Basic Bricks for Cement Rotary Kilns

Webinar for PT SEMEN INDONESIA

Vienna, 27th May 2021

Basic Bricks for Cement Rotary Kilns

1 Introduction

2 Raw materials Sintered Magnesia

3 Raw materials Spinel

4 Brick types and Lining Recommendation

2
 Basic Bricks for Cement Rotary Kilns
Composition of conventional magnesia spinel bricks

In general bricks for cement rotary kilns consist of two components:

➢ Magnesia
High thermal resistance
High chemical resistance

High thermal expansion,

Low thermal shock resistance
No structural elasticity

➢ Spinel
needed, as flexibilizing additive

3
Basic Bricks for Cement Rotary Kilns

1 Introduction

2 Raw materials Sintered Magnesia

3 Raw materials Spinel

4 Brick types and Lining Recommendation

4
Types of Sintered Magnesia

• Synthetic sintered magnesia, MgO content > 98%

out of sea water or salt lakes, salt brines and salt deposits

• Natural sintered magnesia, MgO content < 98%

In nature magnesium carbonate is always associated with other minerals.

Typical impurities are calcium carbonate

quartz, silicates,
iron compounds (pyrite)

Two types of natural magnesia can be distinguished:

o coarse crystalline alpine magnesia, iron rich
o fine crystalline magnesia, low in iron
DBM97, DMB96, DBM95,…

5
From Raw Material to Sintered Magnesia (DBM)

Magnesite deposits occurence in form of

magnesium carbonate (MgCO3)

coarse crystalline:
Alpine type: Breitenau / Austria
Hochfilzen / Austria
Radenthein / Austria

microcrystalline (cryptocrystalline): Tutluca / Turkey

Magnesium-chloride
sea water or salt lakes, salt brines and salt
deposits

Breitenau Mine/Styria, Austria

6
 Types of Magnesia
Synthetic Magnesia
Natural Magnesia Source: salt brine MgCl
Source: Magnesite MgCO3 sea water MgCl
natural MgCO3 + flotation process for purification

Iron rich: Low iron: typical composition:

typical composition: typical composition:
MgO 88 – 93 % MgO 90 – 97 % MgO 97,7 – 99,3 %
CaO 1,2 – 2,2 % CaO 0,5 – 1,9 % CaO 0,5 – 1,1 %
SiO2 0,8 – 2,5 % SiO2 0,5 – 2,5 % SiO2 < 0,1 – 0,3 %
Al2O3 0,1 – 1,5 % Al2O3 0,1 – 1,5 % Al2O3 < 0,1 %
Fe2O3 5–7% Fe2O3 0,2 – 1,0 % Fe2O3 0,1 – 0,5 %
BD 3,05 – 3,45 g/cm3 BD 3,05 – 3,45 g/cm3 BD 3,40 – 3,45 g/cm3

9
Quality Criteria of Magnesia

▪ Chemical Composition

- Amount of Secondary Phases

SiO2, CaO, Fe2O3, Al2O3, MnO

- CaO / SiO2 ratio

- Boron content (in seawater magnesia)

▪ Periclase (MgO) Crystal Size

Magnesite from Breitenau

▪ Bulk Density / Apparent Porosity

10
Influences on Final Brick Properties

11
Natural versus Synthetic Sintered Magnesia
Iron-rich magnesia sinter versus low iron magnesia sinter

12
CaO/SiO2 ratio

CaO/SiO2 ratio
Short 1 1,5
Name Formula Sm°C <1 1-1,5 1,5 – 2 2 >2
Notation (0,94) (1,4)
Periklas MgO M 2840 x x x x x x x
Magnesiaferrit MgFe2O4 MF 1715 x x x x x x x
Spinell MgAl2O4 MA 2135 (x) (x) (x) (x) (x) (x) -
Forsterit Mg2SiO4 M2S 1890 x - - - - - -
Monticellit CaMgSiO4 CMS 1492 x x x - - - -
Merwinit Ca3Mg[SiO4]2 C3MS2 1575 - - x x x - -
Dicalciumsilikat Ca2SiO4 C2S 2130 - - - - x x x
Calciumoxid CaO C 2580 - - - - - - x
Triclaciumsilikat Ca3[O/SiO4] C3S 2070 - - - - - - (x)
Calciumaluminat Ca3[AlO3]2 C3A 1535 - - - - - - (x)
Tricalciumborat Ca3[BO3]2 C3B 1485 (x) (x) (x) (x) (x) - -
Periclase (MgO) Crystal Size

Standard sintered magnesia

increased corrosion
BD: > 3,38 g/cm3

increased flexibility
Crystal size: 30-120 µm

resistance
LC-dead burned magnesia

BD: > 3,38 g/cm3

Crystal size: + 150µm

Fused magnesia

BD: > 3,38 g/cm3

Crystal size: > 350µm
 1 Introductions

2 Raw materials Sintered Magnesia

3 Raw materials Spinel

4 Brick types and Lining Recommendation

15
Types of Spinels

The spinel group is a big mineral family with similar crystal structure but different chemical
composition:

General formula: AB2O4 or AO·B2O3

where : A: Mg2+, Fe2+, Mn2+, Zn2+
B: Al3+ = Aluminate spinel
Fe3+ = Ferrite spinel

Cr3+ = Chromite spinel

Important spinels:
MgO · Al2O3 Spinel (MA)
FeO · Al2O3 Hercynite (fA)
MnO · Al2O3 Galaxite
MgO · Cr2O3 Picrochromite MA67

FeO · Fe2O3 Magnetite

(MgO, FeO)(Fe2O3, Al2O3, Cr2O3) Chromite
Hercynite
MA-Spinel, pre-reacted by sintering or fusion process

Sintered or fused MA Spinel

Production via sintering process in shaft kilns or fusion process in electric arc furnaces.
e.g. used in ANKRAL R2, ANKRAL R8, ANKRAL RC

Types of MA spinel:

MA78
Type MA 67 MA 78 MA 90
SiO2 0,08 0,09 0,07
CaO 0,28 0,21 0,09
Fe2O3 0,20 0,16 0,09 MA67

Na2O 0,08 0,08 0,17

fused spinel
Al2O3 66,70 76,60 90,70
MgO 32,70 22,90 8,90

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Hercynite, Galaxite – “Active Spinels”

Hercynite FeAl2O4
Galaxite MnAl2O4

Type Hercynite Galaxite

BD 4,2 4,2
SiO2 0,11 0,13
Production of Hercynite and Galaxite Spinel
via electro fusion in plant Radenthein (Austria)
CaO 0,18 0,15
Fe2O3 47,05 1,23

MnO 49,23

Al2O3 49,47 46,34

MgO 1,85 1,56

Fused Hercynite Spinel (iron-alumina)

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Classification of Magnesia Spinel Bricks

❑ Classification according to type of sintered magnesia

• Synthetic sintered magnesia AL-R1, AL-R2, AL-Z1, AL-QF

• Synthetic blend sintered Magnesia AL-R8, AL-Q1
• Natural sintered magnesia - low iron AL-RC, AL-ZC, AL-QC
• Natural sintered magnesia - iron rich AL-ZE, AL-ZE AF

❑ Classification according to type of spinel used

Pre-reacted,sintered or fused Spinel In-situ spinel
Self development during firing of
• MA-Spinel AL-R2, AL-R8, AL-RC magnesia bricks during production
• Hercynite Spinel AL-Z1, AL-ZC, AL-ZE, AL ZE-AF
• Q-Series AL-QF, AL-Q1, AL-QC • MA Spinel AL-R1, AL-RN
 Brick Types
Raw material combination

80-95% Component A 5-20% Component B

Resistor Flexibilizer

MgO
Spinel Spinosphere
(SYNTHETIC) Technology

NATURAL SYNTHETIC
PREFABRICATED IN SITU
Electrofused During Burning Process:
or Sintered •Corundum
Low iron •Tabular Alumina
High iron •Calcined Alumina

MgO-Al2O3 Fe2O3-Al2O3 Q-Series

(Hybrid Spinel)
(„conventional“ Spinel) (fused Hercynite)
 Product overview: Nomenclature

ANKRAL R_ R for magnesia MA-Spinel bricks

ANKRAL Z_ Z for magnesia Hercynite-Spinel bricks
ANKRAL Q_ Q for magnesia hybrid Spinel
ANKRAL X_ X for novel Spinosphere technology bricks

ANKRAL _E E for economic version in Europe

ANKRAL _C special products produced in China

Basic Brick Types

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Classification of (Basic) Magnesia Spinel Bricks

BASIC
Transition Zones Central Burning Zone
Magnesia Spinel Magnesia
CHEMICAL + THERMAL + MECHANICAL Spinel

ANKRAL R2 ANKRAL R1 ANKRAL ZC

ANKRAL QF
High-Severe ANKRAL RX ANKRAL Z1
ANKRAL QFX
ANKRAL QC
ANKRAL RX ANKRAL QCX
CHEMICAL

Medium- ANKRAL R8 ANKRAL Q1

ANKRAL R8X ANKRAL ZC
High ANKRAL R8X ANKRAL Q1X

ANKRAL RC ANKRAL RN ANKRAL QC

Standard ANKRAL RCX ANKRAL RCX ANKRAL QCX
ANKRAL ZC
Magnesite Sources
for basic cement rotary kiln bricks

Breitenau/AT

Aoding/CN

Eskeshehir/TR

Brumado/BR

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 Production of basic cement rotary kiln bricks

Mainzlar/D
MGG

Veitsch/AT
MGG

York/US Dalian/CN
DGG MGG

Ramos Arizpe/MX
MGG

Contagem/BR
MGG

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 Approach Asia Pacific
Shipping

Mainzlar/D
MGG

Veitsch/AT
MGG

York/US Dalian/CN
DGG MGG

Ramos Arizpe/MX
MGG

Contagem/BR
MGG

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 1 Introduction

2 Raw materials Sintered Magnesia

3 Raw materials Spinel

4 Brick types and Lining Recommendation

29
Product Range
for specific operation conditions

UTZ
CBZ

Outlet / LTZ

Central Burning Zone (CBZ) → bricks able to promote the formation of stable coating

Lower- and Upper Transition Zone (LTZ, UTZ) → bricks with elevated resistance to
chemical attack, mechanical stresses and thermal load

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Central Burning Zone (CBZ)
ANKRAL ZC made of low-iron magnesia from China
ANKRAL ZE and ZE-AF made of iron-rich magnesia from Europe

Alpine sintered magnesia significantly promotes the formation of a stable coating in

the CBZ due to the unique properties of the raw material.

Properties
• outstanding ability to form stable protective coating
• high flexibility due to use of Hercynite Spinel
• low thermal conductivity
Products

ANKRAL ZE
ANKRAL ZE AF

ANKRAL ZC (made of low-

iron magnesia from China)

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Products for the Central Burning Zone (CBZ)
ANKRAL product line of Standard Magnesia Hercynite Spinel Bricks
ANKRAL ZE ANKRAL ZE AF ANKRAL ZC

Special features:

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Products for Transition Zones with less chemical stresses

Magnesia Spinel bricks, manufactured at Dalian Plant (CHINA)

For Transition Zones without particularly severe operating conditions and with only
moderate chemical stress, RHIM supplies normal basic brick types based on natural
sintered magnesia.

▪ ANKRAL QC
▪ ANKRAL RC
▪ ANKRAL ZC

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Products for Transition Zones with less Chemical Stresses
Magnesia Spinel bricks, manufactured at Dalian Plant (CHINA)
ANKRAL ZC ANKRAL RC ANKRAL QC

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Thermal Load
Top-Quality brands based on high-purity, low-iron magnesia

In case of high thermal load refractories with a particular high content of MgO are
required. These products are also used for the lining of White cement kilns.

Due to the high MgO content these products are also very resistant to clinker melt
infiltration.

▪ ANKRAL Z1

▪ ANKRAL R1

▪ ANKRAL RN

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High Thermal Load
Top-Quality brands based on high-purity, low-iron magnesia
ANKRAL Z1 ANKRAL R1 ANKRAL RN

Properties
• MgO content >90% →
• Low in Al2O3 and Fe2O3
• Refractoriness >1700°C

Special features

+ ANKRAL Z1 and R1

36
Severe loaded Transition Zones (LTZ / UTZ)
The Transition Zones can be particularly exposed to severe stresses.
For the selection of the best suitable refractory material the process conditions need
to be evaluated in regard to the predominant stress phenomenon.
The nature of these phenomena can be

Thermal Mechanical Chemical

Specially designed brick grades are available for specific conditions.

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High Chemical Load I
Top grade basic bricks consisting of high purity magnesia and fused MA Spinel

High chemical stresses by the infiltration of alkali salts requires the use of
high purity sintered magnesia, in order to reduce the impact of corrosion of
the ceramic bonding. These top grade basic bricks are based on synthetic
sintered magnesia and therefore provide excellent chemical resistance.

▪ ANKRAL Z1
▪ ANKRAL R1
▪ ANKRAL R2
▪ ANKRAL R8

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 High Chemical Load I
Top Quality basic bricks consisting high purity magnesia and fused MA Spinel
ANKRAL Z1 ANKRAL R1 ANKRAL R2 ANKRAL R8

Properties
▪ Excellent chemical
resistance
▪ Low amount of secondary
phases (SiO2 + CaO)

▪ Excellent Refractoriness

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Chemical Load

Chemical wear is characterized by two effects:

I. Corrosion of the
brick structure,
ceramic
bonding
Chemothermal
Load
II. Densification of
the brick structure,
loss of flexibility

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High Chemical Load II

Besides the corrosion of the ceramic bonding, the infiltration of alkali salts
also severely reduces the structural flexibility of the refractory.
The implemented hybrid spinel technology significantly reduces this effect
and thus also significantly reduced the risk of crack formation and spalling.

▪ ANKRAL QF
▪ ANKRAL Q1
▪ ANKRAL QC

41
High Chemical Load II

ANKRAL QC Q1 QF

Properties
▪ Outstanding micro-structural flexibility
▪ Excellent refractoriness
▪ High to outstanding chemical resistance
▪ Excellent thermal-shock resistance

Special features

42
 Solutions for High Chemical Load
Top grade basic bricks based on top grade sintered magnesia (with low
CaO and SiO2 contents) and with outstanding resistance to chemical attack

ANKRAL R8 ANKRAL R1 ANKRAL R2 ANKRAL Z1 ANKRAL Q1 ANKRAL QF

conventional MA-spinel Hercynite Q-Series
Mechanical Load

The ANKRAL Q-Series is a product range designed to withstand the critical

conditions often encountered in the tyre section or in areas with kiln shell
deformations. The bricks of hybrid spinel technology provide a superior
flexibility and thermal shock resistance and have proved excellent results in
mechanically highly stressed areas.

▪ ANKRAL QF
▪ ANKRAL Q1
▪ ANKRAL QC

44
High Mechanical Load
Products for the LTZ / CBZ / UTZ
ANKRAL QC Q1 QF
Properties
• Outstanding micro-structural flexibility
• Excellent refractoriness
• High to outstanding chemical resistance
• Excellent thermal shock resistance

Special features

45
Comparison Youngs Modulus
Modulus of Elasticity

ANKRAL Q1

Even when infiltrated ANKRAL Q1 shows a lower Young’s modulus than a

conventional MA spinel brick type (e.g. ANKRAL R2, ALMAG 85 or MSN80).

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BASIC BRICKS Chinese production
Brand MgO CaO SiO2 Al2O3 Fe2O3 BD AP CCS TSR RUL Raw material
Air ta
% % % % % g / cm3 Vol. % N / mm2 Cycles ta °C

ANKRAL Q-Series

ANKRAL QF 87,0 0,7 0,3 9,3 2,7 2,97 15,5 70 >100 > 1700 Magnesia fused Hercynite +

ANKRAL Q1 86,8 1,1 0,5 9,0 2,6 2,97 16,0 70 >100 > 1700 Magnesia fused Hercynite +

ANKRAL QC 85,4 1,5 0,7 9,3 3,1 2,90 17,0 60 >100 > 1700 Magnesia fused Hercynite +

based on top grade sintered magnesia

ANKRAL Z1 91,8 0,8 0,3 3,4 3,8 2,99 15,0 80 >100 > 1700 Magnesia fused Hercynite

ANKRAL R1 90,8 0,8 0,3 7,5 0,5 2,96 15,0 70 >100 > 1700 Magnesia MA-Spinel

ANKRAL R2 87,9 0,8 0,3 10,5 0,5 2,95 16,0 65 >100 > 1700 Magnesia MA-Spinel

ANKRAL R8 85,7 1,1 0,5 12,0 0,5 2,92 16,0 70 >100 > 1700 Magnesia MA-Spinel

based on high quality natural sintered magnesia

ANKRAL ZC 89,5 1,5 0,7 4,0 4,3 2,96 15,5 80 >100 > 1700 Magnesia fused Hercynite

ANKRAL RC 86,6 1,5 0,7 10,5 0,7 2,92 16,0 70 >100 > 1700 Magnesia MA-Spinel

48
Case studies and references of ANKRAL Q1 and ANKRAL R8 for the
use in the Transition Zones

49
 Introduction & Brick Concept
ANKRAL Q1
ANKRAL Q1 made of top-grade synthetic sintered magnesia and application of unique Hybrid Spinel Technology

Raw Material Base

• Top-grade synthetic sintered magnesia
• Fused hercynite (FeO+Al2O3) + Fused MA Spinel
(Hybrid Spinel Technology)

Properties & Characteristics

• Outstanding micro-structural flexibility
• Very high resistance to chemical attack
• Excellent refractoriness
• Excellent thermal shock resistance
• High resistance to changing coating conditions

Areas of application in cement process

• Transition zones with severe mechanical and/or
thermo-chemical loads due to the use of
alternative fuels.

50
Case Study I – Germany
Upper Transition Zone and extended Upper Transition Zone
Kiln Type / Dimension: PC kiln, dia. 5,2 x 61 m
Clinker Capacity [tpd]: ~ 5400 tpd
Fuel Type: 75-80% AF

Brand: ANKRAL Q1
Kiln Zone: UTZ and extended UTZ

1st Application in area: 47,6 – 51,7 m (from Outlet), tire area

Date of Installation: Feb 2019 and removal in Feb 2020
Residual Thickness [mm]: no information

2nd Application in Area: 41,0 – 51,0 m (from Outlet)

Date of Installation: Feb 2020 - no removal in Feb 2021
Residual Thickness [mm]: 220 mm (in September 2020)
150-220 mm (January 2021)

Usual time in Operation: 1 year – now 2nd campaign in a row

and
no removal of bricks after 12 months

Previous used Materials: ANKRAL QE

Wear Mechanism: Increased thermo-chemical attack

and mechanical stresses from tire

Performance Indicator: Excellent performance

51
 Case Study I – Germany
Upper Transition Zone and extended Upper Transition Zone

• Pictures taken from the second use, again after 1 year operation, in February 2021
• Spalling only on a few (individual) bricks due to additionally mechanical loads
• No reason for exchange of ANKRAL Q1 and accordingly use for a further production campaign

52
 Case Study II – Turkey
Upper Transition Zone
Kiln Type / Dimension: PC kiln, dia. 5 m x 58,66 m
Clinker Capacity [tpd]: ~ 5200 tpd
Fuel Type: ~ 80% Petcoke + Lignite

Brand: ANKRAL Q1
Kiln Zone: UTZ
Area of 1st Application: 27,3– 29,8 m (from Outlet)
Date of Installation Mai 2016

Area of 2nd Application: 16 – 28,8 m (from Outlet)

Date of Installation: March 2017

Area of 3rd Application: 1,6-3 m (Kiln Outlet area)

16–30 m (from Outlet)
Date of Installation: Jul.2019
Kiln Zone: Mainly UTZ

Time in Operation: continuous use of ANKRAL Q1

in the UTZ area within the last
5 years

Date of Removal: Full campaigns (yearly)

Performance Indicator: Excellent performance,

without notable premature wear

53
Case Study III – Turkey
Upper Transition Zone
Kiln Type / Dimension: PC kiln, dia. 6 m x 90 m
Clinker Capacity [tpd]: ~ 11300tpd
Fuel Type: ~ 30% Petcoke + Lignite

Brand: ANKRAL Q1
Kiln Zone: UTZ

1st Area of Application: 34 m – 43,2 m (from

Outlet)
Date of Installation September 2019

2nd Area of Application: 34 m – 43,2 m

Date of Installation November 2020

Date of Removal: Full campaigns (yearly).

last 2 campaigns with
14 months service life

Time in Operation: Continuous use in the

last 3 years

Performance Indicator: Excellent performance

54
Case IV : ANKRAL Q1 – United Arab Emirates
PC kiln, 5,0 / 5,2 x 78 m – Kiln Outlet Zone and Lower Transition Zone
ANKRAL Q1 in Outlet Section (02/2017 –
09/2017)
In February 2017 ANKRAL Q1 had been
installed instead of ALMAG 85 in Kiln Outlet
area and Lower Transition.
2 x 500 mm Bonded Lining had been
installed (interlock) to combat increased
lining thrust. (Caused by bad mechanical
condition of the tire at kiln outlet side)
In September 2017 the kiln had to be
stopped as segments from the Nosering
had been fallen (TUFDURA S600)
ANKRAL Q1 found to be twisted in the
outlet area – 20 pcs had been patched.
Residual thickness 200 mm after 7 months
in the kiln outlet area, despite unusually
high tire migration of 40 mm/revolution on
Tire # 1 and thus effect of extremely high
shear forces on the installed brickwork.

2 x 500mm bonded brickwork in

front of the retaining ring

55
Case V : ANKRAL Q1 - United Arab Emirates
PC kiln, 6,2 x 98 m – Upper Transition Zone and Kiln Outlet Section

▪ Kiln Data:
▪ Design capacity = 10.000 tpd
▪ operating capacity =11.000 tpd
▪ Natural Gas fired kiln, severe load
Na2O, Cl and K2O load, long flame
with even heat distribution
▪ Mechanical Condition alarming
high at tire # 1 with more than
40mm tire clearance
▪ In thermo-chemically highly
stressed UTZ area ANKRAL Q1
shows very good performance with
repeated 12 months service life

New installed ANKRAL Q1 in UTZ

area (22m-35m), in April 2021
56 Note: Olo verione por adis que
Comparison between ANKRAL Q1 and ANKRAL QF

57
 Introduction & Brick Concept
Top Quality grade ANKRAL R8

Raw Material Base

• Top-grade synthetic sintered magnesia
• High-grade natural sintered magnesia
• Pre-fabricated, fused MA-spinel (MgO*Al2O3)

Properties & Characteristics

• Excellent refractoriness
• Very high resistance to chemical attack
• Excellent micro-structural flexibility
• Excellent thermal shock resistance
• High resistance to changing coating conditions

Areas of application in cement process

• Heavily loaded transition zones with high chemo-
thermal, thermal or mechanical loads and
frequently changing coating conditions.

59
 CASE STUDY : ANKRAL R8
3 References in INDIA

KILN NAME A B1 B2
KILN  (mts) 4.0 x 60 4.0 x 60 4.0 x 60
Tyre Position (T1 mts 5 5 5
from outlet)
Tyre Position (T2 in 23 23 23
mts from outlet)
Tyre Position (T3in 48 48 48
mts from outlet)
Fuel (Main Burner) 100% Pet Coke 100% Pet Coke 100% Pet Coke
Production TPD 4200 4200 3600

Previous History : In all the three kilns previously customer using Ankral R1 in the Upper
Transition Zone and the customers were getting lining life close to 345 days.
Refractory Cost Optimization : In order to optimize the cost of refractory the customer installed
Ankral R8 in his kiln B1 in area 27m-31m on trial basis during 2016.
After 331 days in spite of good residual thickness, the lining was changed as Company policy.

60
 CASE STUDY : ANKRAL R8 (continued)
Reference : INDIA
Kiln B1 Kiln A

Based on excellent performance of Ankral R8 in kiln B1, customer relined with this Top grade in Kiln
B1 kiln from 17-30 mts during Aug’2018 annual shutdown and moreover also in a problem area 17-25
mts in his kiln A during October 2018 annual shutdown.
Then again customer installed Ankral R8 in Upper Transition Zone in Kiln A during Aug’2019 annual
shutdown and lining was changed in Aug’2020. Customer achieved therefore full one year life.
Similarly, customer installed Ankral R8 in UTZ of kiln B1 during April’2019 (Kiln was stopped before
scheduled due to mechanical issues) and during July’2020 shutdown. Refractory lining is still under
service today.
61
CASE STUDY : ANKRAL R8 (Continued.....)
Reference : INDIA

Kiln B 2

Based on Kiln B1 performance Ankral R8 installed in UTZ area in Kiln B2 during Oct 2019 from
17-31 mtrs. Customer got in 17-24 mtr area 440 days lining life.
The remaining bricks in 24-31 mtr are still in service as shown in above photograph.
Customer overall optimized the cost with improved performance over Ankral R1 and other, similar
competitor refractory.
Now customer has planned to install Ankral R8 in LTZ areas also in the upcoming shutdowns for
Kiln B1 and Kiln A.

62
Case Study – Vietnam
ANKRAL R8 in Lower Transition Zone

Kiln Type / Dimension: PC kiln, dia. 5,2 x 82 m

Clinker Capacity [tpd]: ~ 6150 tpd
Fuel Type: Anthracite Coal, 40% main burner
+ 60% Calciner Burner

Brand: ANKRAL R8
220mm lining thickness 175 mm residual thickness, after use of
Kiln Zone: LTZ 12 months
1st Application in area: 1,74 – 4,2 m (from Outlet)
Date of Installation: August 2013

Kiln inspection: January 2014

Residual Thickness [mm]: 210 - 220 mm (after 5 months)

Date of Replacement: August 2014

Residual Thickness [mm]: 175 mm (after 12 months)

Service life in Operation: 1 year

Previous used Materials: TOPMAG A1 (6 – 8 months)

Wear Mechanism: Increased thermo-chemical attack

and thermal shocks

Performance Indicator: Excellent performance

63
Case Study – Vietnam
ANKRAL R8 in Lower Transition Zone
Date of Installation: August 2013

Kiln inspection after 5 months: January 2014

64
Case Study – Saudi Arabia
ANKRAL R8 in LTZ and Burning Zone
Kiln Type / Dimension: PC kiln, dia. 4,8 x 52 m
Clinker Capacity [tpd]: ~ 4100 tpd
Fuel Type: HFO, 40% main burner
+ 60% Calciner Burner

Brand: ANKRAL R8 MSN 80 bricks (after 8 months)

220mm lining thickness
Kiln Zone: LTZ

1st Application in area: 1,25 – 10,25 m (from Outlet)

Date of Installation: 12th July 2016
Date of Replacement: October 2017
Residual Thickness [mm]: 140 mm (after 14 months)
Service life in Operation: 14 months

2nd Application in area: 13 – 18,2 m (from Outlet)

Date of Installation: 14th May 2016
Service life in Operation: 17 months

Previous used Materials: MAGKOR B2 (8 months),

TOPMAG AF (11 – 13 months)
MSN 80 (8 months)

Wear Mechanism: Increased thermo-chemical attack

by clinker melt infiltration + very
high mechanical load

Performance
65
Indicator: Very good performance
Comparison between ANKRAL R8 and ANKRAL R2

66
Lining Concepts
RHI MAGNESITA VS REFRATECNIK

LTZ CBZ UTZ SZ CZ

RESISTAL B50
ANKRAL RC ANKRAL ZC ANKRAL RC RESISTAL B70
Normal MAXIAL 42
Conditions
REFRAMAG S FERROMAG S REFRAMAG S RA SIC T RA 40T

RESISTAL B50SIC GS
ANKRAL RC, QC ANKRAL RC, QC RESISTAL B55SIC GS
Higher ANKRAL ZC MAXIAL 334SIC
ANKRAL RCX, QCX ANKRAL RCX, QCX RESISTAL M55SIC-IN
MAXIAL 42DIS-IN
Thermo-chemical
load TOPMAG TR PLEOMAG 90 TOPMAG TR RA SIC T RA 60T

ANKRAL R8, Q1 ANKRAL R8, Q1 RESISTAL B65SIC RESISTAL B55SIC GS

Severe ANKRAL ZC, QC, QCX
ANKRAL R8X, Q1X ANKRAL R8X, Q1X RESISTAL S60IS-IN RESISTAL B50ZIS-IN
Thermo-chemical
load TOPMAG AF, A1 TOPMAG FS, TR TOPMAG AF, A1 RA SIC T RA SIC T

Caution!!! : Do not mistaken all products for being in the same grade
67
Lining Concepts
RHI MAGNESITA VS SRIC

LTZ CBZ UTZ SZ CZ

RESISTAL B50
ANKRAL RC ANKRAL ZC ANKRAL RC RESISTAL B70
Normal MAXIAL 42
Conditions TUFMAG XS TUFMAG XS
NEOMAG F PH 70 AF PH 40 AF
TUFMAG AF TUFMAG AF
RESISTAL B50SIC GS
ANKRAL RC, QC ANKRAL RC, QC RESISTAL B55SIC GS
Higher ANKRAL ZC MAXIAL 334SIC
ANKRAL RCX, QCX ANKRAL RCX, QCX RESISTAL M55SIC-IN
MAXIAL 42DIS-IN
Thermo-chemical
load NEOMAG S 90
TUFMAG AF TUFMAG AF KEMRESIS KEMRESIS
MULTIMAG
ANKRAL R8, Q1 ANKRAL R8, Q1 RESISTAL B65SIC RESISTAL B55SIC GS
Severe ANKRAL ZC, QC, QCX
ANKRAL R8X, Q1X ANKRAL R8X, Q1X RESISTAL S60IS-IN RESISTAL B50ZIS-IN
Thermo-chemical
load TUFMAG AF
MULTIMAG MS 80 AF KEMRESIS KEMRESIS
MS 80 AF

Caution!!! : Do not mistaken all products for being in the same grade
68
Get in touch
Edgar Schulz

Technical Marketing Manager

Kranichberggasse 6
A - 1120 Vienna (Austria)
Phone: +43 699 1870 6339
E-mail: edgar.schulz@rhimagnesita.com

Important notice:

These materials do not constitute or form part, or all, of any offer of invitation to sell or issue,
or any solicitation of any offer to purchase or subscribe for, any securities in any jurisdiction
in which such solicitation, offer or sale would be unlawful, nor shall part, or all, of these
materials form the basis of, or be relied on in connection with, any contract or investment
decision in relation to any securities.

These materials contain forward-looking statements based on the currently held beliefs and
assumptions of the management of RHI Magnesita N.V. or its affiliated companies, which are
expressed in good faith and, in their opinion, reasonable. Theses statements may be
identified by words such as “expectation” or “target” and similar expressions, or by their
context. Forward-looking statements involve known and unknown risks, uncertainties and
other factors, which may cause the actual results, financial condition, performance, or
achievements of RHI Magnesita N.V. or its affiliated companies to differ materially from the
results, financial condition, performance or achievements express or implied by such forward-
looking statements. Given these risks, uncertainties and other factors, recipients of this
document are cautioned not to place undue reliance on these forward-looking statements.
RHI Magnesita N.V. or its affiliated companies disclaims any obligation to update these
forward-looking statements to reflect future events or developments.