k1 nabal 0014 update alumina based refractories broschuere a4
TRANSCRIPT
Alumina basedRefractories
Calcined aluminas
Standard aluminas
Reactive aluminas
Synthetic sintered mullite
Cement free binder
Content
01 Calcined aluminas (NABALOX®) Refractory applications ...................................................................................................................... 07
02 Standard aluminas (NABALOX®)NABALOX® milled hard calcined aluminas ............................................................................................. 09
Properties of standard aluminas ...................................................................................................... 10
Shaped refractories ............................................................................................................................ 10
Unshaped refractories ........................................................................................................................ 11
03 Reactive aluminas (NABALOX®)NABALOX® reactive monomodal aluminas ........................................................................................... 14
NABALOX® super-reactive monomodal aluminas ................................................................................. 15
NABALOX® reactive bimodal aluminas .................................................................................................. 15
Theory and practice of particle packing ........................................................................................... 17
Viscositiy optimized reactive alumina NO 530 ................................................................................. 18
04 Synthetic sintered Mullite (SYMULOX® M 72)SYMULOX® in unshaped refractories ...................................................................................................... 24
Reactive Mullite SYMULOX® M 672 ........................................................................................................ 25
05 Cement free binder (NABACAST®)No-cement castables ......................................................................................................................... 27
Binder .................................................................................................................................................. 28
Micro-fi ller ........................................................................................................................................... 28
Defl occulant ........................................................................................................................................ 28
Practice compatibility ........................................................................................................................ 29
Corrosion-resistance .......................................................................................................................... 31
06 Special applicationViscosity adjustment for gunning mixes ................................................................................................ 34
NABALOX® calcined aluminium oxides
4
Calcined aluminas (NABALOX®)
Nabaltec is a worldwide leading and large scale
producer of synthetic raw materials for a wide
range of application areas in the refractory indus-
try. These include high performance aluminas
(NABALOX®, NABACAST®) and synthetic sin-
tered Mullite (SYMULOX®).
High class raw materials are selected according
to standardized parameters of quality. By working
within tightly controlled production parameters,
Nabaltec is able to control and tailor the degree
of calcination from very “soft” to very “hard” by
sophisticated temperature regulation of the rota-
ry kilns. This high level of control allows the pro-
duction of aluminas with defined properties such as α-Al
2O
3-content, size of primary crystals and
specific surface area. In addition, using our pat-ent-registered technique we are able to reduce the
Na2O-content to levels below 0.1 %. The high level
and long term experience of our staff members
guarantees a reliable and consistent high quality
product.
Rotary kiln for calcination of basic NABALOX®-
grades.
5
Primary crystal size
~ 0.02 μm ~ 0.2 μm ~ 2 μm ~ 3 μm
Specifi c surface area (BET)
60 – 80 m2/g 6 – 12 m2/g 0.6 – 0.9 m2/g 0.4 – 0.7 m2/g
Crystal modifi cation
< 5 % α-AI2O
370 – 90 % α-AI
2O
395 – 98 % α-AI
2O
3> 98 % α-AI
2O
3
Very soft Soft Hard
5 μm
Very hard
5 μm 5 μm 5 μm
Size of primary crystals, specifi c surface areas, α-Al2O
3-content of different calcination degrees.
20 μm 20 μm 20 μm 20 μm
Calcination temperature
Degree of calcination (Calcination temperature)
6
Typical chemical analysis [%]
Al2O
3< 99
SiO2
0.04
Fe2O
30.03
Na2O (low soda) 0.1
Na2O (standard soda) 0.3
Typical chemical composition of NABALOX® raw
materials for refractories.
These above listed calcined NABALOX® aluminas
are continuously processed by different refining steps after calcining. The refinement capabilities of Nabaltec are outstanding and highly sophisti-
cated.
Production include different types of milling, like:• continous or discontinous,
• vibration or ball,
• wet or dry,
• jet,
• high energy
and
• air separation
For refractory applications with demanding or
specific application-needs our products are re-
producible and use reliable materials with a maxi-
mum of processing safety.
Due to their outstanding homogeneity, Nabaltec
products are characterized by highly consistent
properties which provides significant advantag-
es in their refractory applications (s. table), along
with an excellent price-to-performance ratio.
These characteristics make NABALOX® aluminas
and as well SYMULOX® Mullite the ideal raw ma-
terials for the demanding applications and needs
of refractories.
Typical characteristics of NABALOX® aluminas:Calcined powders with primary crystal size of < 0.5 µm
to 3 µm result in
• reduced sintering temperatures,
• optimized corrosion resistance,
• low water demand,
• high thermal shock resistance,
• excellent high temperature properties, e.g. high RUL*,
• long life time in applications with high wear exposure…
Typical characteristics of SYMULOX®, the synthetic sintered Mullite, are:Sintered aggregates in standard refractory grain siz-
es offer:
• excellent thermal fatigue and corrosion resistance,
• highest thermal shock resistance,
• excellent high temperature properties,
• reliable creep resistance,
• ultimate durability, e.g. in kiln applications.
This provides significant advantages in their re-
fractory properties along with providing a maxi-
mum processing safety.
*RUL: Refractoriness under load
7
NABALOX®
1. Bfoundry products
kiln furniture
high temperature ceramics
shaped products
unshaped products
gunning material
NO 105 • •NO 115-71 • • •NO 115-25 • • • •NO 115 G • • • •NO 115 TC • • • •NO 125 TC • • • •NO 135 • • • • •NO 315 • • • •NO 325 • • • •NO 113 • • •NO 313 • • •NO 615-10 • • •NO 625-10 • •NO 715-10 • • •NO 725-10 • •NO 613-10 • • • •NO 713-10 RF • • •NO 625-30 • • • • •NO 645 • •NO 652 •NO 660 • •NO 530 • • •NABACAST® • • • •SYMULOX® M 72 • • • • • •
Refractory applications (in excerpts)
Standard aluminas (NABALOX®)
9
The materials are used for a number of different
applications (s. table), depending the established
materials of this product group. They are mainly
used for the production of refractories.
NABALOX® milled hard calcined (α-Al2O3 content
95 - 98 %) standard aluminas (< 325 mesh) are
very common worldwide for use in shaped and
NABALOX® milled hard calcined aluminas
unshaped refractory formulations with a particle
fraction “< 45 µm” (s. table). With their high purity
and their defined and adjusted grain size distribu-
tion they are an essential element in high temper-
ature applications. They contribute as a key fac-
tor to the main properties of all materials in the
system Al2O
3 - SiO
2, such as Andalusite, Bauxite,
Mullite and Corundum.
NABALOX® standard aluminas. Type: < 45 µm (< 325 mesh). Examples of typical refractory applications.
foundry products
kiln furniture
high temperature ceramics
shaped products
unshaped products
gunning material
NO 115-25 • • • •NO 115 TC • • • •NO 125 TC • • • •NO 135 • • • • •NO 315 • • • •
Recommended NABALOX® grades for different groups of refractory materials.
Raw materialRUL (T05)*
[°C]Al
2O
3 content [%]
shaped refractories unshaped refractories
Chamotte 1300 40 NO 115-25 NO 115 TC
Andalusite 1600 60NO 115-25NO 115 TC
NO 115 TC
SYMULOX® M 72 (synthetic Mullite)
1680 72NO 115-25
NO 135NO 135
Bauxite 1500 80NO 115-25NO 115 TC
NO 115 TC
Alumina > 1700 > 95NO 135NO 315
NO 135NO 315
*) RUL: Refractoriness under load
10
• < 45 µm (325 mesh)
• Al2O
3 ≥ 99.5 %
• Na2O ≤ 0.3 %
• high degree of calcination
D50[µm]
< 45 µm (325 mesh)
[%]
BET [m²/g]
Degree of calcination
NO 115-25 5 95 0.9 Hard
NO 135 5 98 0.8 Very hard
NO 115 TC 4 98 1.0 Hard
NO 315 3 99 1.5 Hard
In shaped products NABALOX® aluminas are ap-
plied, e.g. for higher refractoriness. NABALOX®
standard aluminas are an effi cient way to fi ne tune the Al
2O
3-content of all refractory materials
in the system Al2O
3 - SiO
2. With their high degree
of calcination they are an appropriate additive to
reduce shrinkage and the high temperature creep
of refractories.
Shaped refractories
These characteristics make them an approved
and well established raw material.
Low soda types of this product group
(325 mesh / < 45 µm) are mainly used in refractory
applications for the production of fi lters and cata-lyst carriers.
Properties of standard aluminas
Main properties of grades of 325 mesh NABALOX® aluminas.
Kiln furniture: Cassette for roof tiles.
Dis
trib
uti
on
[%]
Grain size [µm]
0 1 100
80
60
40
20
0
10
NO 115-25
NO 115 TC
11
The main difference in the group of 325 mesh
NABALOX® aluminas between NO 115-25 and the
group of NO 115 TC, NO 135 and their fi ne variety NO 315 is defi ned in the lower (<) 45 µm-value. In opposite to NO 115-25 all other NABALOX® alu-
minas have a special production-accompanying
step, termed “TC” for “top cut”. By a process of
air separating, the lager amount of coarse alumi-
na-agglomerates which are present after the mill-
ing procedure are separated away.
NO 115-25: The amount of alumina < 45 µm is lower
(95 %) compared to the other three products
(98 – 99 %), with the additional production step of
“air separation”.
Unshaped refractories
NO 115-25: Remaining alumina agglomerates, after milling without air separation.
Grain size distribution of milled hard calcined aluminas with (NO 115 TC, no agglomerates are left) and without air separation (NO 115-25, remaining agglomerates between approx. 15 to 40 µm).
This results in a lower water demand of “top cut”-
types and results thus in better fl owability of un-shaped refractories when > 45 µm particles have
been removed, e.g. at NO 115 TC (s. image).
Cu
mu
lati
ve p
erce
nta
ge
pa
ss [v
ol.-
%]
Grain size [µm]
0 1 1000
100
10
1
10 100
REAL CASTABLE (example)
THEORY (Andreassen)
12
These agglomerates exhibit, e.g. when used in
unshaped refractories, a behaviour similar to a
“sponge”. They only absorb water but cannot of-
fer any flowability effect. Image of the two refrac-
tory castable formulations shows the difference
in wettability/flowability schematically when an air separated alumina is compared to a “just
milled” type in identical proportions of solids and
water in a castable.
For the highest refractory properties, an opti-
mized particle packing is required for all mix-
tures. Thus, a continuous cumulative particle
size distribution is required, in analogy to the the-
ory of Andreassen*.
NABALOX® standard aluminas represent the
grain spectrum between 1 and 15 µm and are
utilized in an amount of 10 – 20 % to design casta-
bles with the highest packing density and higher
alumina content for a better refractoriness.
Cumulative particle size distribution curve shows how close the grain size distribution of the real castable (standard mixture) narrows to the theoretical optimum (black curve). Red circle: Grain size area for standard aluminas: 2 – 15 µm.
Identical refractory castable formulation “A” with air separated alumina, “B” without. Both with iden-
tical water content.
*
d: grain size
D: maximum grain size Q: Andreassen coefficientCPP: cumulative percentage pass
CPP = (–)qd
D
A B
Reactive NABALOX® aluminas
Dis
trib
uti
on
[%]
Grain size [µm]
0 1 100
80
60
40
20
0
10
NO 715-10NO 725-10
NO 615-10NO 625-10
14
In shaped and unshaped refractory applications
the reactive NABALOX® special aluminas are
characterized by an extremely reproducible and
homogeneous processability. NABALOX® reac-
tive aluminas enable a wide processing window
and a significant reduction in water demand. This class of reactive aluminas lowers the production
costs and raises the efficiency of the refractory solutions by improving packing density, corrosion
resistance and durability of refractory materials.
Properties of Reactive NABALOX® aluminas:• D50 < 2.5 µm
• Al2O
3 ≥ 99.5 % - 99.8 %
• Na2O ≤ 0.3 % - 0.1 %
• high degree of calcination
• high specific surface area, results in high sintering ability (starting from 1100 °C)
Reactive aluminas (NABALOX®)
Aluminas with a high amount (~ 98 %) of α-Al2O
3
are milled, partially down to the primary crystal (2
μm). These carefully processed raw materials are used as foundry products or for refractory mixes.
The product specific fineness results from the use of a high milling energy. In addition, the grain
size distributions of the material are specifically defined and confined within close limits. Material properties of interest include high lifetimes, good
workability, etc. These hard calcined aluminas pro-
NABALOX® reactive monomodal aluminas
NABALOX®Al
2O
3
[%]
Na2O
[%]
D50[µm]
BET[m²/g]
NO 615-10 99.6 0.3 2.5 1.6
NO 625-10 99.8 0.1 2.5 1.6
NO 715-10 99.6 0.3 2.0 2.0
NO 725-10 99.8 0.1 2.0 2.0
vide a reliable base for the production of sophisti-
cated refractories with a wide variety of different
application areas.
Dis
trib
uti
on
[%]
Grain size [µm]
0 1 100
80
60
40
20
0
10
NO 713-10 RF
NO 613-10
15
Nabaltec produces super-reactive, calcined alumi-
nas with a monomodal grain size distribution for
a variety of applications. For this purpose, alumi-
nas with a lower content of α-Al2O
3, (~ 95 %), so-
called “soft” calcined are milled down close to the
primary crystal (< 0.5 μm) level. The exceedingly high reactivity of this product group is based on the
fineness of the alumina as well on the small prima-
ry crystals and their high specific surface area. The low soda-content makes the material suitable for
the production of corrosion resistant refractories
e.g. ladle linings or precast shapes. Using these ul-
tra-fine α-Al2O
3-raw materials, very low viscosities
can be achieved.
NABALOX® super-reactive monomodal aluminas
NABALOX®Al
2O
3
[%]
Na2O
[%]
D50 [μm]
BET [m2/g]
NO 613-10 99.7 0.1 1.0 6
NO 713-10 RF 99.7 0.1 0.8 7
The hi gh specific surface area (up to 7 m²/g) of these super-reactive grades is of significant interest for the fabrication of ULC (ultra low cement) and NC (no
cement), e.g. chemically bonded, castables or for
producing high performance refractory products.
Nabaltec produces super-reactive, calcined alu-
minas with a bimodal grain size distribution for a
variety of applications.
In connection with this application, there is a need
for a homogeneous mixture (see SEM-image) of
NABALOX® reactive bimodal aluminas
fine and coarse alumina primary crystals (< 0.5 – 2 μm) in precisely balanced proportions. Opti-mized, long milling and homogenization proce-
dures guarantee a consistent product to achieve
the best processability results. For example, for
the production of free flowing refractory mixes,
Dis
trib
uti
on
[%]
Grain size [µm]
0 1 100
80
60
40
20
0
10
NO 625-30
NO 652
16
PRIMARY CRYSTAL SOFT CALCINED 0.2 – 0.5 μmPRIMARY CRYSTAL HARD CALCINED 2.0 – 3.0 μm
NABALOX®Al
2O
3
[%]Na
2O
[%]D50 [μm]
BET [m2/g]
NO 625-30 99.7 0.1 2.0 3.0
NO 645 99.7 0.1 2.0 4.0
NO 652 99.7 0.1 3.0 3.0
NO 660 99.7 0.1 2.0 3.0
5 μm
Fine and coarse aluminas „deeply“ homogenised• combination of soft and hard calcined aluminas
• interacting of “fi ne” and „coarse“ grain size distributions
• homogenisation via intensive mixing or milling
• sophisticated grain size distribution for castables
All this result in higher refractorinessgreen density
sinter density
porosity
water demand
fl owability
the formation of bimodal reactive aluminas with
coarse grains added by the user, results in an op-
timized grain size distribution. This leads to a re-
duced water demand combined with an excellent
fl owability.
17
Theory and practice of particle packing
Reactive aluminas are mainly used in unshaped refrac-
tories to represent the particle fraction < 5 µm, and thus,
to act as a micro-filler. They are able to fill the smallest
Theory: Optimized particle packing with continuous grain size distribution.
Practice: Real refractory microstructure with reactive alumina particles filling the gaps between the coarse aggregates.
SYMULOX®
Coarse Aggregates
NABALOX®
Reactive alumina
SYMULOX®
Coarse Aggregates
NABALOX®
Reactive alumina
pores in the microstructure of refractory casta-
bles, reducing the water content/demand and thus
also its viscosity.
Cu
mu
lati
ve p
erce
nta
ge
pa
ss [v
ol.-
%]
Grain size [µm]
0 1 1000
100
10
1
10 100
Real castable (expample)
Theory(Andreassen)
18
Cumulative particle size distribution curve shows how close the grain size dis-
tribution of the real castable (standard mixture) narrows to the theoretical op-
timum (black curve). Orange circle: Grain size area for super reactive aluminas (0.2 – 1.5 µm). Red circle: Grain size area for reactive monomodal aluminas (1 – 5 µm). Blue circle: Grain size area for bimodal reactive aluminas (0.2 – 5 µm).
Viscosity optimized reactive alumina NO 530
In modern refractory applications, niches can be
found, where highest demand for thermomechani-
cal properties meets the necessary for easy work-
ability. State of the art reactive aluminas common-
ly need a compromise between a.m. properties.
So highest refractoriness resp. slag resistance
can be achieved with lowest water demand, but
followed by extremely dilatant castable viscosity
or the need for vibration.
NABALOX®Al
2O
3
[%]Na
2O
[%]D50 [μm]
BET [m2/g]
NO 530 99.7 0.1 1.5 3.5
The new generation of NABALOX®, viscosity opti-
mized reactive alumina NO 530 allows the combi-
nation of both, lowest water demand and practice
compatible free flowing consistency.
Alumina Medium grain size D50 [µm] Water demand for free flowing properties [%]
NO 115 TC 4 5.5
NO 315 3 5.0
NO 615-10 2.5 4.8
NO 715-10 2 4.5
Water demand of a free flowing castable can be reduced by the use of fine reactive aluminas
Dis
trib
uti
on
[%]
Grain size [µm]
0
100
80
60
40
20
0
1 10 100
NO 530
19
[mm] [%]
Tabular alumina 3 – 6 24
Tabular alumina 1 – 3 16
Tabular alumina 0.5 – 1 15
Tabular alumina 0 – 0.5 7
Tabular alumina 0 – 0.3 5
Tabular alumina 0 – 0.045 12
NABALOX® NO 315 5
NABALOX® NO 530 (or common bimodal reactive alumina) 13
CAC* 3
PCE** 0.1
Water (deion.) 3.8
Test castable formulation
NO 530 shows via SEM bimodal grain size distribution.
* Calcium-aluminate-cement** Poly-carbonate-ether
5 µm
Po
wer
co
nsu
mp
tio
n [W
]
Mixing time [s]
0 100 400
1800
1600
1400
1200
1000
800
600
400
200
0
200 300 500
wet out point
fully dispersed
water addition
comm
on bimodal
reactive alumina
NO 530
20
Flow spread 3.8 % H2O (EN1402-4) [%] 125
Green density (110 °C) [g/cm3] 3.2
CCS (110 °C) [MPa] 66
Setting time (ultrasonic) [h] 10
Properties of test castable
“Wet out point” is the state during the mixing process of a castable when all particles are wettened. At this point the power consumption of the mixer is very high, due to tough consistency of the mix. Once, this point is passed, dis-
persion starts to improve and viscosity decreases until complete dispersion, i.e. highest flowability is reached.
Viscosity optimized reactive aluminas can provide:
• Lower power consumption at peak Higher loading of mixer possible
• Lower resistance to mixing tool Higher lifetime of equipment
• Shorter time from “wet out” to “fully dispersed”
• Shorter mixing time at the construction place Lower maintenance costs in the steel mill
• Good workability is achieved quickly in the mixer Lower risk of too high water addition
Synthetic sintered Mullite SYMULOX® M 72
T [°
C]
Wt - [%] (after Aramaki and Roy)
SiO2
10 AI2O
3
2100
1900
1700
1500
0
7030 50 90
liquid
SiO2 +
liquid
corundum + liquid
corundum + mullite
mullite+ liquid
SiO2 +
mullite
SY
MU
LOX
M7
2
22
Synthetic sintered Mullite SYMULOX® M 72, a refractory grain
Nabaltec has been manufacturing synthetic sin-
tered Mullite for many decades under the brand
name SYMULOX®. The adjunct “M 72” stays for
stoichiometric Mullite with 72 % alumina content.
M 72 and is widely used as a high-quality grade
raw material, primarily in the refractory industry.
The homogeneous phase constitution of
SYMULOX® M 72 and the extremely low level of
impurities offers considerable advantages over
naturally occurring aluminosilicates.
Products based on sintered Mullite
SYMULOX® M 72 also exhibit excellent chemical
resistance and high refractory properties. Micro-
crystalline Mullite shows high strength, combined
with a low thermal expansion, resulting in excel-
lent thermal shock resistance. Since there are
only a limited amount of amorphous components
(glass formers), its high-temperature creep resist-
ance can exceed that of aluminium oxide ceram-
ics. The use of SYMULOX® M 72 at temperatures
of up to 1700 °C, even in an oxidizing atmosphere.
Thermally etched surface of SYMULOX® M 72.
Phase diagram Al2O
3-SiO
2Stable single phase region
Variations of the chemical composition in the
Al2O
3 – SiO
2 system will influence the mineralog-
ical and physical properties of Mullite. Stoichi-
ometric Mullite (3 Al2O
3: 2 SiO
2) consists of ap-
prox. 72 % Al2O
3 and approx. 28 % by weight SiO
2.
Mullite exists as single phase (at atmospheric
Typical advantages of Mullite-refractories
• low uniform thermal expansion
• excellent thermal shock resistance
• very good chemical resistance
• high refractoriness also under load and a high creep resist-ance
23
Analysis M 72[mm]
K1 0 – 0.5
K2 0.5 – 1.5
K3 1.5 – 3.0
K4 3.0 – 5.0
pellets > 8.0
Standard and fine grain sizes of SYMULOX® M 72:
Mineralogical composiition Unit M 72
Mullite [%] 90 – 95
Glassy phase [%] 5 – 10
Corundum [%] ~ 1
Physical properties* M 72
Bulk density [g/cm3] 2.8
Specific density [g/cm3] 3.13
Water absorption [%] 1
Open porosity [%] 1.5
Total porosity [%] 9
* measured on pellets
Analysis M 72 [%]
Al2O
372
SiO2
26
Na2O 0.2
K2O 0.6
CaO 0.05
MgO 0.1
Fe2O
30.3
TiO2
0.2
Chemical and physical analysis of SYMULOX® M 72:
SYMULOX® M 72 pellets.
Analysis M 72[µm]
K0 C 3 – 5
K0 7 – 15
K0 coarse 15 – 30
SYMULOX® M 72 various grain sizes.
Synthetic Mullites are excellent for high tempera-
ture, long term applications, combined with mechan-
ical loading. Defined grain size distributions (coarse and fine) of SYMULOX® M 72 make it of use in all
mentioned applications and give the opportunity to
adjust the porosities of the final product.
Due to its relatively low thermal conductivity and
high corrosion resistance, SYMULOX® M 72 is
used in many different refractory areas (e.g., see
table):
• foundry products
• kiln furniture
• thin-walled high-temperature ceramics
• (un)shaped refractories
• gunning mixes
• refractory castables
• precast refractories…
Examples of common applications of SYMULOX® M 72:The low thermal expansion of the material, re-
sults a high thermal shock resistance. Due to
that, synthetic Mullite M 72 is widely used in
shaped refractories, mainly for the glass- and ce-
ment-industries.
pressure) only in a narrow stability field (s. green zone, in image). SYMULOX® M 72 of Nabaltec
has the exact chemical composition of the only
truly stable single phase area in the system Al2O
3
- SiO2. The lower the number of phases in a (sol-
id) phase-system, the higher the refractoriness.
∆L
/L0/%
Temperatur [°C]
0 600 1600
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0
1000
Sintered mullite
Sintered alumina*
200 400 800 1200 1400
Cu
mu
lati
ve p
erce
nta
ge
pa
ss [v
ol.-
%]
Grain size [µm]
0 1 1000
100
10
1
10 100
Real castable (expample)
Theory(Andreassen)
24
*After: Petzold A, Ulbricht J, Aluminiumoxid – Rohstoff-Werkstoff- Werkstoffkomponente Deutscher Verlag für Grundstoffindustrie, Leipzig.
SYMULOX® in unshaped refractories
Unshaped refractories are widely used in the steel industry due to their better handling capability e.g. quicker lining.
Cumulative particle size distribution curve shows how close the grain size distri-bution of the real castable (standard mixture) narrows to the theoretical optimum (black curve). Blue circle: Grain size area for standard SYMULOX® grain size
(K1 – K4). Orange circle: Grain size area for fine SYMULOX® grain size (K0-types).
25
Raw materials [wt.-%]
SYMULOX® M 72 K4 (3.0 – 5.0 mm) 10.0
SYMULOX® M 72 K3 (1.5 – 3.0 mm) 32.0
SYMULOX® M 72 K2 (0.5 – 1.5 mm) 8.0
SYMULOX® M 72 K1 (0 – 0.5 mm) 15.0
SYMULOX® M 72 K0 (7 – 15 µm) 7.5
NABALOX® NO 135 5.0
NABALOX® NO 325 10.0
NABALOX® NO 625-10 4.5
Microsilica® 971-U 4.5
SioxX® Zero 3.0
Secar® 71 0.5
Application example: Formulation of Mullite refractory concrete
Green strength [MPa]
MOR* 2.7
CCS** 12
Dried 110 °C / 24h
MOR 7.5
CCS 52.9
Fired 600 °C / 24h
MOR 7.2
CCS 46.4
Physical properties of Mullite refractory concrete recipe
* Modulus of rupture** Cold crushing strength
Reactive Mullite SYMULOX® M 672
In unshaped refractory products reactive Mullite
SYMULOX® M 672 is used as an easily dispersi-
ble micro-filler to improve the flow behavior of free flowing castables.
Advantages of SYMULOX® M 672 granules are:• high specific surface area
• highly sinter-able
• very fine milled
• spray dried
• easy to disperse…
Since the mullitization of the raw material is largely
complete, refractory precast shapes that contain
reactive Mullite SYMULOX® M 672 as a micro-filler do not exhibit subsequent shrinkage, which would
be typical for micro-silica containing materials.
In unshaped refractory products the packing den-
sity can be maximized by the use of reactive Mul-
Many M 72 primary particles result in one spray dried granulate M 672.
lite, which increases the corrosion resistance of
these products.
This product contains a marginal amount of free
alumina (α-corundum) and silica (amorphous). Due to wet milling and subsequent spray drying, the
product appears granulated. This soft and easily
dispersible granulate is ideally suited for all refrac-
tory castables.
Cement free binder (NABACAST®)
27
For the production of a new class of no-ce-
ment-castables NABACAST®, an innovative
cement-free binder, based on reactive alumina,
was developed by Nabaltec. The products of the
NABACAST®-group act also as a binder, a
micro-filler and a deflocculant.
The reduction of cement content in refractories
has been undergoing for decades and has led to a
significant increase in the performance of refrac-
tory castables. Alternative hydraulic binders on
the basis of Al2O
3 or MgO, allow the formulation of
corundum based no cement castables (NCCs) that
even outperform state of the art ultra low cement
castables (ULCCs) with cement contents of max.
3 %. Corundum based castables free of CaO exhibit
higher hot modulus of rupture and higher refrac-
toriness under load (RUL), than those containing
CaO, coming from the addition of calcium alumi-
nate cement (CAC). Furthermore, the corrosion of
Al2O
3-based refractories by metallurgical slags can
be understood by the incorporation of CaO into the
castables microstructures. CaO-free refractories
No-cement castables
Analysis NABACAST® RM 16 [%]
Al2O
392
MgO 7
Na2O < 0.3
CaO < 0.3
SiO2
< 0.05
Typical chemical analysis of NABACAST®.
have a higher capacity to incorporate CaO from the
slag resulting in a higher corrosion resistance.
Highly refractoryNABACAST®-bonded refractory materials do not
form a liquid phase at temperatures up to 1700 °C.
This guarantees excellent properties regarding hot
bending strength and refractoriness under load.
Cement-freeNABACAST® contains only alumina and magne-
sia. This provides a possibility to produce unshaped
refractories, containing only the high temperature
stable refractory phases Corundum and Spinel.
28
NABACAST® fulfils with particle sizes of < 3 μm the same function as reactive aluminas in estab-
lished, cement-containing, formulations.
Micro-Filler
NABACAST®-Binder shows a multimodal grain
size distribution for lowest water demand and
highest packing density.
There is no need to add a deflocculant to the castables.
Deflocculant
Al2O
3-particles < 0.5 µm
Al2O
3-particles ~ 2 – 3 µm
MgO-particles ~ 10 – 20 µm (porous)
NABACAST® reacts hydraulically via forming hy-
drates (see reaction equation), which causes con-
solidation of the refractory concrete.
Setting mechanism:Al
2O
3 + 4 MgO + 10 H
2O [Mg
4Al
2 (OH)
12]2+ [2 (OH) 3 H
2O]2-
Binder
Analysis Unit RM16
D10 [µm] 0.5
D50 [µm] 2
D90 [µm] 8
Setting time [h] 5
Cold crushing strength* [MPa] 35
* measured on a test formulation
Cu
mu
lati
ve p
erce
nta
ge
pa
ss [v
ol.-
%]
Grain size [µm]
0 1 1000
100
10
1
10 100
Real castable (expample)
Theory(Andreassen)
29
Due to difference in particle size, NABACAST®-
Binder and CAC cannot be exchanged 1 : 1 in the
castable formulation. Therefore, for the following
comparison, the decision was taken, to exchange
NABACAST® by two reactive aluminas with a me-
dian grain size of 1.7 µm (NO 625-30) and 0.9 µm
(NO 713-10 RF), and to exchange CAC by tabular
Practice compatibility
Cumulative particle size distribution curve shows how close the grain size distribution of the real castable (standard mixture) narrows to the theoretical optimum (black curve). Red circle: Grain size area for micro fillers, reactive aluminas and/or NABACAST® (0.2 – 5 µm).
alumina in the fraction 0 – 45 µm. Result of this
exchange are two castables with equal flowability, water demand and density. Chemical composition
is the important difference: While ULCC contains
99 % Al2O
3 and 1 % CaO but NCC contains 99 %
Al2O
3 and 1 % MgO.
c [1
0³
m/s
]
t [min]
0 500 1500
5
4
3
2
1
0
1000
K99 ULCC
K99 NCC
30
Formulation example of NABACAST®-refractory concrete K99
Analysis Unit K99 NCC K99 ULCC
Tabular alumina 3 - 6 mm [%] 30 30
Tabular alumina 1 - 3 mm [%] 17 17
Tabular alumina 0.5 - 1 mm [%] 10 10
Tabular alumina 0 - 0.5 mm [%] 6 6
Tabular alumina 0 - 0.3 mm [%] 6 6
Tabular alumina 0 - 45 µm [%] 11.35 9.75
Calcined alumina NO 135 [%] 3.25 3.25
Reactive alumin NO 625-30 [%] 0 7.5
Reactive alumina NO 713-10 RF [%] 0 7.5
NABACAST® [%] 16.49 0
Aluminate cement [%] 0 3
Deflocculant (PCE) [g/100g] 0.09
H2O [ml/100g] 4.4 4.4
Development of sound velocity (c) during the setting process of castables bonded with NC-Binder or CAC. Comparison of setting kinetics of K99 NCC vs. K99 ULCC.
Setting kinetics The setting process was monitored by a continuous
measurement of sound velocity in the castable sam-
ples during the setting process. The sound velocity
was measured with an IPS-measurement system
(Ultratest GmbH) at a ping rate of 1 min-1.The time to
reach a sound velocity of 1500 m/s was defined as the setting time. As setting time is the central issue
of this paper, a statistical analysis on data quality
was done by the evaluation of 14 repetitions of the
formulation without any additive addition.
BA
31
Physical main properties of NABACAST®-refractory concrete K99 NCC in comparison to K99 ULCC
Unit K99 NCC K99 ULCC
Spreading [%] 100 100 Same consistency
CCS*25 °C
[MPa] 7 17.2 Slower strength evolution
CCS*110 °C
[MPa] 31.5 20.8 Similar dried strength
Bulk density110 °C
[g/cm³] 3.04 3.08 Same bulk density
Based on its completely CaO-free phase constitu-
tion, NABACAST® exhibits also an optimal chem-
ical resistance.
Corrosion resistance
By using NABACAST® life time expectancy of re-
fractory parts, exposed to corrosive slag attack,
can be improved significantly.
Slag test:
A: Crucible with K99 ULCC; B: With K99 NCC (NABACAST®)
Slag front of erosion
un-infiltrated castable
infiltrated castable front of infiltration
CAC
CaO content of the matrix:~2.5 %
NABACAST®
Higher CaO-absorptioncapacity
32
Mode of action:After a few millimeters, the infiltration stops and a slag bath remains in the crucibles. It is obviousely
that slag is penetrating through the microstruc-
ture of the CaO-containing castable quickly and
without a significant reaction between slag and re-
fractory material that could cause a retardation of
infiltration. In contrast, infiltration of slag into the CaO-free castable is retarded at a very early stage
and stops after a few mm.
Castable Matrix:Al
2O
3 + CaO
Slag:
CaO + SiO2 + MexOy
--> Increased slag viscosity--> Slowdown of further infiltration
MexOy:
Unspecified metal oxides of slag
Special applications
34
NABALOX® milled soft calcined aluminas:By comparison with the hard calcined aluminas,
the soft calcined exhibit a high specific surface area, based on their typically small primary crys-
tals (< 0.5 μm). As a result, they are an ideal raw material to adjust the viscosity of plastic materials
or e.g. refractory gunning mixes.
Viscosity adjustment for gunning mixes
Application recommendations NO 113 NO 313 NO 183 NO 283
Foundry products • •Shaped refractories • • • •
Gunning mixes • • • •
The use of other additives for plasticizing is often
not necessary. A number of foundry products, e.g.
coatings are influenced positively regarding their refractoriness and stability.
Analysis Unit NO 113 NO 313 NO 183 NO 283
Al2O
3[%] 99.6 99.6 99.7 99.7
Na2O [%] 0.3 0.3 0.3 0.3
SiO2
[%] 0.03 0.03 0.03 0.03
Fe2O
2[%] 0.03 0.03 0.03 0.03
Spec. surface area (BET) [m2/g] 9 10 10 10
α-Al2O
3 content [%] 95 95 95 95
D10 [µm] 0.4 0.6 0.8 0.7
D50 [µm] 3 2 10 5
D90 [µm] 31.5 16.2 50 25
Primary crystal size [µm] < 1 < 1 0.2 0.2
Typical chemical and physical analysis of NABALOX® for viscosity adjustment
Service for our customers
36
Technical service development / production Nabaltec AG develops new products and refines innovative products in close cooperation with our
customers and raw material suppliers.
Here we use our own lab facilities as well as our
excellent contacts to external test institutes and
laboratories to offer our customers a wide range
of service to support them in formulation develop-
ment and test procedures.
The successful implementation of this develop-
ment and the intensive customer consultations
enable Nabaltec AG an interaction with our cus-
tomers in a cooperative, responsible and innova-
tive manner. This culminates in the development
of high performance products at the customer as
well as in our facility.
Additionally, we have the capacity to fashion tailor
made products for special customer requirements
and their highly sophisticated and demanding
markets.
Servicefor our customers
Laboratory services Our analysis centre is responsible for independent
production control and quality offers laboratory
services for customers intending to use our large
analytical equipment.
With this excellent equipment we are able to exe-
cute analytic tests in the area of inorganic solids,
trace elements and water quality.
The certification in accordance with DIN EN ISO 17025 confirms the high service standards of our lab.
We will gladly inform you about our capabilities.
37
Nabaltec
product portfolio
NABALOX®
Aluminium oxides, for the production
of ceramic, refractory and polishing
products
APYRAL®
Aluminium hydroxides, as flame
retardant and functional filler
APYRAL® AOH
Boehmite, as flame retardant filler
and functional filler
GRANALOX®
Ceramic bodies, for the production
of engineering ceramics
SYMULOX®
Synthetic sintered Mullite, for the pro-
duction of e.g. refractory products
NABACAST®
Hydraulic, cement-free binder,
based on α-alumina
ACTILOX®
Boehmite, as flame retardant filler
and catalyst carrier
Schwandorf, Germany
Nabaltec AG
Chattanooga, TN, USA
Naprotec LLC
Corpus Christi, TX, USA
Nabaltec USA Corporation
Corpus Christi, TX, USA
Nashtec LLC
38
Visit us at our website www.nabaltec.de where you will fi nd the latest company updates andrecent versions of all available certifi cates free for download as PDF-documents.
Locations Agencies
Nabaltecworldwide
Tokyo, Japan
Nabaltec Asia Pacific K.K.
Shanghai, China
Nabaltec (Shanghai) Trading Co., Ltd.
39
Further information:
Nabaltec AG
P.O. Box 1860 · 92409 Schwandorf
Phone +49 9431 53-0
www.nabaltec.de
Customer Service
Phone +49 9431 53 910
Technical Service
Phone +49 9431 53 920
Nabaltec AG
P.O. Box 1860 · 92409 Schwandorf
Tel +49 9431 53-0
Fax +49 9431 61 557
www.nabaltec.de
All data listed in this brochure are reference values and subject to production tolerance. These values are exclusive to the prod-
uct description and no guarantee is placed on the properties. It remains the responsibility of the users to test the suitability of
the product for their application.
02 / 2020