PERILEX CF - REFRAMAG CF -ALMAG CF

The new basic brick concept

1st Refratechnik Refractory Seminar SUDAN
February 10 -11.2016
Peter Wilk
Area Sales Manager Africa

Influences on the properties of basic refractory bricks

Resistor
Modifier/Elastifier
Technology of the refractory producer

Combination of properties relevant for application

System of Elastified Basic Brick Grades

Magnesia

+ Porosity + Elastifier

good performance

Magnesia

+ Porosity + Elastifier

mechanically sensitive

Magnesia

+ Porosity + Elastifier

mechanically sensitive

Design of basic bricks

pleonaste

Alkali-attack on basic bricks

Salt accumulations
cause crack formation!
The lifetime is reduced due to spalling
Spalling typically occurs:
a) during heating up
after a shut down
b) if mechanical loads are
acting upon the lining

Alkali-spalling in basic lining

it does not only

appears by using
alternative fuels, but
also in case of high
capacities!!!

The chromium-oxide issue

Consumption of magnesia-chromite bricks drastically decreased over the years:

- 2004: approx. 70.000 to PERILEX 83 /80
- 2008: approx. 36.000 to PERILEX 83 /80
- 2012: approx. 11.000 to PERILEX 83 /80
Reasons:
- Ban of MgCr-bricks by company policy (Holcim, Lafarge, Heidelberg, Wacem, PPC, Afrisam)
- Environmental reasons (debris deposition, poisonous alkali-chromate-salts)
- Performance limitation / thermochemical resistance

Chrome spinel corrosion, surplus of alkalis in kiln atmosphere (ASM >1)

Corrosion of chrome spinel in the presence of free alkalis
at higher temperature
Formation of toxic, hexavalent alkali chromate sulfate
(yellow efflorescences = water soluble)
Contamination of ground water, mason eczema

Basics of PERILEX CF
Successfull longterm use of high grade raw materials :
Sintermagnesia Europe
Pleonastic fused spinel a development of Refratechnik Cement R&D
Superiority compared with Hercynite (alkaliresistance , clinker infiltration resistance)
Strategy: European raw materials

Development of PERILEX CF
Increase of refractoriness by use of ironreduced magnesia sinter
Patented Pleonast elastification resulting in unchanged mechanical properties

PERILEX CF

Summary
Combined with mechanical standard properties advantages of the chrome ore free
elastification are:
very good coatability
high thermochemical resistance
high structural elasticity
good alkali resistance
reduced open porosity

Pleonast elastified refractory bricks based on high grade synthetic and

natural magnesite sinter
Properties

PERILEX CF

REFRAMAG CF

ALMAG CF

ALMAG AF

Bulk dens. [g/cm3]

Porosity [%]

3.09
14.60

3.07
14.70

3.02
14.60

3.01
14.25

E-Modul [GPa]
CCS [MPa]

22.80
103.00

20.50
92.00

25.00
90.00

23.60
90.00

DE: T05 [C]

1520

1610

>1700

>1700

HBS 1000 [C]

HBS 1200 [C]
HBS 1400 [C]

11.4
12.2
0.9

12.1
12.3
0.7

13.6
13.9
2.5

8.6
7.7
1.4

SSI [MPa]

233

340

380

338

Alkaliresistance of the new brick grade REFRAMAG CF

REFRAMAG CF

ALMAG AF

Alkaliresistance of the new brick grade ALMAG CF

ALMAG CF

ALMAG AF

Comparison
ALMAG AF
ALMAG CF

Thermal:
operating temperature
thermal cycling
temperature gradients

Mechanical:
weight of the lining
abrasion
fluctuating loads
(rotation/deformation/
ovality)

Chemical:
kiln feed
atmosphere
reaction products

Exception alkalis:
fuels
raw materials

Comparison
REFRAMAG CF/
PERILEX CF

Thermal:
operating temperature
thermal cycling
temperature gradients

Mechanical:
weight of the lining
abrasion
fluctuating loads
(rotation/ deformation/
ovality)

Chemical:
kiln feed
atmosphere
reaction products

Exception alkalis:
fuels
raw materials

Comparison
PERILEX CF,
REFRAMAG CF
ALMAG CF

Thermal:
operating temperature
thermal cycling
temperature gradients

Mechanical:
weight of the lining
abrasion
fluctuating loads
(rotation/ deformation/
ovality)

Chemical:
kiln feed
atmosphere
reaction products

Exception alkalis:
fuels
raw materials

PERILEX CF
Coating-friendly chrome-free magnesia brick

Raw material basis: Magnesia-Spinel (fMA spinel)

Physical properties
Bulk density
Apparent porosity
Cold crushing strength
Refractoriness under load

ta
te

Pyrometric cone equivalent S.C.

2.95 - 3.10

g/cm

13 - 15

70

N/mm

1550
1700

C
C

42

Thermal expansion

at 400 C
at 800 C
at 1200 C

0.4
1.0
1.6

Thermal shock resistance

(950 C/air)

100

Thermal conductivity
(ASTM)

at 1000 C

2.8

Chemical analysis
MgO
Al2O3
Fe2O3
CaO
SiO2

lin.-%

W/mK
weight-%

approx.
approx.
approx.
approx.

78 - 82
5-7
8 - 10
2.3
1.1

Properties:
good structural elasticity combined with high strength
good resistance to alkali salt condensates
very good coatability
reduced open porosity, chrome ore-free
Application area:
normal thermally loaded sintering zones,
high alkali load

REFRAMAG CF

Mechanically thermomechanlically
optimized Pleonast spinel brick

Raw material basis: Magnesia-fused spinel

Physical properties
Bulk density
Apparent porosity
Cold crushing strength
Refractoriness under load

ta
te

Pyrometric cone equivalent S.C.

Thermal expansion

Thermal shock
resistance
Thermal conductivity
(ASTM)

3.00-3.15

g/cm

14-16

65

N/mm

1650
1700

C
C

> 42
at 400 C
at 800 C
at 1200 C

0.4
0.9
1.5

(950 C/air)

100

at 1000 C

2.8

Chemical analysis
MgO
Al2O3
Fe2O3
CaO
SiO2

lin.-%

W/mK

Properties :
Flexible
Thermochemical resistance
Alkaliresistance
Higher refractoriness
High elasticity

wt%

approx.
approx.

81-85
5-7
7-9
1.7
0.7

UTZ
SZ
LTZ

ALMAG CF

Thermally optimized
Magnesiapleonast brick

Raw material basis: Magnesia-fused spinel

Physical properties
Bulk density
Apparent porosity
Cold crushing strength
Refractoriness under load

ta
te

2.95-3.10

g/cm

14-16

65

N/mm

> 1700
> 1700

C
C

Pyro metric cone equivalent S.C.

Thermal expansion

Thermal shock
resistance
Thermal conductivity
(ASTM)

> 42

at 400 C
at 800 C
at 1200 C

0.4
0.9
1.5

(950 C/air)

100

at 1000 C

2.9

Chemical analysis
MgO
Al2O3
Fe2O3
CaO
SiO2

lin.-%

W/mK

Properties
Good reduction of thermo-mechanical tensions
High thermo-chemical resistance
High alkali resistance
High refractoriness

wt%

approx.
approx.

86-90
5-7
4-6
1.0
0.4

Fields of application in the Cement- Lime and Pulp

& Paper industry:
LTZ, CBZ & UTZ

Full solution REFRATECHNIK for hot kiln zones

Lower transition zone:

Upper transition zone:

Magnesia spinel brick with low porosity

Magnesia spinel brick with low porosity

ALMAG 85, ALMAG CF,

REFRAMAG CF, TOPMAG A1

TOPMAG A1, ALMAG CF,

REFRAMAG CF

Sintering zone:
Magnesia spinel, magnesia pleonast brick, fMA spinel

PERILEX CF,

REFRAMAG CF,

ALMAG CF

The success story of PERILEX CF

The success story of PERILEX CF

- Interesting cost-performance-ratio
- Introduced in 2010
- 243 customers in 73 countries worldwide (85 customers in 39 countries last time)
- meanwhile close to 45.000 tons in the market since introduction
References in Africa:

Ethiopia
RSA
Tunisia
Kenya
Egypt
Morocco
Nigeria

and others

Conclusion

New elastifaction concept

Increased thermal and thermochemical resistance compared to PERILEX CF

Increased mechanical resistance compared to ALMAG AF

Fills the segment between PERILEX CF and ALMAG AF

Made of European raw material only

Cost-wise very interesting solution

CF - The new concept after AF

CF = chrome free
CF = coating friendly
CF = coating formation
CF = cost friendly
CF = cash friendly
CF = cement friendly
CF= cration fantastique
CF = competitors fear
CF = suggestions?

Africa

Tunisia
Morocco
Algeria
Libya

Western
Sahara

Mauritania

Mali

Egypt

Sudan

Niger

Eritrea

Chad

Senegal
Burkina

Guinea

Nigeria

Sierra Leone

Cameroon

Liberia
Ivory
Coast

RoSS

RCA

Ethiopia
Somalia

Togo
Uganda

Ghana
Gabon

Kenya
Congo D.R. Congo
Tanzania

Angola
Zambia
Mozambique
Zimbabwe

Madagascar

Namibia Botswana

Swaziland
South Africa
Lesotho