2 - Basic Bricks - Dec 2017 Incl RED2
2 - Basic Bricks - Dec 2017 Incl RED2
Subtitle
Vienna, Nov. 1st 2017
1 Introduction
2
Production of basic cement rotary kiln bricks
Hagen/D
DGG
Mainzlar/D
MGG
Veitsch/AT
MGG
York/US Dalian/CN
DGG MGG
Ramos Arizpe/MX
MGG
Contagem/BR
MGG
3
Approach E – ME – A – CIS – IN
Shipping
Hagen/D
DGG
Mainzlar/D
MGG
Veitsch/AT
MGG
York/US Dalian/CN
DGG MGG
Ramos Arizpe/MX
MGG
Contagem/BR
MGG
4
Products for the Cement Industry
BRICKS CASTABLES
ANKRAL
BASIC
MAGKOR
MAXIAL COMPRIT
NON-BASIC RESISTAL DIDURIT
LEGRAL LEGRIT
shaped unshaped
13
Conditions in a Cement Rotary Kiln
High temperature
Dynamic mechanical load
Chemical attack /
alkali salts,
clinker melt
15
Basic Bricks for Cement Rotary Kilns
Magnesia
High thermal resistance
High chemical resistance
Spinel
as flexibilising additive
16
1 Introductions
17
Types of Sintered Magnesia
18
From Raw Material to Sintered Magnesia (DBM)
coarse crystalline:
alpine type: Breitenau
Hochfilzen
Radenthein
Magnesium-chloride
sea water or salt lakes, salt brines and salt
deposits
Magnesium-hydroxide (brucite)
deposits (CIS; China …)
without importance for refractories
Breitenau Mine/Styria, Austria
19
From Raw Material to DBM
Example of Breitenau
20
Production of Magnesia from Sea Water
Synthetic Magnesia
1000°C
Mg(OH)2 MgO + H2O (CCM) D~2 g/cm3
Briquetting
21
Types of Magnesia
Natural Magnesia Synthetic Magnesia
Source: salt brine MgCl
Source: Magnesite MgCO3
sea water MgCl
22
Quality Criteria of Magnesia
Chemical Composition
- CaO/SiO2 ratio
- Boron content
23
Influences on Final Brick Properties
24
Natural vs. Synthetic Sintered Magnesia
25
CaO/SiO2 ratio
CaO/SiO2 ratio
Short 1 1- 1,5 2
Name Formula Sm <1 1,5 – 2 >2
Notation (0,94) 1,5 (1,4) (1,87)
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
Dicalciumferrit Ca2Fe2O5 C2F 1449 - - - - - - x
Brownmillerit Ca2FeAlO5 C4AF 1415 - - - - - - x
Calciumaluminat Ca3[AlO3]2 C3A 1535 - - - - - - (x)
Periclase Crystal Size
increased corrosion
BD: > 3,38 g/cm3
increased flexibility
Crystal size: 30-120 µm
resistance
LC-dead burned magnesia
Fused magnesia
28
Types of Spinels
The spinel group is a big mineral family with similar crystal structure but different chemical
composition:
Important spinels:
MgO · Al2O3 Spinel (MA)
FeO · Al2O3 Hercynite (fA)
MnO · Al2O3 Galaxite
MgO · Cr2O3 Picrochromite MA67
MgO
Spinel Chromite
(SYNTHETIC) (NATURAL)
NATURAL SYNTHETIC
PREFABRICATED IN SITU
Electrofused During Burning Process:
or Sintered •Corundum
Low iron •Tabular Alumina
High iron •Calcined Alumina
MA FA MnA Q-Series
(Hybrid Spinel)
(„Standard“ Spinel) (fused Hercynite) (fused Galaxite)
1 Introductions
33
Nomenclature
for basic cement rotary kiln bricks
ANKRAL R 2 CB XY
Type of spinel:
R – MA-spinel
Z – Hercynite
Q – Hybrid spinel technology
S – Chromium spinel
34
Nomenclature MAGKOR
MAGKOR S 2
Product lines:
Superior
Special products for extreme conditions
Top grade
MAGKOR: basic brick for cement rotary kilns
products for aggressive conditions
Standard
products for regular conditions
35
Product Range
for specific operation conditions
UTZ
CBZ
Outlet / LTZ
Central burning zone (CBZ) bricks able to promote the formation of stable coating
36
Central Burning Zone (CBZ)
Properties
• outstanding ability to form stable protective coating
• high flexibility due to use of hercynite
• low thermal conductivity
Products
ANKRAL ZE
ANKRAL ZE AF
ANKRAL QE
37
Products for the Central Burning Zone (CBZ)
ANKRAL range
ANKRAL ZE ANKRAL ZE AF ANKRAL QE
Special features:
38
Products for the Central Burning Zone (CBZ)
MAGKOR range
MAGKOR A1 MAGKOR A2 MAGKOR A3
Special features:
MAGKOR A2
39
Transition Zones (LTZ/UTZ)
40
Thermal Load
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
41
High Thermal Load
Products for the LTZ / UTZ
ANKRAL Z1 ANKRAL R1 ANKRAL RN
Properties
• MgO content >90%
• Low in Al2O3 and Fe2O3
• Refractoriness >1700°C
Special features
+ ANKRAL R1/RN
42
High Thermal Load
Products for the LTZ / UTZ
MAGKOR S7
Properties
• Addition of ZrO2
- improves hot properties
- improves resistance to clinker melt infiltration
• Refractoriness >1700°C
Special features
43
Mechanical Load
RHI has developed a complete new product range to withstand the critical
conditions often encountered in the tyre section or in areas with kiln shell
deformations. The so called hybrid spinel technology provides superior
flexibility and has proved excellent results in mechanically highly stressed
areas.
ANKRAL QF
ANKRAL Q1
ANKRAL Q2/QC
ANKRAL QE
44
High Mechanical Load
Products for the LTZ / CBZ /UTZ
ANKRAL QE Q2 Q1 QF
Properties
• Outstanding micro-structural flexibility
• Excellent refractoriness
• High to outstanding chemical
resistance
Special features
ANKRAL QE ANKRAL Q2 / Q1 / QF
45
Chemical Load
I. Corrosion of the
brick structure,
ceramic
bonding
Chemothermal
Load
II. Densification of
the brick structure,
loss of flexibility
46
High Chemical Load I
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.
RHI´s top grade basic bricks are based on synthetic sintered magnesia and therefore
provide excellent chemical resistance.
ANKRAL Z1
ANKRAL R1
ANKRAL R2
ANKRAL R8
47
High Chemical Load I
ANKRAL range
ANKRAL Z1 ANKRAL R1 ANKRAL R2 ANKRAL R8
Properties
Excellent chemical
resistance
Low amount of side phases
(SiO2 + CaO)
48
ANKRAL R8: Reference India
Kiln Details
Kiln:
FLS 4,35 x 66m
PC with grate cooler
4.300 tpd
Situation:
ANKRAL R8 lined in the LTZ between 0-8m. Before used ANKRAL Z1 and ANKRAL R2..
49
ANKRAL R8: Reference India
Results after a full campaign
50
ANKRAL R8: Reference India
Chemical Investigation
51
High Chemical Load I
MAGKOR range
MAGKOR B1 MAGKOR B2 MAGKOR B3
Properties
Excellent chemical
resistance
Low amount of side phases
(SiO2 + CaO)
52
High Chemical Load I
MAGKOR S2
53
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
thereby significantly reduced the risk of crack formation and spalling.
ANKRAL QF
ANKRAL Q1
ANKRAL Q2
54
High Chemical Load II
ANKRAL Q2 Q1 QF
Properties
Outstanding micro-structural flexibility
Excellent refractoriness
Outstanding chemical resistance
55
Comparison Youngs Modulus
Modulus of Elasticity
56
ANKRAL QF
Reference Germany
Kiln: 5,2 x 87m SP with satellite coolers, 2.500 tpd
Lining area: UTZ tyre between rm 31,6 and 35,6
Tyre creep within campaign: about 40mm/rev
Fuels:
Main burner: bituminous coal, plastics, solvents (AF approx 70%)
Inlet: tyre chips
Situation:
The usual lining life until now has been limited to 4 months due to strong mechanical
and chemical load in the tyre section.
57
Results
after full campaign of 12 months
Brick shows nearly full residual thickness (205mm from original 220mm) with clear
signs of severe chemo-thermal and mechanical load (scratch marks and damages on
the cold face).
Furthermore there are reducing operation conditions.
58
Results
after full campaign of 12 months
59
Results
Chemical investigation Cusomter SPZ
Plant Germany
Aggregate Cement Rotary Kiln
Lining Area UTZ
Brick type ANKRAL QF ANKRAL QF
2-25 mm 75-100 mm 130-155 mm 180-205 mm
Data sheet
Sampling from hot face from hot face from hot face from hot face
61
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
thereby significantly reduced the risk of crack formation and spalling.
ANKRAL QF
ANKRAL Q1
ANKRAL Q2
62
Products for TZ with Moderate Chemical Stresses
For transitions zones without particular severe operation conditions and moderate
chemical stresses RHI provides basic bricks based on natural sintered magnesia.
ANKRAL RE
ANKRAL RN
ANKRAL ZC
ANKRAL RC
63
Products for TZ with Moderate Chemical Stresses
ANKRAL range
ANKRAL RE ANKRAL RN ANKRAL ZC ANKRAL RC
64
Products for TZ with Moderate Chemical Stresses
or higher loaded burning zones
MAGKOR A1
65
Coating Repellent Bricks
66
BASIC BRICKS European production
Brand MgO CaO SiO2 Al2O3 Fe2O3 Cr2O3 BD AP CCS TSR RUL Raw material
Product overview basic bricks Air ta
% % % % % % g / cm3 Vol. % N / mm2 Cycles °C
Q-concept bricks
ANKRAL QF 87,0 0,7 0,3 9,3 2,7 --- 2,97 16,0 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 Q2 86,3 1,6 0,8 9,0 2,3 --- 3,00 16,0 70 >100 > 1700 Magnesia fused Hercynite +
ANKRAL QE 81,4 2,0 0,6 9,0 6,5 --- 2,99 16,5 75 >100 1680 Magnesia fused Hercynite +
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
REXAL 2S Extra R2 85,9 0,8 0,2 12,5 0,4 --- 2,94 15,5 60 >100 > 1700 Magnesia MA-Spinel
ANKRAL RE 86,8 1,7 0,8 10,5 0,2 --- 2,96 16,0 70 >100 > 1700 Magnesia MA-Spinel
ANKRAL RN 91,2 1,8 0,8 6,0 0,2 --- 2,94 16,5 75 >100 > 1700 Magnesia MA-Spinel
ANKRAL ZE AF 87,8 2,0 0,9 3,0 6,3 --- 3,04 16,0 90 >100 > 1700 Magnesia fused Hercynite
Basic Brick85,9
ANKRAL ZE Types
2,0 1,0 3,0 8,0 --- 3,02 16,5 90 >100 1600 Magnesia fused Hercynite
BASIC BRICKS Mexican Production
Brand MgO CaO SiO2 Al2O3 Fe2O3 Cr2O3 BD AP CCS TSR RUL Raw material
Air ta
3 2
% % % % % % g / cm Vol. % N / mm Cycles °C
Q-concept bricks
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 Q2 86,3 1,6 0,8 9,0 2,3 --- 3,00 16,0 70 >100 > 1700 Magnesia fused Hercynite +
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
REXAL 2S Extra 85,9 0,8 0,2 12,5 0,4 --- 2,94 15,5 60 >100 > 1700 Magnesia MA-Spinel
ANKRAL RE 86,8 1,7 0,8 10,5 0,2 --- 2,96 16,0 70 >100 > 1700 Magnesia MA-Spinel
BASIC BRICKS Chinese production
Product
Brandoverview
MgO basic
CaO SiO bricks
Al O Fe O 2 2 3 2 3 BD AP CCS TSR RUL Raw material
Air ta
3 2
% % % % % g / cm Vol. % N / mm 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 +
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
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
69
Basic Brick Types
BASIC BRICKS Brazilian/European production
Brand MgO CaO SiO2 Al2O3 Fe2O3 ZrO2 BD AP CCS TSR RUL Raw material
Air ta
Product overview
% basic
% % bricks
% % % g / cm3 Vol. % N / mm2 Cycles °C
MAGKOR S-Grades
MAGKOR S2 86,5 0,8 0,30 11,5 0,5 --- 3,03 14,0 85 > 100 > 1700 Magnesia MA Spinel
MAGKOR S3 89,0 0,8 0,30 9,0 0,5 --- 2,95 16,0 79 > 100 > 1700 Magnesia MA Spinel
MAGKOR S7 84,5 1,0 0,30 11,0 0,4 1,80 3,00 15,0 70 > 100 > 1700 Magnesia MA Spinel
MAGKOR B-Grades
MAGKOR B1 85,9 0,8 0,20 10,5 0,5 --- 2,94 16,0 65 > 100 > 1700 Magnesia MA Spinel
MAGKOR B2 87,9 0,8 0,30 10,5 0,5 --- 2,95 16,0 65 > 100 > 1700 Magnesia MA Spinel
MAGKOR B3 90,8 0,8 0,30 7,5 0,5 --- 2,96 15,0 70 > 100 > 1700 Magnesia MA Spinel
MAGKOR B5 91,5 0,8 0,40 6,5 0,6 --- 2,95 16,0 60 > 100 > 1700 Magnesia MA Spinel
MAGKOR A-Grades
MAGKOR A1 86,6 1,5 0,70 10,5 0,7 --- 2,92 16,0 70 > 100 > 1700 Magnesia MA Spinel
MAGKOR A2 87,1 0,5 1,30 7,5 2,2 --- 2,87 19,7 64 > 100 > 1700 Magnesia MA Spinel
MAGKOR A3 87,0 0,6 1,20 8,5 1,4 --- 2,90 18,0 65 > 100 > 1700 Magnesia MA Spinel
70
Basic Brick Types
Get in touch
Roland Krischanitz
Head of Technical Marketing
Wienerbergstrasse 9
1100 Vienna Austria
Phone: +43 50213 6720
E-mail: roland. krischanitz@rhimagnesita.com
rhimagnesita.com
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