CHOOSING AND INSTALLING MONOLITHIC REFRACTORIES

1. 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)

2. 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

3. 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

4. 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

5. Relative Tendencies of the SiO2 – Al2O3 Castable Refractories Tendency 1 - Higher Alumina Castables tend to have higher Service Temperatures. Engineers and Consultants Refractory Specialists Manufacturer’s Representative 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 lowerThermal 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 silica-alumina. 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.

6. 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. SiC SiO2 SiO2 SiC Al2O3 Al2O3 O2 O2 SiO2 O2 O2 Engineers and Consultants Refractory Specialists Manufacturer’s Representative O2 O2 O2 O2 Al2O3 Al2O3 Al2O3 Al2O3 SiC (gas) SiC SiC O2 O2 SiC SiC SiC CO2 O2 O2 O2 O2 O2 O2 O2 O2 Al2O3 SiC O2 (gas) Al2O3 O2 Al2O3 Al2O3 O2 SiC CO2 CO2 O2 Al2O3 Al2O3 Very Oxidizing conditions and High Temperature More Oxidizing conditions and Higher Temperature

7. COMPARISON – 1: ECONOMICS BETWEEN HASLE REFRACTORY CASTABLES VS. SOME TYPICAL EQUIVALENTS (Based on ALKALI ATTACK Resistance Requirements) Cost Comparisons and its Impacts Assumed Prices: P85/kg. & P85/kg. Given Densities: 2,200kgs./m3 3,050kgs./m3 Viewed from the 2nd Dimension of Cost: D39A = P85*2,200 = P187,000/m3 Gibram = P85*3,050 = P259,250/m3 (39% more expensive) 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) Engineers and Consultants Refractory Specialists Manufacturer’s Representative

8. 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.

9. The IMPLIMENTATION of Tactical Plans – The Effects of castable Temperatures. Engineers and Consultants Refractory Specialists Manufacturer’s Representative

10. The Dangers of Water Control through plastic containers. Engineers and Consultants Refractory Specialists Manufacturer’s Representative

11. The Dangers of Water Control through plastic containers. Engineers and Consultants Refractory Specialists Manufacturer’s Representative

12. 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

13. 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

14. The Dangers of Water Control through plastic containers. Engineers and Consultants Refractory Specialists Manufacturer’s Representative

15. The Dangers of Water Control through plastic containers. Engineers and Consultants Refractory Specialists Manufacturer’s Representative

16. The Effects of Adding More Water Than Necessary. Engineers and Consultants Refractory Specialists Manufacturer’s Representative

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18. The Critical Pre-Shutdown Activities Do Not Assume. If In doubt, Ask. Engineers and Consultants Refractory Specialists Manufacturer’s Representative

19. The IMPLIMENTATION of Tactical Plans – The recommended water addition manner. Engineers and Consultants Refractory Specialists Manufacturer’s Representative

20. 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.)

21. 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.

22. Beating the castable ’Setting Time’ by use of multiple and/or rightly-sized Castable Mixers. Engineers and Consultants Refractory Specialists Manufacturer’s Representative

23. Choosing the Right Metallic Anchor Supports

24. . 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)

25. . Actual footages of metallic anchors used in Line 2 Cooler Bull Nose Section. Indonesia. April 2011.

26. . 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

27. 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.

28. Guide to Welding Electrode Compatibilities .

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31. The Person Who Knows HOW will become the EXPERT. But the Person Who Knows WHY will become the Boss. Engineers and Consultants Refractory Specialists Manufacturer’s Representative