Magnesita Refractory Optimization Model™ · 2015-04-25 · Magnesita Refractory Optimization...
Transcript of Magnesita Refractory Optimization Model™ · 2015-04-25 · Magnesita Refractory Optimization...
Magnesita Refractory Optimization Model™
Eduardo Reis – AFCM Hanoi April 15
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Magnesita Refractory Optimization Model™
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Magnesita Refractory Optimization Model™
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Magnesita Refractory Optimization Model™
Process Audit
Clinker analysisFuel & Alternative Fuels, FlameCoating area and its stability areaKBC - Kiln Brick Chart….
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Magnesita Refractory Optimization Model™
What is/are the wear mechanism phenomenon ?
Is it Thermal, Mechanical, Chemical or combination among them?
Cold FaceIntermediate Face
Hot faceCoating
Hot Face 1 Hot Face 2 Inter. Face Cold Face TDS
Distance from hot face mm 180-140 140-80 80-40 40-0
Apparent Porosity % 11,4 13,5 12,8 11,8 13-16
Bulk Density g/cm3 3,03 2,97 3,00 3,01 2,96-3,06
Elasticity Gpa 15 17,5 18,5 37
X-Ray Diffraction MgO, MA, K2SO4, C12A7
MgO, MA, βC2S MgO, MA, C12A7 MgO, MA, KCl,K2SO4,
MgO, MA,
ChemicalAnalysis
MgO % 83,1 85,8 83,3 81,6 83-87
Al2O3% 12,0 12,2 12,2 12,4 10,5-14,5
Na2O % 0,0 0,0 0,0 0,0 -
K2O % 0,16 0,04 0,09 0,28 -
SO3% 0,14 0,02 0,10 0,17 -
CaO % 2,8 0,9 2,6 3,4 < 0,9
Post Mortem Analysis22
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Magnesita Refractory Optimization Model™
Numerical simulation and finite element analysis
Thermal Mechanical Studies33
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Magnesita Refractory Optimization Model™
Complete modeling for full clinkerprocess and or separate equipments
in order to have total assertiveness on the calculated amount of materials.
As well as double checking on theequipments interconnection.
ComputerAided Design
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Magnesita Refractory Optimization Model™
Inlet kilnInlet kiln
Rotary Rotary KilnKiln
Detail Detail –– Inlet Inlet
kilnkiln
Rotary Rotary KilnKiln
CONECTION CONECTION DETAILDETAILComputer
Aided Design
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Magnesita Refractory Optimization Model™
Meedon Equation:
Ec = 3 . Ws . h . Me 4 R2
Ec : Compression force (N/mm2) –Limited by Refractory CCS
Ws : Kiln Ovality (mm)h : Lining thickness (mm)R : Kiln RadiusMe : Brick Elastic modulus (N/mm2)
Ovality Analysis55
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Magnesita Refractory Optimization Model™
Anticipating the near future and or planning the next shutdown,mainly on the equipments not
covered by on line system.
Comparative Table
Internal Temperature 1500 °C
Max. Temp. Thermograph 303,6 °C
Diagnostic Range
Critical 1500°C – 1050°C
Serious 1049°C – 600°C
Attention 599°C – 150°C
Normal 149°C - 0°C
Equipment Condition Attention
Thermo Graphics66
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Magnesita Refractory Optimization Model™
From which type of raw material ?
Basic Material : Magnesia-Spinel, Magnesia-Doloma, Doloma
Non basic Material : Alumina, Andaluzite, Silicon-Carbite, Bauxite.
Tailored Product Recommendation77
Which type of physical properties? Density Bulk, Apparent PorosityCold Crushing StrengthPermeability , ElasticityHot modulus of ruptureThermal conductivity…..
Which type of chemical properties?
Refractory Physical & Chemical Properties
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Magnesita Refractory Optimization Model™
Installation Services88
Kiln inspection
Supervision.
In house training.
Installation techniques.(Method & Equipments)
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Magnesita Refractory Optimization Model™
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MAGKOR DB 1
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Magnesita Refractory Optimization Model™ - Magkor DB1
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Magnesita Refractory Optimization Model™ - Magkor DB1
Suitable for:Severe Thermal overloadHigh abrasion areaLow liquid phase viscosity.
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MAGKOR S5
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Magnesita Refractory Optimization Model™ - Magkor S5
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Magnesita Refractory Optimization Model™ - Magkor S5
Magkor S5
Typical Mag-spinel brick
Stre
ss (
Mp
a)
Strain (%)
Pertinent Characteristics:
Very Low permeabilityHigh mechanical resistanceHigh abrasion resistanceLow porosityHigh refractorinessHigh Chemical resistance
Highly suitable for :
High mechanical stress areasNo protective coatingg area and unstable ones.Severe alkaline and salt infiltrationLow viscosity liquid phase of clinkerHigh abrasion in the outlet and lower transition zones
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BRANDS MAGKOR DB1 MAGKOR S5
Technology AZT LPT
Chemical Analysis
MgO (%) 85,5 86,5
Al2O3 (%) 11,5 12,0
Fe2O3 (%) 0,5 0,5
SiO2 (%) 0,3 0,3
CaO (%) 0,8 0,8
ZrO2 (%) 1,7 -
Physical Properties
Bulk Density (g/cm3) 3,01 3,03
Apparent Porosity (%) 15,2 14,0
CCS (MPa) 68 85
Permeability (cD) - 15
Suitable for environment conditions such as:
Extreme Thermal overload and high abrasion areas
LP technology results in low infiltration deleterious gases, high abrasion areas,
Extreme mechanical stress
Magnesita Refractory Optimization Model™ - Product Details
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Magnesita Refractory Optimization Model™
Calcinations U.T.Z. C.Z.B. Z. L.T.Z.
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Magnesita Refractory Optimization Model™
There’s no kiln refractory performance that we can’t improve.
Give us the opportunity to go through our optimization model.
You’ll see the results. We’re up to the challenge.
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Eduardo Reis
Global Technical Assistance Area
55 (31) 3368 1768 | 55 (31) 8646 1007
Thanks
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