CHOOSING AND INSTALLING MONOLITHIC REFRACTORIES
‘BOY’ ILANO III (PME) - President & GM
360 Degrees Marketing and Services Industry, Inc.
(Engineers and Consultants, Refractory Specialists, Manufacturer’s Representative)
In order to design a
lining that will
work,
we need to
understand
the reasons why
linings fail.
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
Factors that cause linings to fail include:
•
•
•
•
•
•
•
Material selection
Thermal design
Mechanical design
Mechanical / Chemical damage
Anchoring failure
Installation
Commissioning
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
THE FOUR (4) MAJOR INSTALLATION GRADES OF
MONOLITHIC REFRACTORIES
CASTING Grades
GUNNING Grades
RAMMING Grades
PATCHING (Trowelling) Grades
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
Relative Tendencies of the SiO2 – Al2O3
Castable Refractories
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
Tendency 1 - Higher Alumina Castables tend
to have higher Service Temperatures.
Tendency 2 - Higher Alumina Castables tend
to have higher Densities (Net Quantity of
Dry Material Required for Placement,
kg/m³), hence, higher material
consumptions.
Tendency 3 - Higher Density Castables tend
to have higher Compressive Strengths but
lower Thermal Shock Resistance.
Tendency 4 - High Alumina Castables tend to
have lesser resistance to Alkali Attack.
Conversely, lower Alumina Castables are
more resistant to Alkali Attack.
Tendency 5 - Mullite is the only stable
compound in the binary system of the silicaalumina. It has excellent high temperature
properties with improved thermal shock and
thermal stress resistance owing to its low
thermal expansion, good mechanical
strength and interlocking grain structure.
Generality 5 – Silicon Carbide is a high
thermal conductivity material coupled with
low thermal expansion and high strength
giving it an exceptional thermal shock
resistant qualities. It is not attacked by any
acids or alkalis or molten salts up to 800°C.
Silicon Carbide is a high thermal conductivity material coupled with
low thermal expansion and high strength giving it an exceptional
thermal shock resistant qualities. It is not attacked by any acids or
alkalis or molten salts up to 800°C.
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
SiC
O2
Al2O3
SiC SiC
O2
O2
Al2O3
Al2O3
O2
SiC
O2
Al2O3
O2
SiC
O2
Al2O3 O2
O2
SiC
SiC
O2
SiC
Al2O3
Very Oxidizing conditions and
High Temperature
SiO2 SiO2
SiO2
(gas)
CO2
(gas)
CO2 CO2
Al2O3
O2
O2
O2 Al2O3
Al2O3
O2
O2
O2
O2
O2
O2 Al2O3
O2
Al2O3
O2 Al2O3
O2
SiC
SiC
More Oxidizing conditions and
Higher Temperature
COMPARISON – 1: ECONOMICS BETWEEN HASLE REFRACTORY CASTABLES VS. SOME TYPICAL EQUIVALENTS
(Based on ALKALI ATTACK Resistance Requirements)
Cost Comparisons and its Impacts
HASLE
P a r t i c u l a r s
Caldery's
Caldery's
Caldery's
D39A
Gibram SR E
Taicast L60 A
SR
Thercoflow
5560
1,500
2,200
1,700
3,050
1,550
2,500
1,500
2,600
PHYSICAL DATA:
Maximum Serice Temperature
(deg.C)
Density (Net Quantity of Dry Material Required for Placement)
(kgs./m3)
MODULUS OF RUPTURE
(Mpa)
after heating to
110deg.C
500deg.C
1,000deg.C
1,500deg.C
COLD CRUSHING STRENGTH
after drying to
Viewed from the 2nd
Dimension of Cost:
D39A = P85*2,200
= P187,000/m3
Gibram = P85*3,050
= P259,250/m3
(39% more expensive)
16
16
18
16
(Mpa)
110deg.C
500deg.C
1,000deg.C
1,500deg.C
115
120
130
150
62
37
50
135
66
71
(@1450deg.C
1.15
6.3
(@1450deg.C
THERMAL CONDUCTIVITY:
400deg.C W/mK
800deg.C W/mK
1,200deg.C W/mK
ALKALI TEST
(scale 0 - 10 mm.)
RESISTANCE TO ABRASION (Abrasion Loss by Grinding, g/cm3)
at 20deg.C
RESISTANCE TO ABRASION (Erosion Loss by Blast Abrasion @ 90deg. angle, cm3)
1,000deg.C
RESISTANCE TO THERMAL SHOCK (Retained Strength)
CHEMICAL ANALYSIS
2.40
(%)
Al2O3
SiO3
Fe2O3
CaO
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
1.16
1.28
1.51
0
0.30
4.40
Good
SiC
39
56
1.4
1.6
0
Assumed Prices:
P85/kg. & P85/kg.
Given Densities:
2,200kgs./m3
3,050kgs./m3
87.4
7.6
0.5
1.2
0
58.4
36.8
0.8
1.3
0
26.2
0.2
1.5
59
Gibram + Thercoflow 5560
= P85/kg. + P125/kg. (assumed)
= P105/kg., average price
Average Density = 3,050 +
2,600 = 2,825kgs./m3
Composite Price = P105* 2,825
= P296,625/m3
(59% more expensive)
Taicast L60A + Thercoflow
5560
= P75/kg. + P125/kg. (assumed)
=P100/kg., average price
Average Density = 2,500 +
2,600 = 2,550kgs./m3
Composite Price
=P100*2,550kgs./m3
= P255,000/m3
(36% more expensive)
The Effects of castable Temperatures.
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
WATER ADDITION
=
5.2%
SO CASTABLE MATERIAL = 94.8%
TOTAL MASS PER MIX
= 100.0%
SO, COOL YOUR CASTABLES
MORE,
THAN CONCENTRATING ON
COOLING YOUR WATER.
The IMPLIMENTATION of Tactical Plans – The Effects of castable Temperatures.
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
The Dangers of Water Control through plastic containers.
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
The Dangers of Water Control through plastic containers.
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
The Dangers of Water Control through plastic containers.
1.5liters Mineral Water plastic container filled-up 100%
weighed exactly 1.5kgs. in calibrated weighing scale.
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
The Dangers of Water Control through plastic containers.
1.5liters Mineral Water plastic container filled-up partially to
simulate the most likely section where it will be cut to facilitate
easy scoping of water during water addition weighed only around
1.3kgs. in calibrated weighing scale. This translates to approx.
13.33% loss in water addition which will find its effects to the
castable mix during casting installations.
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
The Dangers of Water Control through plastic containers.
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
The Dangers of Water Control through plastic containers.
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
The Effects of Adding More Water Than Necessary.
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
.
The Critical Pre-Shutdown Activities
WATER ADDITION GUIDELINES FOR HASLE LCC MONOLITHIC MATERIALS
Particulars
D39A
%
5.0
5.5
6.0
Particulars
D52A
%
4.0
4.6
5.2
Particulars
D59A
%
4.0
4.4
4.8
KILOGRAMS TO BE MIXED
25
50
75
100
125
150
175
200
225
1BAG
2BAGS
3BAGS
4BAGS
5BAGS
6BAGS
7BAGS
8BAGS
9BAGS
250
275
300
10BAGS 11BAGS 12BAGS
1.25 2.50 3.75 5.00 6.25 7.50 8.75 10.00 11.25 12.50 13.75 15.00
1.38 2.75 4.13 5.50 6.88 8.25 9.63 11.00 12.38 13.75 0.50 16.50
1.50 3.00 4.50 6.00 7.50 9.00 10.50 12.00 13.50 15.00 16.50 18.00
KILOGRAMS TO BE MIXED
25
50
75
100
125
150
175
200
225
1BAG
2BAGS
3BAGS
4BAGS
5BAGS
6BAGS
7BAGS
8BAGS
9BAGS
250
275
300
10BAGS 11BAGS 12BAGS
1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00 11.00 12.00
1.15 2.30 3.45 4.60 5.75 6.90 8.05 9.20 10.35 11.50 0.60 13.80
1.30 2.60 3.90 5.20 6.50 7.80 9.10 10.40 11.70 13.00 14.30 15.60
KILOGRAMS TO BE MIXED
25
50
75
100
125
150
175
200
225
1BAG
2BAGS
3BAGS
4BAGS
5BAGS
6BAGS
7BAGS
8BAGS
9BAGS
250
275
300
10BAGS 11BAGS 12BAGS
1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00 11.00 12.00
1.10 2.20 3.30 4.40 5.50 6.60 7.70 8.80 9.90 11.00 0.63 13.20
1.20 2.40 3.60 4.80 6.00 7.20 8.40 9.60 10.80 12.00 13.20 14.40
Do Not Assume. If In doubt, Ask.
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
The IMPLIMENTATION of Tactical Plans – The recommended water addition manner.
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
Beating the castable ’Setting Times’.
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
Castable SETTING TIMES come in 2 stages, i.e. INITIAL Setting Time, and FINAL Setting Time.
Generally, INITIAL Setting Time starts between 20-60minutes. FINAL Setting Time is between 60-90minutes.
If the area to be casted is, say, 1.5meters x 1.5meters x 0.30meters, then volume to be casted = 0.675cubic
meter/panel.
If Nett Material Reqt. Per Cubic Meter of dry castable is = 2,800kgs./cubic meter, then total quantity of dry
castable required = 1,890kgs. (0.675m3/panel * 2,800kgs./m3 = 1,890kgs./panel).
If capacity of mixer is, say, 350kgs./mixture, and mixing cycle time is, say, 10minutes then Mixer Discharge
Rate (or, Output) = 2,100kgs./hr. (60mins. per hr. / 10mins. per mix = 6 mixes /hr. * 350kgs./mix =
2,100kgs./hr.)
Therefore, it will only take approx. 54mins. to finish the whole panel (i.e. 1,890kgs. per panel / 2,100kgs.
per hr. = 0.9hr. per panel * 60mins. per hr. = 54minutes/panel.)
Beating beaten by the castable ’Setting Times’.
If capacity of mixer is, say, 75kgs./mixture, and mixing cycle time is, say, 10minutes
then Mixer Discharge Rate (or, Output) = 450kgs./hr. (60mins. per hr. / 10mins. per
mix = 6 mixes /hr. * 75kgs./mix = 450kgs./hr.)
Therefore, it will only take approx. 54mins. to finish the whole panel
(i.e. 1,890kgs. per panel / 450kgs. per hr. = 4.2hr. per panel *
60mins. per hr. = 252minutes/panel). . . which is way above the FINAL
Setting Time of a typical Dense Low Cement Castable Refractory.
Beating the castable ’Setting Time’ by use of multiple and/or rightly-sized Castable Mixers.
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative
Choosing the Right Metallic Anchor Supports
.
Metallic anchoring material
grades must be properly
specified since different
metals oxidize differently
under
different
temperature levels. If not
properly selected, metallic
anchors ‘rusts’ and the
process
is
expansive,
meaning it will ‘grow’ and
inflict
unnecessary
stresses to the refractory
linings. Such is the start of
cracking which could lead
to
refractory
spalling.
(LOCATION – FORTUNE
CEMENT CORP., Phils. –
Cyclone Roof)
.
Actual
footages
of
metallic
anchors used
in
Line
2
Cooler
Bull
Nose Section.
Indonesia.
April 2011.
.
MAXIMUM ANCHOR SPACINGS, mm.
Anchor Diameter, mm.
Lining Thickness, mm.
75 or less
75 - 100
100 - 200
200 or more
6.0
8.0
10.0
13.0
50 - 100
100 - 200
200 - 300
Conditions determining furnace lining support spacing
1. Support material
2. Hot face refractory
3. Thickness of hot face lining
4. Face operating temperature
5. Lining position
6. Lining shape
7. Lining size
8. Method of installation
9. Mechanical movement of face if any
300 - 350
Be sure to specify that only welding rods with proper grade markings
and color-codings be used to weld metal to metal.Same welding rod specs & manufacturer, but one has
proper markings (rod grade and color coding) whilst the
other has non.
.
Improper welding rod usages to welding metal to metal can
result to poor welding quality and, premature refractory
lining failures.
Guide to Welding Electrode Compatibilities
.
.
.
Engineers and Consultants Refractory Specialists
Manufacturer’s Representative