ANKRAL Q - Series

Cement

ICTM • R. Krischanitz • March 2013

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

5

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

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 ratio8

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

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”

13

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”

14

thermo-

chemical

load

thermo-

chemical

load

higher

corrosion

resistanceoptimized

flexibility

higher

corrosion

resistance

ANKRAL QF

Concept:

• top grade sintered magnesia

• Q-concept flexibilizing

Properties:

15

• 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:

16

• 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:

17

• 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:

18

• 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

“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

21

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 !

23

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).

25

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

26

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%.

30

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

31

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.

“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

34

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

36

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

38

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.

39

There was no visible

difference in thickness

or condition.

All bricks were removed

after the campaign.

rm 18 15 12 9 6 3

Plant C, UK

40

Competition / ANKRAL Q2 (5.8 to 9.8) / Competition

outlet

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

41

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

46

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 F, Germany

47ANKRAL Q2 vs. competitor AF brick res. thickness 220mm

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.

48

thickness and strong spalling.

Permal 5E

Thank you for your attention!

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www.rhi-ag.com