ANKRAL Q - Series
Cement
ICTM • R. Krischanitz • March 2013
Product Portfolio, Q – Series: Due to the success of the bricks based on the “Q-concept”, a complete product line has been implemented, based on this concept: top grade special solutions
top grade
high grade
economic grade 2
Q - Series
ANKRAL QF
ANKRAL Q1
ANKRAL Q2 (T2)
ANKRAL QE
Use of Q-concept Bricks Worldwide
3
Austria Belgium Brazil Bulgaria Canada China Costa Rica Croatia Cuba Czech Republic Denmark Ecuador Egypt Germany Greece Hungary Iran Iraq Ireland Israel Italy Jordan Kenya Lebanon Lithuania Luxembourg Mexico Nigeria Norway Peru Portugal Serbia Slovakia South Africa Spain Switzerland Togo Tunesia Turkey United Kingdom USA Venezuela
Innovation in Basic Bricks for Cement Rotary Kilns
Introduction of ANKRAL ZC into the Chinese market
2012
2010
2009
2008
2007
2006
Development of Q-concept
2011
Introduction of Q-series including ANKRAL Q1 and ANKRAL QE
Introduction of ANKRAL QF
2005
2004
2003
2002
2001
2000
1999
1998
1997
1996
1995
1994
1994
First installations of ANKRAL ZE (R63)
4
Rebranding of all RHI CRK brands in ANKRAL
Introduction of ANKRAL Z1
Grant of the Hercynite patent
Introduction of ANKRAL Q2 (T2)
The Q-Concept
5
The Q-concept bricks:
own raw material
Qflexibilizing concept
• Sintered magnesia, mainly of own resources • Q-concept flexibilizing for optimized performance
excellent price performance ratio 6
Excellent price/ performance ratio
Own Raw Material Production Sites Austria: Breitenau Hochfilzen Radenthein Italy: Marone Turkey: Eskisehir Norway: SMA Mineral Ireland: PPL China: Dashiqiao South Africa: Isethebe 7
Main Benefits of the Q – Series: Outstanding flexibility due to implementation of the Q-concept
+
Mechanical properties as CCS and HMOR are not sacrificed
Reduced loss of flexibility when infiltrated by alkaline salts Increased resistance to alkali salt infiltration due to implementation of Q-concept (hybrid spinel technology) Excellent price performance ratio 8
Development Focus: Wear Mechanisms
thermal load 9
Chemical Wear Chemical wear is characterized by two effects:
10
Dynamic E-Modul – Increased Flexibility
11
Diagram showing the development of E-modul during heating up and cooling down. There is a reduction in flexibility (increase in E-modul) during cooling down at around 1100°C. This effect can be reduced significantly by use of the Q-concept technology, resulting in an overall higher flexibility.
E-modul Comparison
12
ANKRAL Q2 shows even infiltrated a lower E-modul compared to conventional MA spinel brick of type e.g. ANKRAL R2, ALMAG 85 or MA11.
How to Combat thermo-chemical Attack? – Change in Concepts Kiln with easy operation conditions. Max
90%
80%
“performeter”
thermochemical load
13
70%
How to Combat thermo-chemical Attack? – Change in Concepts Severe chemical attack: strong chemical attack causing reduced performance Max
90%
80%
“performeter”
higher corrosion resistance
14
thermochemical load
Q-concept: combined optimization of corrosion resistance + reduced loss of flexibility Max
70%
“performeter”
higher corrosion resistance optimized flexibility
90%
80%
70%
thermochemical load
ANKRAL QF Concept: • top grade sintered magnesia • Q-concept flexibilizing Properties: • high refractoriness • excellent resistance to chemical attack • outstanding flexibility • outstanding thermal shock resistance • Low thermal conductivity Application: For special application and lining areas with severe thermo-chemical and especially in combination with high mechanical load (e.g. tyre sections)
15
ANKRAL Q1 Concept: • top grade sintered magnesia • Q-concept flexibilizing Properties: • high refractoriness • excellent resistance to chemical attack • outstanding flexibility • outstanding thermal shock resistance • low thermal conductivity Application: Transition zones of kilns with severe load due to use of alternative fuels (thermo-chemical, mechanical)
16
ANKRAL Q2 Concept: • high grade sintered magnesia • Q-concept flexibilizing Properties: • high refractoriness • high resistance to chemical attack • outstanding flexibility • outstanding thermal shock resistance • low thermal conductivity Application: Central burning and transition zones of kilns with increased load (thermo-chemical, mechanical)
17
ANKRAL QE Concept: • natural alpine sintered magnesia • Q-concept flexibilizing Properties: • coating friendly • high refractoriness • outstanding flexibility • outstanding thermal shock resistance • low thermal conductivity Application: Central burning zone of kilns with moderate to severe load Transition zone of kiln with moderate load
18
Lining Recommendation “Conventional” Q-concept increased chemothermal load
extreme conditions at use of AF
ANKRAL QE
ANKRAL QF in case of excessive thermo-chemical and/or mechanical load e.g. tyre, deformations, outlet!
ANKRAL Q2 ANKRAL Q1
“Best of” ANKRAL QF
20
Plant A, 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. 21
Result 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. 22
Result after full campaign of 12 months Severe chemical attack and mechanical load !! The colour is gone, but nothing serious happened.
Increase of life time from 4 to 12 months !
23
Chemical investigation ANKRAL QF
Brick grade Area
A
B
C
D
5 - 25 mm
75 - 100 mm
130 - 155 mm
180 - 205 mm
MgO
83,80
80,40
83,60
86,8
87
Al2O3
9,69
9,73
8,80
9,26
9,3
SiO2
0,26
0,25
0,27
0,26
0,3
CaO
0,47
0,74
1,30
0,76
0,7
MnO
0,12
0,12
0,13
0,12
Fe2O3
2,33
2,97
2,73
2,71
Loss on ignition
4,18
7,09
3,62
-0,08
SO3
0,03
0,60
0,60
0,13
Cl
1,84
3,24
1,51
0,07
K2 O
1,07
1,88
0,92
0,05
Na2O
0,05
0,08
0,11
0,05
Cl + SO3 + K2O + Na2O
2,99
5,80
3,14
0,30
-43,92
-3,25
-1,30
0,23
Sampling for chemical analyses (distance from hot face)
Technical data sheet
Chemical analysis (wt.%)
Despite severe chemical load no spalling or crack formation. 24 RHI AG
Molar alkali sulphur ratio (ASR) (K2O/94)+( Na2O/62)-(Cl/71) (SO3/80)
2,7
Mineralogical investigation Pore filling densification of the microstructure by alkaline salts. But bonding structure still present. Magnesia (1), potassium chloride (2), magnesia alumina spinel (4).
Detail showing the precipitation of periclase (3). Sample from area 3. Magnesia (1), potassium chloride (2). 25
3
Mineralogical investigation
Microstructural detail from sampling area 2 showing severely densified brick structure but no corrosion or degeneration of hercynite. Formation of monticellite as corrosion product of dicalcium-silicate. Magnesia (1), potassium chloride (2), monticellite (3), hercynite (4), complex spinel (5). 26
Plant B, Czech Republic Kiln: & 5,6 x 90m SP 2.800 tpd Lining area: UTZ, rm 36 – 40, second trye Fuel: coal, 35-40% AF
Despite strong mechanical stresses in the tyre area (creep=30mm/rev) ANKRAL QF is the only brick which remains in place for a second campaign. Residual thickness after one campaign 150 – 170mm. Previous installations achieved only 1 campaign. 27
Plant C, Slovakia Kiln: & 5,0 x 78m PC (hot disc), 3.600 tpd Lining area: UTZ, rm 30 – 35 tyre section Approx. 60% alternative fuels Situation: The usual lining life until now has been limited to 6 months due to strong mechanical load in the tyre section. Kiln had to be stopped usually for intermediate repair in summer. For a trial ANKRAL QF was installed in March 2009 in the UTZ tyre section.
28
Plant C, Slovakia ANKRAL QF was inspected in August 20th 2009 after 6 months in operation showing full residual thicknesses of 220mm . After a full campaign (10 months) bricks still show excellent performance without spalling and smooth surface (see pic). Bricks were in place until November 2011 (more than 2 years) and were replaced with res. Thicknesses of 180 – 200mm due to a change in kiln shell. The bricks clearly outperformed previous installations which did not reach more than 6 months. 29
Plant D, Austria Kiln: & 4,5 x 78m SP, 2.000 tpd Lining area: UTZ, rm 24 – 26 Content of AF used about 70% (plastics, tyres, sewage sludge, animal meal and solvents). During this campaign trials with 100%. Changes between different clinker types PC and Contra Gress. Lining in this area stayed in place for the first time for a second campaign (see pic). Kiln had to be stopped to to a hot spot in the neighbouring lining. ANKRAL QF still had residual thicknesses of 150-190 mm. 30
Plant D, Austria
ANKRAL QF after about 18 months in operation. Despite severe chemical load and reducing operation conditions residual thicknesses of 150 – 180mm. 31
Plant E, Italy Kiln: & 4,6 x 60m SP, 2.300 tpd Lining area: UTZ, rm 19 – 24 Installation: March 2012 – July 2013 still in service, thicknesses 160 – 170 mm (from original 200mm), no spalling even wear
Competition, AF product: Lining area: UTZ, rm 24 – 31 Installation: March/May 2012 – July 2013 Residual thickness 30 – 40 mm Competitor product was replaced by ANKRAL QF. 32
“Best of” ANKRAL Q2
33
Plant A, UK FLS, PC kiln, 2450 tpd 3,950 x 58 m 50% alternative fuels:
pelletized sewage sludge tyre chips recycled liquid fuel with coal.
ANKRAL Q2 installed in Jan. 2011 1rm (23,8 - 24,8) trial field After a full campaign the brick was in most parts almost full depth although for part of the panel infiltration spall was noted. The customer is satisfied with performance and will install 5 metres of Q2 over the front tyre during this stop. 34
Plant A, UK
ANKRAL Q2 after a full campaign in operation. The cut section shows severe infiltration by alkaline salts. The cold face shows also magnetic properties due to corrosion of the kiln shell. This outlines the strong chemo-thermal load within the lining area.
35
General information
Plant A, UK
Customer Plant Aggregate Position Brand Sampling
Lafarge Cauldon, UK Cement rotary kiln Upper transition zone ANKRAL T2 ANKRAL Q2 5-20 mm 145-165mm from the hot face from the hot face
ANKRAL T2 ANKRAL Q2 Technical data sheet
Chemical analyses Loss on ignition (1050 °C) (DIN 51081)
Wt.%
Wt.%
0.59
3.77
86.51 8.47 0.89 0.26 0.02 2.24
80.58 8.59 0.84 2.00 0.04 2.37
0.24
1.62
0.24 0.61
0.87 2.17
0.74 0.03
1.68 0.11
0.66
-0.12
Wt.%
Determination by XRF1) (ISO 12677) MgO Al2O3 SiO2 CaO MnO Fe2O3
Determination by titration 2) Chloride
Determination by C-S elemental analysis2) (DIN 51085)
Sulfur SO3
Determination by ICP-OES2)3) (ISO 26845) K2 O Na2O
Alkali-sulfate ratio, molar 4) (K2O/94)+( Na2O/62)-(Cl/71) (SO3/80) 36
86.3 9.0 0.8 1.6 2.3
Plant A, UK
The trial was only 1 running meter but was in the worst area and gives positive indications. The photo below shows the Q2 in position and spalls can be seen in the brickwork either side (competitor high grade brick). The brick top missing from the lower part was removed by the author to check for infiltrating salts. In comparison to the competitive high cost product ANKRAL Q2 shows an excellent 37 ANKRAL QF price performance ratio.
Plant B, UK FLS, PC kiln, 2450 tpd 3,950 x 58 m 50% alternative fuels:
pelletized sewage sludge tyre chips recycled liquid fuel with coal.
ANKRAL Q2 installed in Jan. 2012 in LTZ area of unstable coating Residual thickness after a full campaign about 150mm. Some spalling in the key area. Removed for safety reasons.
38
Plant C, UK 4 m of ANKRAL Q2 were fitted last year from 5.8 to 9.8 metres between competitor AF brick at the front and competitor AF brick at the back. The interface of LTZ and CBZ is considered to be 8 metres from nose. There was no visible difference in thickness or condition. All bricks were removed after the campaign.
39
rm 18
15
12
9
6
3
Plant C, UK
Competition / ANKRAL Q2 (5.8 to 9.8) / Competition outlet 40
Plant D, Austria Voest, PC kiln, 4.0 x 60 m Capacity 2400 tpd Fuels: coal, petcoke (3.5 sulphur), 25-30% mixture of plastic, animal meal & sunflower seeds Installation area: r.m. 3.2 - 6.2 Installation date: 09.03.2011 Inspection in Feb. 2012 stays in kiln for another year in kiln Total service life up to now: ~ 1 year Residual thickness: 180-190 mm Former installed product: ANKRAL ZE Total service life ZE: 1 year 41
Plant D, Austria
ANKRAL Q2 after one full campaign in operation (LTZ rm. 3,2 - 6,2). 42Residual ANKRAL QFthicknesses 180 – 190 mm.
Plant D, Austria
ANKRAL Q2 after two campaigns still under coating (LTZ rm. 3,2 436,2). Residual thicknesses about 140 mm. ANKRAL QF
Plant E, Portugal PC kiln Ø= 4,8 x 88 m, 3000tpd Fuels: Petcoke, animal meal, RDFs, biomass ANKRAL Q2 installed in UTZ between rm 20-22 Installed: Replaced: Total service life: Residual thickness:
44
May 2011 May 2012 12 months 12-14cm, despite twisting of the lining ( also increased mechanical load)
Plant E, Portugal, Result Customer satisfied with price/performance ratio. ANKRAL Q2 achieved same result as more expensive competitive product.
45
Plant F, Germany Kiln details: Pol – SP kiln, Ø= 5,6 x 90m, 3200 tpd ANKRAL Q2 was installed at Schwenk Karlstadt in May 2011. After 6 months of operation ANKRAL Q2 shows a very good performance equal to ANKRAL R1 and competitor AF brick, installed in direct neighborhood in the upper transition zone. Secondary fuel rate about 90 % mainly consisting of sewage and plastics. Bricks removed in October 2012, together with ANKRAL R1 and competitor AF brick. The customer reordered 10 rm.
46
Plant F, Germany
ANKRAL Q2 vs. competitor AF brick res. thickness 220mm
47
Plant G, Austria Kiln details: Pol – PC kiln, Ø= 3,4 x 48m, 900 tpd (tyres 4,2/20,5/39,4) ANKRAL Q2 installed in UTZ between rm 27,4 and 29,2 results after one full campaign in UTZ (see pic). Permal 5E, installed together with Q2 and adjacent to Q2 (rm 25,4 to 27,4), showed partly only 3 cm res. thickness and strong spalling.
Permal 5E
48
Thank you for your attention!
www.rhi-ag.com
49
