Introduc)on  

Experiment

Comparison  

Case Study  4

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4 3. Diversity and complete pallet of products

2. Supply consistent quality CE and ISO

1. Own production , r&d and product development

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4. Sintered and fused special cements;

CSA – CAC – ACA – GREEN BINDERS

raw materials are produced by selected producers–proofed over years to have the skills to produce, control and supply consistency in compliance to Caltra specifications.

We have 2 separate fully automated packing lines one for pe the

other for paper bags of 20 or 25 kg , a semi-automated filling station for super sacks of

1,25 mt own weigh station for loading bulk trucks

After control in our own laboratory and external survey,goods are

adapted to satisfy client needs. In coöperation with

renowned institutes and universities we develop

innovative binder systems and materials.

WHAT WE DO

a stable binder in any way used ;castable, gunning, ramming, and self-flowing

CAC  70  has  a  low  silica  and  iron  content  

high  early  strength  under  low  and  normal  temperature  enables  quick  de-­‐molding    

through  fusion  a  reduced  water  uptake  

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fast  con)nious  growth  of  strength  at  increased  temperature  3

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stability  is  a  key  advantage  when  designing  LLC  and  deflocculate  system    castable  

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op)mized  grain  size  distribu)on    

Mineral  Phases  

CA

CA2

High  speed  and  high  degree  of  hydra)on Sensi've  to  addi'ves  and  hard  to  control  

High  degree  of  heat  on  hydra'on  

Low  shelf  life  

High  reac'vity  ,  difficult  to  control  

Slow  hydra'on    

Low  intensity  

Forming  CA6  phase  -­‐  high  temperature  resistance    

AH3  phase  ,  good  mid-­‐temperature  strength      

Blaine  

Mpa

Formula:  hard  refractory  clay  aggregate  75%,    CA70  25%,    20  ℃  

op'mum

Optimum Blaine between 2500 to 4500, more fine particle size gives better castable strength – reduction of strength at higher Blaine

C - A - S

A — S C — A

CAC 70

> 5% CAC 70< 3%

Low Cement Castable

Improve high temperature Performance

Reduce CaO

High  Temperature  phase  A3S2mullite  phase  

ULLC Ultra low cement castable

Improve high temperature Performance

Reduce SiO2

High  Temperature    Phase  CA6-­‐  hexagonal shape

Alumina Base LLC Low cement castable

CAC-70F has excellent performance in both systems

C  =  CaO    A  =  Al2O3    S  =  SiO2  

Vibra'on   Ramming   Self  Flow   Dry/Wet  Spraying  

Methods  

0.5% 1% 3% 2% 1.5% 2.5%

MCC LCC ULCC

Semi  Dry  Spray  or  Wet  spray  high  

performance  light  weight  castable  

8%~20% CA70

Tradi)onal    Medium  Cement  Castable  

Deflocculate Castable

Vibration Casting Self flow Casting Wet Spray

2% CAC  70   5% CAC 70 8%CA70

CaO Content in Castable

1. Chemical

2. Blaine

Typical Al2O3 70.39 CaO 28.57 SiO2 0.27 Fe2O3 0.26 MgO 0.14 Na2O 0.23

Blaine 4500  cm2/g

>  325  Mesh  (44.5  μm) 7.5%

D50 3.12  µm

3. Physical Data

Comp / Flex (MPa) 6h ≥ 8 / ≥2

24h ≥ 40 / ≥5

Setting Time (min)

Initial ≥ 60

Final ≤ 360

Flow (mm)

10 min ≥ 150

30 min ≥ 140

60 min ≥ 130

Castable Type Corundum Base

High Alumina Base

Corundum Base with silica fume

℃ 14 14 14 Water % 5.0 5.8 4.8

Flow mm Initial 150 140 140

30 min 145 140 135 60 min N/A 125 120

Setting Time（min） 112 145 95

Comp / Flex Mpa

20℃ 1d 27.5 / 4.9 40.5 / 5.5 32.75 / 5.2 110℃×24h 67.1 / 10.1 95 / 12.3 98.12 / 14.3 1100℃×3h 83.7 / 13.5 103.6 / 13.5 135 / 18.1 1500℃×3h 120.9 / 18.89 135 / 12.3 156 / 36.5

Linear length change %

1100℃×3h +0.03 -0.07 -0.08 1500℃×3h +0.45 -0.20 -0.36

Bulk Density g/cm3 110℃×24h 3.1 2.78 3 1500℃×3h 3.0 2.76 2.9

Date Blaine cm2/g

325 Mesh (44.5μm)

w/c flow mm

Begin min

End min

6h

Comp/Flex MPa

24h

Comp/Flex MPa

2014.4 4588 5.5 0.4 145 105 195 15.7 / 3.8 90.85 / 12.3

2014.1 4510 6.1 0.4 140 98 170 19.3 / 4.1 97.3 / 12.5

Date of Production 2014.4 2014.1

Temperature℃ 14 14

Water % 6.0 6.0

Flow mm 145 140

Setting time（min） 160 150

Comp / Flex Mpa

20℃ x 1d 38.5 / 5.2 41.2 / 5.5

110℃×24h 88.0 / 10.3 90.3 / 10.5

1100℃×3h 100.6 / 13.5 105.5 / 13.3

1500℃×3h 129.5 / 13.8 135.3 / 13.5

Linear length change % 1100℃×3h -0.07 -0.05

1500℃×3h -0.22 -0.20

Bulk Density g/cm3 110℃×24h 2.78 2.78

1500℃×3h 2.76 2.76

Type Al2O3 CaO SiO2 Fe2O3 MgO Na2O

CAC-­‐70F 70.59 28.57 0.26 0.15 0.14 0.21

CA-­‐270  (ALMATIS) 72.32 26.43 0.41 0.15 0.23 0.22

SECAR71  (KERNEOS) 69.14 29.35 0.38 0.16 0.44 0.34

Type > 325 Mesh (44.5μm) Blaine D50 Color

CAC-­‐70F 6.2% 4558 3.12 Grey  white

CA-­‐270 12% 4017 5.95 Grey  white

SECAR-­‐71 9.5% 4253 5.49 Light  yellow-­‐white

Type w/c flow mm

Begin Set min

End Set min

6h

Comp/Flex MPa

24h

Comp/Flex MPa

CAC-70F 0.40 140 110 172 20.5 / 4.3 95.5 / 11.5

CA-270 0.43 145 140 195 17.4 / 3.2 65.2 / 8.1

SECAR-71 0.43 140 130 185 19.6 / 3.6 60.7 / 8.2

Type ℃ water（%） Initial Setting （h : min)

Final Setting (h : min)

CA-70 20 25 3 ：30 4 ：50

CA-270 20 25 3 ：20 5 ：10

SECAR-71 20 25 4 ：10 7 ：20

Type CAC-­‐70F CA-­‐270 SECAR-­‐71

10  min 200 180 210

30  min 200 170 200

60  min 190 170 195

Type CAC-­‐70F CA-­‐270 SECAR-­‐71

℃ 14 14 14

Water  % 5.0 5.0 5.0

Flow    mm ini)al 150 150 150

30  min 145 145 135

Seeng  )me（min） 112 135 165

Comp  /  Flex  

Mpa

20℃  -­‐  1d 27.5  /  4.9 21.62  /  3.1 19.5  /  2.8

110℃×24h 67.1  /  10.1 60.5  /  10 68.7  /  11

1100℃×3h 83.7  /  13.5 80.2  /  12.3 88.7  /  14

1500℃×3h 120.9  /  18.89 119.4  /  17.6 110.5  /  19.7

Linear  length  change  % 1100℃×3h +0.03 +0.03 +0.05

1500℃×3h +0.45 +0.50 +0.52

Bulk  Density  g/cm3 110℃×24h 3.1 3.1 3.1

1500℃×3h 3.0 3.0 3.0

Type CAC-­‐70F CA-­‐270 SECAR-­‐71

℃ 14 14 14 Water  % 5.8 5.8 5.8

Flow    mm ini)al 140 140 140 30  min 140 140 135 60  min 125 130 120

Seeng  )me（min） 145 160 185

Comp  /  Flex  

Mpa

20℃  -­‐  1d 40.5  /  5.5 33  /  4.9 30.84  /  3.1

110℃×24h 95  /  12.3 87.3  /  10.3 83.8  /  11.4 1100℃×3h 103.6  /  13.5 97.5  /  12.3 100  /  11.3 1500℃×3h 135  /  12.3 124.3  /  13.3 128.1  /  15.2

Linear  length  change  % 1100℃×3h -­‐0.07 -­‐0.06 -­‐0.11 1500℃×3h -­‐0.20 0.22 -­‐0.25

Bulk  Density  g/cm3 110℃×24h 2.78 2.78 2.78 1500℃×3h 2.76 2.76 2.75

Type CA-­‐70 CA-­‐270 SECAR-­‐71

℃ 14 14 14

Water  % 4.8 4.8 4.8

Flow    mm

Ini)al 140 140 135

30  min 135 135 130

60  min 120 120 120

Seeng  )me（min） 95 100 110

Comp  /  Flex  

Mpa

20℃  -­‐    1d 32.75  /  5.2 28.05  /  4.9 25.95  /  2.5

110℃×24h 98.12  /  14.3 97.7  /  13.5 88.6  /  10.2

1100℃×3h 135  /  18.1 126.8  /  17.76 130.55  /  14.5

1500℃×3h 156  /  36.5 145  /  30 150.2  /  27

Linear  length  change  % 1100℃×3h -­‐0.08 -­‐0.10 -­‐0.07

1500℃×3h -­‐0.36 -­‐0.40 -­‐0.33

Bulk  Density  g/cm3 110℃×24h 3 3 3

1500℃×3h 2.9 2.9 2.9

  SECAR71 CAC-­‐70F DF ZZ

Bulk  Density  g/cm3

110℃,  24h 3.24   3.29   3.28   3.14   1000℃,  3h 3.17   3.22   3.23 3.08   1300℃,  3h 3.15   3.19   3.20   3.04   1600℃,  3h 3.12   3.16   3.15   3.08  

Porosity  %

110℃,  24h 12.3   11.9   12.0   15.8 1000℃,  3h 15.2   14.7 14.5   18.1 1300℃,  3h 16.2   16.1 14.9 19.2   1600℃,  3h 18.0   17.9 17.4 18.8  

Linear  length  change  %

110℃,  24h -­‐0.03   -­‐0.03 -­‐0.03   -­‐0.03   1000℃,  3h +0.12   +0.13   +0.08   +0.20   1300℃,  3h +0.50   +0.57 +0.09   +0.45 1600℃,  3h +0.67   +0.60   +0.53   +0.01

Flexural  20℃  MPa

110℃,  24h 11.2   10.5   11.4   3.4   1000℃,  3h 15.8   14.6   14.3   3.0   1300℃,  3h 32.4   28.4   27.3   13.7   1600℃,  3h 31.2   33.0   29.4   25.4  

  SECAR71 CA70 DF ZZ

Comp  strength  MPa 20℃  

110℃,  24h 76.6   76.2   76.8   26.6  

1000℃,  3h 85.9   92.5   91.7   36.2

1300℃,  3h 99.6   97.9   69.2 39.1  

1600℃,  3h 121.8   127.1   69.5   102.8  

Flex    strength  MPa    20℃   1450℃,  1h 8.23 8.15 6.96 2.68

Water  （%） 4.3 4.3 4.3 5.3

flow（mm） 198 206 202 188

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4 3. Improved granular size distribution

2. low silica and low calcium content gives CA6-hexagonal shaped crystal

1. CAC-70F proofs to be a good alternative to other

70 grade refractory cements in the market

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4. Fusion gives low water / cement ratio and

improved flowability

Castable  micro-­‐structure    

STM（X3000）