5_introduction q-series vs2 customer version2
DESCRIPTION
Q series refractory of RHITRANSCRIPT
Product Portfolio, Q – Series:
top gradespecial solutions
Q - Series
ANKRAL QF
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
high grade
economic grade
ANKRAL Q1
ANKRAL Q2 (T2)
ANKRAL QE
2
Use of Q-concept Bricks WorldwideAustria
Belgium
Brazil
Bulgaria
Canada
China
Costa Rica
Croatia
Cuba
Czech Republic
Denmark
Ecuador
Egypt
Germany
Greece
Hungary
Iran
Iraq
3
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
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
Introduction
of ANKRAL QF
Introduction of Q-series
including ANKRAL Q1
andANKRAL QE
1994
Grant of the
Hercynite patent
Rebranding of all
RHI CRK brands
in ANKRAL
Introduction of
ANKRAL Z1
1994
2000
2001
2002
1995
1996
1997
1998
1999
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
First installations of
ANKRAL ZE (R63) Introduction
of ANKRAL Q2 (T2)
1994
1994
2000
2001
2002
1995
1996
1997
1998
1999
Introduction of
ANKRAL ZC
into the Chinese
market
Development
of Q-concept
4
The Q-concept bricks:
own raw material
Q-flexibilizing
Excellent price/
performance
• Sintered magnesia, mainly of own resources
• Q-concept flexibilizing for optimized performance
excellent price performance ratio
own raw material
flexibilizingconcept
performance ratio
6
Own Raw Material Production Sites
Austria:
Breitenau
Hochfilzen
Radenthein
Italy:
Marone
Turkey:
Eskisehir
Norway:
SMA Mineral
Ireland:
PPL
China:
Dashiqiao
South Africa:
Isethebe
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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 ratio8
Dynamic E-Modul – Increased Flexibility
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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
ANKRAL Q2 shows even infiltrated a lower E-modul compared to conventional
MA spinel brick of type e.g. ANKRAL R2, ALMAG 85 or MA11.12
How to Combat thermo-chemical Attack?
– Change in ConceptsKiln with easy operation conditions.
Max 90% 80% 70%“performeter”
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thermo-
chemical
load
How to Combat thermo-chemical Attack?
– Change in ConceptsSevere chemical attack:
strong chemical attack causing reduced
performance
Q-concept:
combined optimization of corrosion
resistance + reduced loss of flexibility
Max 90% 80% 70%
Max 90% 80% 70%“performeter” “performeter”
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thermo-
chemical
load
thermo-
chemical
load
higher
corrosion
resistanceoptimized
flexibility
higher
corrosion
resistance
ANKRAL QF
Concept:
• top grade sintered magnesia
• Q-concept flexibilizing
Properties:
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• 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)
ANKRAL Q1
Concept:
• top grade sintered magnesia
• Q-concept flexibilizing
Properties:
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• 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)
ANKRAL Q2
Concept:
• high grade sintered magnesia
• Q-concept flexibilizing
Properties:
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• 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)
ANKRAL QE
Concept:
• natural alpine sintered magnesia
• Q-concept flexibilizing
Properties:
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• 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
Lining Recommendation “Conventional”
increased chemo-
thermal load
extreme conditions
at use of AF
Q-concept
ANKRAL QF in case of excessive thermo-chemical and/or
mechanical load e.g. tyre, deformations, outlet!
ANKRAL QE
ANKRAL Q2
ANKRAL Q1
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
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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.
Result after full campaign
of 12 months
22
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.
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 !
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Increase of life time from 4 to 12 months !
Chemical investigation
Brick grade
Area A B C D
Sampling for chemical analyses (distance from hot face)
5 - 25
mm
75 - 100
mm
130 - 155
mm
180 - 205
mm
Chemical analysis (wt.%)
MgO 83,80 80,40 83,60 86,8 87
Al2O3 9,69 9,73 8,80 9,26 9,3
ANKRAL QF
Technical data
sheet
24 RHI AG
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 2,7
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
K2O 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
Molar alkali sulphur ratio (ASR)
(K2O/94)+( Na2O/62)-(Cl/71)
(SO3/80)-43,92 -3,25 -1,30 0,23
Despite severe chemical
load no spalling or crack
formation.
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).
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3
magnesia alumina spinel (4).
Detail showing the precipitation of
periclase (3). Sample from area 3.
Magnesia (1), potassium chloride (2).
Mineralogical investigation
Microstructural detail from
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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).
Plant B, Czech Republic
Kiln: &&&& 5,6 x 90m SP
2.800 tpd
Lining area:
UTZ, rm 36 – 40, second trye
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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.
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
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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.
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
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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.
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%.
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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.
Plant D, Austria
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ANKRAL QF after about 18 months in
operation. Despite severe chemical
load and reducing operation conditions
residual thicknesses of 150 – 180mm.
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),
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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.
Plant A, UK
FLS, PC kiln, 2450 tpd
3,950 x 58 m
50% alternative fuels: pelletized sewage sludge
tyre chips
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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.
Plant A, UK
35
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.
Plant A, UK
General information
Customer Lafarge
Plant Cauldon, UK
Aggregate Cement rotary kiln
Position Upper transition zone
Brand ANKRAL T2 ANKRAL T2
Sampling 5-20 mm
from the hot face 145-165mm
from the hot face Technical data
sheet
Chemical analyses
Wt.% Wt.% Wt.%
Loss on ignition (1050 °C) (DIN 51081) 0.59 3.77
Determination by XRF1) (ISO 12677)
MgO 86.51 80.58 86.3
Al2O3 8.47 8.59 9.0
SiO 0.89 0.84 0.8
ANKRAL Q2 ANKRAL Q2
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SiO2 0.89 0.84 0.8
CaO 0.26 2.00 1.6
MnO 0.02 0.04
Fe2O3 2.24 2.37 2.3
Determination by titration2)
Chloride 0.24 1.62
Determination by C-S elemental analysis2)
(DIN 51085)
Sulfur 0.24 0.87
SO3 0.61 2.17
Determination by ICP-OES2)3) (ISO 26845)
K2O 0.74 1.68
Na2O 0.03 0.11
Alkali-sulfate ratio, molar4)
(K2O/94)+( Na2O/62)-(Cl/71) (SO3/80)
0.66 -0.12
Plant A, UK
37 ANKRAL QF
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
price performance ratio.
Plant B, UK
FLS, PC kiln, 2450 tpd
3,950 x 58 m
50% alternative fuels: pelletized sewage sludge
tyre chips
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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.
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.
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There was no visible
difference in thickness
or condition.
All bricks were removed
after the campaign.
rm 18 15 12 9 6 3
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
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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
Plant D, Austria
42 ANKRAL QF
ANKRAL Q2 after one full campaign in operation (LTZ rm. 3,2 - 6,2).
Residual thicknesses 180 – 190 mm.
Plant D, Austria
43 ANKRAL QF
ANKRAL Q2 after two campaigns still under coating (LTZ rm. 3,2 -
6,2). Residual thicknesses about 140 mm.
Plant E, Portugal
PC kiln Ø= 4,8 x 88 m, 3000tpd
Fuels: Petcoke, animal meal, RDFs, biomass
44
ANKRAL Q2 installed in UTZ between rm 20-22
Installed: May 2011
Replaced: May 2012
Total service life: 12 months
Residual thickness: 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
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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.
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.
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thickness and strong spalling.
Permal 5E