55 AR
– VERSAFLOW 60
– KX-99; CLIPPER DP
• Insulating Back-up
173
173
GREENGUN 85 P PLUS Burners
PLASTECH 85 P
High Temperature, shock
resistant castables
174
174
• Jamb/Lintel/Sill
– Abrasion/Impact Resistance
– Thermal Shock
– Cast in Place or Pre-Cast
Shapes
175
175
• Jamb/Lintel • Sill
– Non-Metal Contact – Dross Removal
– High Al2O3 Castables – Heavy Charging
– Coarse Aggregate – AL resistant
Materials – THOR 60 ABR- Silicon
Carbide Containing
Materials
– Coarse Aggregate
• Both metal and non- Materials
metal contact coarse
aggregate castables
176
176
Secondary-Furnaces
• Round Top-Charge- Large Scrap of Various
Sources
183
177
Round Top-Charge Furnace
• Similar Methods to Other Melters
– Larger Scrap
– Increased Mechanical Abuse/Thermal Shock
• High Hot Strength Materials
– (Brick or Monolithic)
• Impact Resistance
• Thermal Shock Resistance
• Monolithic Problem Solver- Coarse Aggregate
Castables
184
178
Secondary-Furnaces
• Rotary- Various Scrap
• Rotary Dross- Recovery of Aluminum Metal
from Dross
185
179
Rotary Furnace
• Constant/cyclic metal contact
• Thermal cycling/intermittent usage is typical
practice
• High-wear areas
– Charging
– Flame Impingement
• Variable melt media
– Dross recovery
– Scrap melting
186
180
Rotary Furnace
• A lot of experience with
rotary furnaces for
dross recovery
operations
• More severe situation
than aluminum/alloy
melting
• Service life is impacted
• Refractory selection
may vary
187
181
Rotary Furnace
• Dross Recovery
– High levels of salt flux agents
• Lining subject to alkali attack
• Formation of „glassy layer‟ (termed “wet-alkali” attack)
• Provides penetration resistance, vulnerable to any
temperature changes
– High temperature
• Increase recovery rate/time
• More active reactions (doubles for 100oF increase)
• Accelerated wear
188
182
Rotary Furnace
• Four Main Sections to Consider

1. Barrel
2. Cone Section
3. Back Wall
4. Door
• Combination or Zoned Approach
– Different types of materials used
189
183
Rotary Furnace
• Brick Products
– UFALA
• Alkali Resistance; good
physical properties
• RKB shapes
– Used in various locations
• Entire lining
• Barrel (majority of use)
• Back walls (straight or
interlocking pieces)
190
184
Rotary Furnace
• Monolithic Products
• Castable
• AL penetration inhibitor
• Alkali and thermal shock resistant
– GREENGUN-85-P PLUS
• Phos-bonded, gun plastic
• Excellent properties
• No cure time/fast dry out
– PLASTECH 85 P
• Phos-bonded, rammed plastic
191
185
Rotary Furnace
• Testimonials:
• UFALA barrel linings:
– 18 to 24 months in dross recovery application
– Zoned with GREENGUN 85 P PLUS or PLASTECH
85 P in cone and/or back walls
• GREENKLEEN 60 PLUS
– 6”-9” tapered walls (barrel); 14”-16” back wall
– 1 year in sidewalls; 2 years in back wall
192
186
Rotary Furnace
• Testimonial:
– HP-CAST ULTRA VC
• Oxy-fuel burner (high temp/some impingement)
• Cyclic practice (each weak)
• Other materials had short service life (~4-6 mo) in
cone section
• HP-CAST is still in service (1 year later) with only
minor repairs (PLASTECH 85 P)
193
187
Rotary Furnace
• Testimonial:
– ON-LINE 65 AL
• Cast or Shotcreted with
short cure time and fast
dry out
• Shot in back wall of
high Zinc alloy melting
furnace
• 3 years of intermittent
service
194
188
Die Cast Furnace
• Smaller, Intricate
Designs
• Typically Increased
Insulation
195
189
Die Cast Furnace
• Aluminum Contact Brick
– ALCOR 32 or ALCOR 60
• Plastic and Castable Easier for Intricate
Installations
– PLASTECH 50 P AL
• Improved AL resistance
• Improved thermal efficiency
• Improved Flow Castables
– EXPRESS ARMORKAST 65 AL
– EXPRESS ARMORKAST 80AL MAX
196
190
Metal Transport
• Launder/Trough Systems
– Metal Contact
– Extreme Thermal Cycling
– Erosion from Molten Metal
• Crucibles/Ladles
– Metal Contact
– Thermal Shock
– Heat Containment
197
191
Launder/Trough Systems
• Pre-cast or Cast-In-Place
• Dense vs. Insulating Material
– THOR 60 ABR
– VERSAFLOW THERMAX AL
– FUSIL CASTABLE 820 I AL
• Al Resistant Insulating Castable
– ARMORLITE 70 AL; ARMORLITE 85 AL
• INSWOOL Paper- to Line Steel Casing
198
192
Crucibles/Ladles
• Over-The-Road Crucible
– Transport Molten Metal
• Heat Containment
• Aluminum Resistance
• Impact Resistance
(Bottom Impact Pad)
199
193
Crucibles/Ladles
• Al Resistant Insulating Castable
– GREENLITE 45 L AL
– ARMORLITE 70AL
– ARMORLITE 85AL
• Bottom Impact Zone
• INSWOOL Paper to Line Shell
200
194
MIDDLEWEIGHT Technology
• Product family to address continuous focus on

increasing thermal efficiency in refractory linings
• Uniquely designed products to yield a combination
of multiple properties including:
– High refractoriness (3000oF/1650C temperature limit)
– High strength
– Improved thermal efficiency over typical dense
castable products
201
195
• Utilization of ANH Refractories proprietary

lightweight aggregate grain: GREENLITE
• Same grain used in select lightweights to improve
physical properties
• GREENLITE aggregate‟s high strength to weight
ratio translates to finished products
• When substituted into a dense refractory, improved
thermal efficiency comes at only a minimal reduction
in physical properties
202
196
• Preliminary products:
– WL-7176: a MIDDLEWEIGHT version of ULTRA-
GREEN 45: a good product suggestion for
intermediate or back-up linings or as a working lining
in doors, lids, flues and duct work
– WM-7235: is VERSAFLOW 70‟s version of a

MIDDLEWEIGHT and provides a 65% alumina, mid-
density product ideal for high wear back-up or
moderate wear hot face linings
203
197
• Preliminary Products:
– WM-7304: provides the same alkali resistance and
comparable hot strength as VERSAFLOW 55/AR
ADTECH, but with approximately 20% lower density.
Designed specifically for aluminum furnace
superstructure applications, WM-7304 will provide
excellent service in any application where high
strength and alkali resistance are a necessity
204
198
MIDDLEWEIGHT Properties
VERSAFLOW
ULTRA-GREEN 55/AR VERSAFLOW
45 WL-7176 ADTECH WM-7304 70 PLUS WM-7235
Mtl. Required (pcf) 146 115 149 122 160 120

MOR (psi)
after 230°F 1750 650 2000 1350 2100 1000

after 1500°F 2500 700 2700 1500 2100 -
after 2500°F 2400 500 - 4100 2700
after 2910°F 1900 2600 - 3800 2200
CCs (psi)
after 230°F 12000 3100 17000 7100 12900 4000

after 1500°F 13000 3400 12000 5500 12800
after 2500°F 14000 6600 - 25400 8100
after 2910°F 16000 9300 - 25600 8300
HMOR (psi)
at 1500°F 2500 1400 - 1600 - -

at 2000°F - - 2200 2800 - -
at 2500°F 900 1100 - - 1600 1300
205
199
MIDDLEWEIGHT Thermal Conductivity
Thermal Conductivity of WL-7176 vs.
ULTRA-GREEN 45
22.5
20
17.5
15
BTU/Hr ft² °F/in
12.5
10
7.5
5
WL-7176 Castable ULTRA-GREEN 45
2.5
0
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000
Temp (oF)
206
200
Thermal Conductivity of WM-7235 vs.
VERSAFLOW 70 PLUS
22.5
20
17.5
15
BTU/Hr ft² °F/in
12.5
10
7.5
WM-7235 VERSAFLOW 70 PLUS

5
2.5
0
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000
Temp (oF)
207
201
Thermal Conductivity of WM-7304 vs.
VERSAFLOW 55/AR ADTECH
22.5
20
17.5
15
BTU/Hr ft² °F/in
12.5
10
7.5
5
WM-7304 VERSAFLOW 55/AR
2.5
0
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000
Temp (oF)
208
202
Maintenance Materials
Cold Repairs • Repair Size and
Time
– GREENGUN
– PLASTECH
– Castable or
Gun Mix
– VERSAGUN 70
AL
209
203
Maintenance Materials
• Hot Repairs
– GREENGUN 85 P
PLUS
– Hot-Gun Mix
– GREFCOTE 70 AL
PLUS
210
204
Special Shapes
• ALUMILOK
– Tongue and Groove Brick
– Multiple Sizes and Mixes
– Good for Free-Standing Walls, and Improving
Overall Wall Strength
211
205
Special Shapes: ALUMILOK
212
206
Thank You
213
207
Thank You
208

ANH Refractories Refractory 101

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ANH Refractories Refractory 101

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ANH Refractories

A.P. Green, Harbison-Walker and NARCO are part of the ANH

According to Ceramic Engineers

• Resists High Temperature

•Matrix = the fine

Plastic Gunning Brick & Mortar

What is this and where do we use it?

How was the sample prepared?

Be careful not to design for this temp

How much mat‟l? Need to calc volume

Pertinent material physical properties

Be sure to understand “At” vs. “After”

Chemistry of CLIPPER DP brick

Refractory materials are

MOR is typically Specimen fails

Same as Specimen fails

Heat brick to predetermined

Measure new length of brick,

2200oF to Water Quench

• High or Excessive Temperature

• High Temperature is “first parameter” for

Refractory Furnace Atmosphere,

• Effects of alkali are cumulative

• Abrasion due to solid-to-solid contact

• Refractories are protective -- they are not

• Each type of refractory construction has inherent

• Types of Monolithic Refractories

• Compositions and Binders

• Curing and Dry out

- • Hand Cast – Rod or Shovel Into Place

•Even Though the

•Even Though the

•Even Though the

Shotcrete – Pump to Nozzle Wet, Add Accelerator

Double piston swing valve concrete pump

Nozzles for Shotcreting

Plastic / Ram/ Patch – Gunning Plastic –

• Requires Special Equipment and Skilled Personnel

Ultra-Low Cement < 1.0 % <4%

Cement Free < 0.2 % No Cement

Many Castable / Gunning / Shotcrete

Water Range Range as

Out of Range Water Will Lead to Degradation

% Cement ↑ Set Time Reliability ↑

Set Time Exotherm Heat

Higher Cement Contents => More Predictable

% Cement ↑ Shelf Life ↑

High Tech Dispersants and Additives Reduce

Cement is a Flux in the System

• Proper Installation Involves:

Be Careful with Water!

• Use clean equipment

• Begins with water addition

CAH10 – Temp < 60 F C2AH8 – Temp > 60 F

Water expands to 1600 times its volume when it

Source: D.L. Hipps and J.J.79

• Allow For Water Removal

• Dry out schedules vary from job to job

• Several monolithic solutions to solve problems

A.P. Green, Harbison-Walker and NARCO are part of the ANH

• Castables and gunned linings

• Operating Temperature of Process

– >2000F (1090C) Use Ceramic Anchors