Cement Customer Seminar Hyderabad

Alumina Monolithics
Training in theory and praxis of correct installation of

refractory products for Cement Industry, Leoben, Austria
2015
Industrial Alumina Marketing and Product Management,

René von der Heyde
1 Classification of Alumina-based
castables
2 92 TCC_Alumina Monolithics_Day 1
1.1 Cement bonded castables – overview and
classification
 Alumina based castables can be divided using:
 Installation method
 Bonding type
 Raw material base
 Application (Industry) or other special features
1.1 Cement Bonded Mixes
1.1 Cement bonded castables – overview and
classification
 Cement bonded castables are the most commonly used type of
alumina based castables.
The different types of cement bonded castables are:

 Conventional Castables (CC, CaO >2,5%)
 Low Cement Castables (LCC, CaO 1,0-2,5%)
 Ultra Low Cement Castables (ULCC, CaO 0,2-1,0%)
 No Cement Castables (NCC, CaO <0,2%)
 No cement castables are a wide range of products with very

different bonding types.
1.1.1 CC – Conventional Castables
RHI Brands: COMPRIT, SUPER COMPRIT
 Commonly used castables with high cement content

(resulting in higher water demand ~10 litres / 100 kg)
Advantages
 Easy to install. Mixes are unproblematic in terms of water demand and
dosage, installation temperature and setting behaviour.
 Shelf life 12 month.
Disadvantages
 High water demand  high porosity and low density
 Lower refractoriness, lower alkaline and chemical attack resistance
 Relatively low CCS at higher temperatures
1.1.2 LCC – Low-Cement Castables
RHI Brands: DIDURIT, CARSIT
 Widely used type of mix with lower cement content
Advantages
 Lower cement content compared to conventional castables (decreased
water demand 5-8 litres / 100 kg)
 Lower water content  lower porosity and higher density, fibres added
 Higher refractoriness, better alkaline and chemical attack resistance
 Higher CCS and abrasion resistance at higher temperatures
Disadvantages
 There are some additives necessary in the mix for an easier handling.
That make them susceptible to errors and bad mixing equipment and
decreases the shelf life (8-9 month).
1.1.3 ULCC – Ultra-Low-Cement Castables
RHI Brands: DIDURIT
 Further reduction of cement compared to other castables and therefore
lowered water demand (below 5 litres / 100 kg)
Advantages
 Lower water demand  decreased porosity, higher density
 plastic fibres necessary in the mix for a proper heating-up
 Higher refractoriness, alkaline and chemical resistance
 Higher CCS and abrasion resistance at higher temperatures
Disadvantages
 For a better workability complex additives (e.g. dispersing additive) are
necessary, therefore the workability is more difficult and shelf life reduced
 Well trained personal / high accuracy / good mixing equipment necessary
1.1.5 RHI NCC – COMPAC SOL and CARSIT SOL
RHI Brands: COMPAC SOL,CARSIT SOL,COMPAC ROX
 NC-castables, bonding based upon Si-O-Si
Advantages
 Setting without development of hydrate phases  very fast, save and easy
heating up procedures (heating finished at 150°C or even below)
 No further additives in the dry mix  easy and simple workability, low
equipment (mixer) requirements
 Superior resistance to thermal shocks, high alkaline-, acid-, sulphur and
chemical resistances
 Homogeneous and very fine pore distribution
Disadvantages
 External binder is very sensible to frost
 Insta. temp. above +5°C (binder will be irreversible destroyed when freezed
1.2.6 Insulating Castables
RHI Brands: LEGRIT
Insulating castables can be casted, poured or gunned but are not allowed to
vibrate or gunned with high air pressures, because they need a certain
porosity to give the right insulating properties.
They are made of very different light materials, resulting in different densities,
application temperatures and heat conductivities:
 light weight fireclay
 foam glass
 Vermiculite
 Perlite
 Wollastonite
 porcelain breakage
 CA6 porous
 bubble alumina
1.2.6 Insulating Castables
RHI Brands: LEGRIT
Most of the insulating castables have low strength and abrasion resistance
with the exception of Litecast 44G, which is high strength and abrasion
resistance gunning mix designed for special use in preheater and cyclone
areas.
General properties:
Bonding: Portland cement or CA-cements (20 – 40%, cement rich)

Material properties: TC: 0,2 – 1,0 W/mK OP = 30 – 70%
Density: 0,5 – 1,9 t/m³ Application Temp. Limit 1000°C – 1800°C
2 Application Technology / Processing /
Installation / Machinery
2 Application Technology / Processing / Installation /
Machinery
All necessary information is given in the RHI-Operating Instruction
manuals (Example: Didurit B83-6, ULCC).
Overall wet
Dry mixing time mixing time
Mixing liquid type

Compaction
Temperature and quantity
method
2 Application Technology / Processing / Installation
Techniques / Machinery
A high value product - handled bad – may

be of worse quality as a perfectly
installed lower quality product.
2 Application Technology / Processing / Installation
Techniques / Machinery
Bricks Castables
R&D R&D R&D
Mixing Mixing
Forming: Pressing Production QC
Tempering/Burning
QC
Storage Storage:
- Storage Facilities
Installation: Bricking - Shelf Life
Installation (Forming):
- Gunning
Customer - Casting
- Self Flowing
Equipment:
- Mixer (Transport)
- Gunning machine
Curing/Drying/Heating
Winter/Summer
2.1 Storage
2.1 Storage
General:
 Alumina monolithic materials must be kept completely dry and frost free at
an ideal temperature of 15 to 25°C (if possible indoors).
 Bags and pallets must be protected from rain or water
 To minimise condensation ensure sufficient ventilation.
 It is necessary to ensure that rain water can easily be drained away to

avoid dampness from the ground.
2.1 Storage
Shelf life:
 RHI castables and gunning mixes have a limited shelf life.
 Typically, storage life for conventional castables and gunning mixes is one
year from date of manufacture.
 Low cement castables and ready for use mortars may have shorter shelf
lives down to 6-3 month.
 Shelf life is given in RHI data sheets and visible the bags.
 In case of outside storage, frozen material has to be warmed up sufficiently

(slowly) to a minimum temperature of +15°C before installing.
2.1 Storage
Effect of wetness:
 Fireclay bricks, high alumina bricks, light weight bricks and insulating bricks
have to be dried carefully before use.
 Refractory concretes, insulating concretes and mortars cannot be used

when they got wet, because the bonding of the cement already started.
 Ceramic fibres, wools and blankets cannot be used when they got wet,
because they are compressed and lost therefore flexibility properties.
 Block insulations can be installed.
2.2 Casting
2.2 Casting
The most important types of proccessing / installation of castables is casting-
vibrating and several gunning applications.
Installation procedure can be divided into the following steps:
1. Moulding (including expansion)

2. Mixing
3. Vibrating
4. Setting
5. Demoulding
6. Drying / Heat up
Step 2 and 3 are replaced by the gunning process in case of gunning

application techniques.
2.2.1 Mixing
2.2.1 Mixing - General
The mixing procedure has to ensure that the fine and reactive components,
such as
 cement, (or alternative binder)
 dispersing agents,
 setting agents
will be wetted perfectly.
The proper wetting of the cement enables the bonding system to form the
CA-phases – being of utmost importance for the final strength of the
product.
The fine dispersed setting agents ensure the desired processability and the
achieved setting behaviour of the mix (particularly for LCC and ULCC).
2.2.1 Mixing - General
 Mixing is a very important procedure since it has decisive influence on the

final quality of the lining.
 It is important to use proper mixing equipment, observe the mixing time and
use the right amount of mixing liquid.
 If mistakes happen here, the installed material will most likely not provide
the service properties you expect.
 Refractory castable are generally mixed in a paddle mixer because only

this mixer type will ensure good blending of the binder.
 Mixing by hand is not allowed.
2.2.1 Mixing - Preparation
The mixer must be:
 1. clean
 2. slightly wet before the first mixing
 Due to a possible material segregation during the transport, the dry

material has to be mixed up to one minute before adding the mixing liquid.
 The working time of castables is approximately half an hour, depending on

the amount of water and ambient temperature.
 Therefore never mix more material as you can install within half an hour
 Placement of insulating blankets, papers or impregnation foil should be

carried out with special care, as it may wrinkle during casting creating
weaknesses in the lining. .
2.2.1 Mixing – Mixing Liquid
 The required amount of mixing liquid is indicated on the bags, the
installation guidelines and in the technical data sheets in litres per 100kg with
maximum and minimum values.
 Mixing liquid volume measuring equipment will be needed!
 The optimum quantity of water will vary with the temperature and the
“vibrating circumstances”.
 Do never use more than the recommended amount of water unless having
talked with our technical service first.
 Decreased castable strength results often from excess moisture.
 Insufficient water reduces workability and result in voids and laminations.
120 16
14
Cold Crushing Strengh (%)
100
Rupture (%)
12
80
10
KBFof[N/mm²]
KDF [%]
60 8
Module
40 6
4
20
2
0 0
4 4,5 5 5,5 6 6,5 4 4,5 5 5,5 6 6,5
Water (%)[%]
Wassergehalt Water (%)
Wassergehalt [%]
20
18
16
Rohdichte [g/cm³]
(%)
3,1
Porosity [%]
Bulk Density (%)
14
off. Porosität
12
3,0 10
8
Open
6
2,9
4
2
2,8 0
4 4,5 5 5,5 6 6,5 4 4,5 5 5,5 6 6,5
Water (%) Water (%)
W assergehalt [%] W assergehalt [%]
If water is the mixing liquid, use always potable water!
Table: Chemical properties for drinking water according to German law.
Key figures for good mixing water:
1. pH-value between 6,5 and 9,5
2. Electrical conductivity <3 mS (sea water has >5.000 mS)
3. Visually clean
4. No special smell or taste
2.2.1 Mixing – Mixing Procedure
 Different castable types have different mixing instructions, please
read them before starting!
Mixing procedure for a conventional dense castable (CC):

1. dry mixing up to 60 seconds
2. add approximately 80% of the minimum recommended mixing liquid
3. mix the material for a minimum of 3 to 4 minutes
4. add the remaining water to achieve the needed consistency (max. in TDS!)
Low cement, ultra low cement and self levelling castables will require more
total mixing time up to seven minutes.
 This Procedure is different for Sol mixes !!!!
2.2.2 Mixing Units
2.2.2 Mixing Units, Paddle Mixer
Zyklos Mixer
DIEM Design
Wesman VAM-R Refractory Mixer

2.2.3 Consistency / Ball-in-Hand-Test
2.2.3 Mixing – Consistency Test
Vibration Testing:
During production quality control and for pre-shape production vibrating tables
are used to determine the spreading values (EN-ISO1402-4)
On Site Testing:
Place the vibrator in the mixing pan or in a bucket:
 if there is a cavity remaining when pulling out the vibrator, the castable
contains too less water
 if the castable flows well, the castable has the proper consistency for
vibration
 if water settles (deposits) on the surface during vibration work, the

castable contains excessive water
2.2.3 Mixing – Consistency Test
When starting the work the consistency of the first batch should be checked.
Ball-in-hand-test:
Form a compact ball with the castable in the hands and toss it upward about
30 to 50 cm and catch it in one hand. Upon catching it:
 if the ball crumbles, the castable contains insufficient water
 if the ball flows apart slowly, the castable has proper consistency for
vibration
 if the ball flows apart immediately, the castable contains too much water
2.2.3 Mixing – “Ball-in-Hand” Test
crumbles – the concrete is too dry
slowly flows apart –

concrete has the
optimum consistency
flows apart quickly – the concrete

was mixed with too much water
Material is mixed with too less water
No compaction possible.
You will find “rat-holes” after vibrating the

material.
Matrix is not dense.
Material is properly mixed
Compaction possible, but has to be done

thoroughly.
You will find a shiny surface after vibrating

the material.
Matrix is optimal.
Material is mixed with excessive water.
Easy compaction.
You will find a wet surface after vibrating

the material.
2.3 Castable Placement
2.3 Castable Placement
Pouring should begin as soon as the mixing procedure is completed.
Quick application is decisive for the quality of the lining.
The total elapsed time from addition of water until the material is in place
should not exceed 30 minutes.
Delays have the risk of premature hardening and the formation of layers.
This can have negative effects on the desired durability of the lined unit.
Note: Take time for transport of the material into consideration !
2.4 Compaction / Vibrating
2.4 Compaction / Vibration
Mixed castables content a relatively high amount of air as small bubbles.
To reach the final properties for dense castables the air must be removed.
Pouring
 mostly used for insulating castables (high porosity)
 done by hand with help of a wooden or metallic stick
Vibrating
 vibration is used for dense castables with exception of free flowing
castables
 done by an electrical or air powered vibrator
 can not be done by hand!
 “modelling” is forbidden!
2.4 Compaction / Vibration
 For dense castables its absolutely necessary to vibrate (excep. free flowing)!
 Start vibrating immediately with the casting
 Vibration is finished, when no more air bubbles escape from the mix
 If vibration is too long it may reduce the quality
 Stop vibration when the mix starts to seggregate
2.4 Compaction – Types of Vibrators
Types of vibrators
Poker vibrator
External vibrator
Two types of poker and external vibrators are available – electrically or

pneumatically. If using a pneumatically vibrator an oilier and a dehumidifier
station is necessary for a constant proper installation work.
Poker vibrator
The diameter of poker vibrator should be not more than a third of the lining
thickness.
Following kind of poker vibrators are used:

Electrically: with approx. 12.000 vibrations / min.
Pneumatically: with approx. 1.500 vibrations / min.
2.4 Compaction – Poker Vibrators
 PV have to be quickly immersed and slowly moved through the material so

that no caves remain
 Choose the right vibrator dimension according to your refractory layer
thickness and anchor density
 When pulling out the vibrator the remaining hole should close smoothly
 touching the shuttering with the vibrator should be avoided
Rule of thumb:
The diameter of the vibrator should be at least 1/6 of the lining thickness but
the bigger the better!
Installation of side walls:

The refractory concrete is installed in different portions one after another
Vibrate during the whole casting in the upper most 10 to 15 cm of the castable
Installation of bottom fields:

Make sure that, in case of a horizontal and closed shuttering, the escaping air
can be released by drilling small holes in the shuttering (roof part).
Sufficient compaction is reached when:
 the sound of the vibrator in the concrete does not change anymore
 the surface is smooth and only a few isolated air bubbles ascend to the
surface
 in general a smooth and shiny surface indicates good compaction.
If vibration is carried out too long, the mix will begin to segregate and the fines
and water drifts towards the surface.
Do never vibrate when the setting process of the mix is beginning to

start.
2.4 Compaction of an open bottom (flat) area
2.4 Compaction of a side wall
2.4 Compaction done wrong
2.4 Compaction with external vibrators
External vibrators transfer the vibration energy from the mould into the
refractory material (maybe useful for burner pipes or meal ducts).
External vibration needs much more energy for the same results compared to
internal vibration and cant be done for large and heavy structures.
Positioning of external vibrators can be done using:
 Tension belts
 Bolting
 Welding
Important:
 You have to use several external vibrators for larger structural elements.
 The number and power of vibrators is depending on lining thickness and
mould design
2.4 Compaction with external vibrators
2.5 Setting Time / Curing / Retarding /
Accelerating
2.5 Optimum Installation Conditions
What may have a major effect on the processing, the setting time and the
quality of the lining :
 the temperature of the refractory product to be installed
 the ambient temperature
 the mixing liquid temperature and quality (chemical composition)
 the residual temperature of the unit to be lined (steel shell, insulating)
Optimum lining conditions are between 15 °C and 25 °C.
Should considerable temperature deviations for one of the abovementioned

parameters exist additional measures might have to be taken.
The physical and chemical reactions taking place after the mixing are highly
influenced by the circumstances of installation.
2.5 Curing
Influence of stetting temperatures and curing time
80 20°C
70 Einfluß der Gießtemperatur auf die Festigkeit
Cold Crushing Strengh (%)
60 24h
KDF(N/mm²)
50
40
30
6h
20
10
0
0 5 10 15 20 25 30 35
Gießtemperatur (°C)
Mixing Temperature
2.5 Optimum Installation Conditions
If you are facing very hot or cold temperatures during installation, you have to
take the following measures:
1. Ask RHI technical service
2. Cool or heat the used materials (mix and liquid)
3. Use retarding (if its too hot) or accelerating agents
4. Gunning materials cant accelerated or retarded adding chemical

substances!
2.5 Site Preparation
Before the installation of refractory castables begins, following precautions

should be taken:
 The area where the castables will be installed must be clean so nothing
can contaminate the refractory
 Mixers, tools, vibrators and conveying (transport) equipment also have to
be clean, checked for function and ready
Note: Contamination particularly by Portland cement or plaster can

cause flash setting adversely affecting the castable mix.
5 Field Arrangement / Shuttering
64 92 TCC_Alumina_Monolithics_Day 2
5 Field Arrangement
 Insulating refractory materials and standard refractory materials are

positioned in so-called work sections according to a chessboard pattern
(refer to figure 1).
 The placement (lining work) of the unshaped refractory materials must be
done continuously and without interruption.
 Removal of templates and boards and placement of unshaped refractory
materials in the remaining section may not be done until complete setting
(hardening) of the refractory mixes.
 This is required in order to prevent the individual sections from sticking
together.
 The methods for placing the mixes in the individual work sections are
described in the instructions for preparation and use for the specific grades.
5 Field arrangement
max. 1000 mm
A B A B
Pos. II Pos.III Pos. II Pos.III
max. 1000 mm
2 4 2 4
Pos. II Pos. III Pos. II Pos. III
1 3 1 3
2 4 2 4
1 3 1 3
Pos. I
Pos. I
Pos. I
Pos. I
Pos. I
Pos. I: Vertical continuous template boards
Pos. II: Horizontal shortened template boards
Pos. III: Horizontal shortened template boards
5 Field arrangement
The installation sequence as well as placement of the refractory mix is
as follows:
 Placement of the vertical continuous template boards (Pos. I).

 Placement of the shortened, horizontal template boards (pos. II) in row A,
next placement of refractory mix in work section .
 Once the refractory mix has hardened, the boards in pos. II are to be
removed and mix can be now placed in work sections .
 After hardening of the refractory mix, it is now possible to remove the
vertical boards (pos. I).
 The short horizontal boards (pos. III) are to be installed in each row B.
Next the work sections  can be lined.
 After setting of the mix, the template boards (pos. III) are removed and the
remaining work sections  lined.
5 Field arrangement
.
5 Field arrangement
.
5 Field arrangement
 The work sections should not exceed a maximum of 1 m².
 In the area of the insulation there are straight working joints.
 The working joints in the front layer have a "z" design (refer to figure 2).
 The working joints of the individual layers may not be vertically on top of
each another. They must be offset. The working joint should be offset by
50 % from front to insulation layer. The joint must, however, be offset by a
minimum 25 %.
5 Contact Areas
 If using insulating layers out of calcium silicate plates, insulating bricks or

insulating refractory bricks, it will be necessary to use water-blocking
materials in order to prevent a sucking out of the setting water from an
adjacent refractory layer.
 This can be accomplished by positioning oiled paper / PE foil or by
applying a coating of acrylic paint / sodium silicate or refractory mastic.
 If using insulating layers out of insulating castable or gunning materials, it

will be necessary to moisten the contact areas or to use water-blocking
materials in order to prevent a sucking out of the setting water from an
adjacent refractory layer.
5 Field Sizes for Repair Work
Maximum Field Size

 should not be larger than one metre by one metre !
Minimum Field Size

 the minimum allowable size is an area of three metallic anchors ( as
shown next page )
 the periphery of any repair shall be located midway between metallic
anchors as shown
 the cut-out has to carried out with a slope as shown
 the cut-out should be cleared of all loose material and the adjacent
material should be thoroughly wetted before new material is applied.
5 Field Sizes for Repair Work
Minimal Field Size
6 Expansion and Joints
6 General & Type of Joints
General
Generally refractory materials could not be installed in fields of any size. The
total area must be split up in fields by stoppage moulds. The result are joints
because the materials will be installed field by field one after the other.
Type of Joints
Working joints
Are “dry” joints between installed fields.
Expansion joints
Are required to compensate the change of geometric dimensions ( length and
volume ) caused by temperature change.
6 Type of Joints - Examples
25
60 30 60
Z-
Working
joint
Joint filled with ceramic

blanket (Pyrostop blanket)
6 Expansion Calculation
Thermal Expansion Coefficient
Quartz glass
Vitrified clay
Chrom-steel
Aluminium
Corundum
Porcelain
Fireclay
Mullite
Material Basalt
Thermal Expansion
23,8 9 10-14 8 5,5 3,8-4,5 0,5-0,6 4-6 4-4,5
Coefficient (10-6.K-1)
Thermal Expansion Coefficient ( 10-6.K-1 )

Temperature (°C )
Metal 100 200 300 400 500 600 700 800
900 1000 1200
X 5 CrNi 18 10
16,7 17,2 17,7 18,1 18,4 18,8 19,1 19,4
(1.4301)
X 6 CrNiNb 18
16,7 17,2 17,7 18,1 18,4 18,8 19,1 19,4 19,7 20,0
10 (1.4828)
GX 40CrNiSi 25
17,0 18,0 19,0 19,5
20 (1.4848)
6 Expansion Calculation - Example
Wall out of fireclay / average temp. 1050°C / expansion coeff. =5,5.10-6/K

length: 15m /
 l=  . ( t1-t0 ) . L0
= 5,5.10-6/K . 1050K . 15.10³mm
= 86,6 mm
This expansion can not be absorbed with one joint in wall centre. Split the
length of into fifteen fields ( are sixteen joints ). These joints can be filled with
compressible fibre materials.
The expansion joints must be carried out that the fibre material will be
compressed about 50% during operation temperature.
These expansion joints could be designed 12 mm wide each and filled with ½”
thick ceramic fibre blanket.
6 Expansion Calculation – Example
Combustion chamber
height: 4m / average temperature: 1200°C / pressure shell temperature: 200°C
Expansion vertical: should be compensate that during operation no tension

will be transferred to the pressure shell and all joints are
closed.
 ( 13 Cr Mo 44 ) = 12,1.10-6/K
 ( of inner layer of corundum brick ) = 1% at 1200°C
 l steel shell= 12,1.10-6/K . 200K . 4000mm = 9,7mm
 l corundum layer= 0,01 . 4000mm = 40mm
Difference = 40mm – 9,7mm = 30,3mm
This difference must be considered constructional in a joint.

7 Anchoring
7.2 Refractory Tile and Metallic Anchor Types
CH1.8-200-310K CH2.8-200-310K CTH.8-200-310K HTH.8-200-310K
Claw GKB Claw GKT Claw Set KSET
7.2 Recommendations for Monolithic Linings -
metal-only Anchoring
7.2 Metallic Anchors for Monolithic Linings
In one line walls the generally accepted anchoring method involves the use of
commonly V anchors.
Anchor types:
CH1 / CH2 / CH3
CV1 / CV2 / CV3
The CH series is a anchoring system designed for fastening by manual welding.

CH1 is used for simple anchoring functions, e.g. with relatively light materials or in flat
positions.
CH2 with its corrugation provides a greater holding capacity for the refractory material.
CH3 is notable for its double corrugation, which provides a further improvement in
anchoring strength.
Positioned metallic anchors with
start of block installation
Block installation finished and sealed,

holes filled with ceramic wool
Installation of washers
Ready installed metallic anchor
Bend up of metallic anchors

7.2 Recommendations for Monolithic Linings -
combined metallic-refractory Anchoring
8 Drying and Heat up
8 Drying and Heat Up - Introduction
Prior to operation, newly lined - or repaired - monolithic parts have to be

dried/heated-up thoroughly, because they contain water from processing.
The service life, as well as the operational reliability/safety, strongly depends

on the appropriate drying/heat-up process of the refractory linings in the
respective facilities (or parts of such facilities).
8 Drying and Heat Up – Why?
Arithmetic example:
A new cement-plant was erected, using 1000 tonnes of monolithics
(castables and gunning mixes; insulation and wear lining). As an average, the
water content of these mixes is 8 %.
This results in an amount of 80 tonnes (80.000 litres) of water used for
processing these mixes. These 80.000 litres have to be withdrawn from the
lining in a safe and gentle way.
During the heating process water will vaporise, forming 1.700 litres of steam
out of 1 litre of water. 1.700 x 80.000 = 136.000.000 litres of steam, that
equals 136.000 m³ !
The resulting volume complies with the area of a common soccer field (100 x
70 m) by a height of 20 meters.
8 Drying and Heat Up – Why?
The single products within the system have their individual thermal behaviour
and particular physical properties:
 different strength (CCS)
 different thermal conductivity
 different thermal expansion
 different ductility
 different (open) porosity
 different temperature gradients within the material
Thus, the most important goal for the heat-up process must be to bring the
whole plant to normal service conditions without damaging any of the
single components within this system.
8 Drying and Heat Up - Heat-up Process
Water exists in different bonding systems in the ready mixed castable:

- crystallisation water (chemical bonded water, Sol-Mixes don’t have it!)
- intermediate / mantle water (chemical-physical bonded water)
- pore and capillary water (physical bonded water)
These distinct working bonding mechanisms are of relevancy to the heat-up

process, because the single water-bonds do not decompose at the same
time. This can be explicated with the variable energy requirement that is
needed to dissolve the different bonds.
8 Drying and Heat Up - Stress
Due to these product-specific properties different stresses will appear whilst

exposing the lining to heat.
Different stresses on
refractory, heat-loaded
from one side only
tangential = parallel to the hot face
radial = vertical to the hot face
8 Drying and Heat Up - Nomenclature
Drying: is the process, during which humidity is driven out of the lining under
controlled conditions. Within the range from ambient temperature up
to 150°C (~ 300 °F) the amount of water is reduced to 20 to 25 %
(of the initial content).
Heat-up: is the process, which brings the lining up to the temperature that is
required for service. During this phase the remaining water has to
be removed.
Cooling-down: is the controlled process, that brings the lining down to

ambient temperature for e.g. maintenance.
8 Drying and Heat Up - Terms
Curing / Air Drying:
All cement containing castables must be allowed to cure prior to exposure to

high heat/service conditions, for at least 24 hours.
During this period the formation of the cement-hydrate-phases starts.
The proper development of these phases is the utmost important basis of the
resulting final strength of the installed products.
Whilst curing, the concretes could loose up to 10 % of the added water due to
vaporization (which is not desired !!). For that reason you have to cover the
lining with foils, plastic, wet textiles or similar materials. Particularly for fast
drying RHI-sol-bonded products this is highly recommended.
Why?
The water – blended into the „unshaped“ refractory product to enable
processing – has to be removed from the concrete prior to putting into
operation.
How:
There are 3 steps during which the water will be removed from the installed
concrete:
curing,
(drying),
heat-up
During air-drying/curing, the formation of the cement-hydrate phases starts,

and with lapse of time, all important phases form. This formation is of utmost
importance for the final strength. Up to 10 % of the added water could
evaporate on the surface if not protected against loss of humidity.
In the drying phase the temperature will be increased above the boiling
point of water (as a rule of thumb up to 150 °C). Due to the added heat water
will be transformed into steam and leaves in this gaseous state the material.
Having been transformed into steam, humidity can migrate even through
narrow capillaries to the surface.
The process step of drying has to fulfil 2 essential assignments:

- to convert water in the material into the gaseous state
- dissipate the resulting steam to the surface through capillaries.
During this dehydrating not only the transition of the humidity to the
surrounding atmosphere has to be considered. Furthermore in the lapse of
the drying period the activities in the core material are of utmost importance.
The location of evaporation may be situated on the surface, or in the core of

the lining.
According to the location of evaporation either steam or water has to be

transported to the surface.
simplified system of alumina-cement phases and

their stability in dependency of the temperature
1000 100
900 90
Curing-period Drying-period
800 80
w ater evaporates w ater evaporates

700 (T < 100 °C) (T > 100 °C) 70
600 60
heat-up rate
500 50
water loss %
400 40
Heat-up-period
300 30
200 20
100 10
0 0
0 10 20 30 40 50 60 70 80 90
Heat-up rate and percentage of dehydration

Initially the only loosely bonded pore- and capillary water, next the mantle-
water, followed by the intermediate water will be removed.
Nevertheless no strict chronological separation occurs, furthermore the

different dehydration phases overlap.
Endmost, at high temperatures (up to 800 °C), the chemical bonded

crystallization water will be removed from the concrete during the final heat-
up phase.
Temperature Saturation vapour pressure
[°C] [bar]
During the heat-up phase the
remaining water has to be driven out of 20 0,02
a hydraulic bonded the concrete. This

50 0,12
has be done through the existing
capillaries. A very important point in this 100 1,01
process is the “saturation vapour
pressure”. During the initial curing and 150 4,76
drying process the pressure is quite

200 15,55
low, e.g. up to approx. 5 bars when
reaching 150 °C. When heating up to 250 39,77
350 °C this pressure rises up to 165
bars ! 300 85,92
350 165,37
Saturation vapour pressure as a function of temperature
Saturation vapour pressure as a function of temperature

8 Drying and Heat Up - Heat-up Schedules
The heat-up instructions refer to a one-sided temperature exposure.
For multi-layer constructions (e.g. gunned insulating material combined with

casted wear-lining) the slowest heat-up schedule has priority.
The measuring of the temperature profile has to be done with suitable

thermo-couples.
The profile has to be plotted automatically with a graphical recorder.
All given temperatures are furnace temperatures!
8 Heat Up Schedule - LCC
Heat-up schedule for ULC / LC / CC-refractories
Universal heat-up schedule for a one-layer lining of 150mm thickness.
The given temperatures are furnace chamber temperatures. Holding-time (HT) is 1h / 1cm at lower
temperatures and 0.5h / 1cm at higher temperatures. For combined lining a individual heat-up schedule is
necessary.
800
working temperature
700
600
50°C/h
500
Temperature [°C]
HT 7,5h
400
15°C/h
300
HT
25°C/
200 HT 15h
15°C/h
100
40°C/h
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65
Time [h]
8 Heat Up - LCC
After heat up
SPEEDCAST F51-6
DIDURIT F50-6
SPEEDCAST F51-6
DIDURIT F50-6
Prior heat up
Record of a 30 K/h heat up schedule of a normal LCC (DID-F50-6) and
the improved Speedcast F51-6 (same raw material base / properties).
8 Drying and Heat Up of Sol-products - Heat-up Process
The average pore size in Sol-mixes is significantly lower than for a LCC (lower
risk of infiltration).
Homogeneous pore-structure and (size) distribution (better heat up properties).
In relation at low temperatures a higher pore-volume (better heat up), because

you can use all the pores at very low temperatures. For cement bonded
castables, a large amount of pores are created lately during the heat up.
No increase of porosity at higher (>200°C) temperatures.
Safe and very fast heat up that can be finished completely even below
200°C!
Sol-Gel mixes: properties - heating
Thermoelemente
Steinschalung
Brenner Abzug
1 Brenner
2
Versuchsblock ANKOCAST 341
Fasermatte 3mm
Drying: Large scaled drying test in TC Leoben

4
3 1 Construction layout
2 Form and
thermocouples
3 Trial tundish
4 Trial block after

heating up
Thermogravimetry of a sol-bound 130 kg block
700 100
90
600
80
500 70
temperature [°C]
dehydration [%]
60
400
50
300
40
temperature in the furnace
temperature on the surface of the block 30

200
temperature in the middle of the block
emitted water 20
100
10
0 0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34
time [h]
8 Heat Up Schedule LCC vs Sol
Heat Up Schedules of Low Cement and Compac /
Carsit Sol Castbales
800
700
600
Temperature (°C)
500
400
LCC
Sol
300
200
100
0
0 10 20 30 40 50 60 70
Time [h]
Thank you for your attention!
www.rhi-ag.com

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Alumina Monolithics

Training in theory and praxis of correct installation of

Industrial Alumina Marketing and Product Management,

 Alumina based castables can be divided using:

The different types of cement bonded castables are:

 No cement castables are a wide range of products with very

 Commonly used castables with high cement content

Bonding: Portland cement or CA-cements (20 – 40%, cement rich)

Mixing liquid type

A high value product - handled bad – may

 Bags and pallets must be protected from rain or water

 To minimise condensation ensure sufficient ventilation.

 It is necessary to ensure that rain water can easily be drained away to

 RHI castables and gunning mixes have a limited shelf life.

 In case of outside storage, frozen material has to be warmed up sufficiently

 Refractory concretes, insulating concretes and mortars cannot be used

 Block insulations can be installed.

Installation procedure can be divided into the following steps:

1. Moulding (including expansion)

Step 2 and 3 are replaced by the gunning process in case of gunning

 Mixing is a very important procedure since it has decisive influence on the

 Refractory castable are generally mixed in a paddle mixer because only

 Mixing by hand is not allowed.

 Due to a possible material segregation during the transport, the dry

 The working time of castables is approximately half an hour, depending on

 Placement of insulating blankets, papers or impregnation foil should be

 Mixing liquid volume measuring equipment will be needed!

Table: Chemical properties for drinking water according to German law.

1. pH-value between 6,5 and 9,5

2. Electrical conductivity <3 mS (sea water has >5.000 mS)

4. No special smell or taste

Mixing procedure for a conventional dense castable (CC):

 This Procedure is different for Sol mixes !!!!

Wesman VAM-R Refractory Mixer

 if water settles (deposits) on the surface during vibration work, the

 if the ball crumbles, the castable contains insufficient water

slowly flows apart –

flows apart quickly – the concrete

Material is mixed with too less water

You will find “rat-holes” after vibrating the

Matrix is not dense.

Material is properly mixed

Compaction possible, but has to be done

You will find a shiny surface after vibrating

Material is mixed with excessive water.

You will find a wet surface after vibrating

Pouring should begin as soon as the mixing procedure is completed.

Quick application is decisive for the quality of the lining.

Note: Take time for transport of the material into consideration !

 Start vibrating immediately with the casting

 If vibration is too long it may reduce the quality

 Stop vibration when the mix starts to seggregate

Two types of poker and external vibrators are available – electrically or

Following kind of poker vibrators are used:

 PV have to be quickly immersed and slowly moved through the material so

Installation of side walls:

Installation of bottom fields:

Do never vibrate when the setting process of the mix is beginning to

Optimum lining conditions are between 15 °C and 25 °C.

Should considerable temperature deviations for one of the abovementioned