Carbon Black 2017

MagAl Spinel – Zirconia Vs. Alumina - Zirconia Refractory

for Hard Black Reactor

Ravikumar N, Ranjan Dey, Eswaran V T, Rajagopalan R

CARBORUNDUM UNIVERSAL LIMITED

Carbon Black 2017

Contents :

Refractory Application in Carbon Black Reactor

Issues in Hard Black Reactor

Issues in Soft Black Reactor

Addressing the issues w.r.t hot face refractory

Study on Alumina – Zirconia and Spinel – Zirconia Composite

Conclusion & Recommendation

Product recommendation for various application areas

Installation Service

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Refractory Application in Carbon Black Reactor

Hard Black Reactor

Soft Black Reactor

Inlet Box

Drier Combustor

Rotary Drier

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Exposure on Refractories in Hard Black Reactor

Extreme Temperature Thermal spalling Higher refractory wear in the restriction zone Temperature fluctuations due to grade changes Reaction between refractory and impurities in CBFS and with

Chemical Additives

Exposure on Refractories in Soft Black Reactor

High Temperature Thermal spalling Reaction between refractory and impurities in CBFS and with

Chemical Additives Localised combustion Localised heating due to improper burner alignment

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Alumina -

Zirconia

99.5%

Alumina

Zirconia

Different Refractory Materials used for Venturi in Hard Black Reactors

Alumina-

Chrome

MagAl Spinel -

Zirconia

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Operating temperatures in hard black reactors are going beyond 1900 Deg.C to improve the operating efficiencies.

We developed Alumina – Zirconia composite for evaluating at high temperature applications. Which is proven to be good upto 1850 Deg.C.

Presently, we are evaluating Mag – Al Spinel + Zirconia composite as a next level to Alumina – Zirconia Composite.

Issues towards Hot Face Refractory….

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Study on Alumina – Zirconia and Spinel – Zirconia Composite

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Comparison of Phase Diagram : Alumina – Silica Vs Magnesia - Alumina

Alumina – Silica Phase Diagram Alumina – Magnesia Phase Diagram

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Two types of samples were taken for the study. Alumina – Zirconia and

Spinel – Zirconia Composite

Sample # Description Raw Material Base Firing Temperature

Sample A 95% Alumina Alumina + Zirconia

1750oC

Sample B 25% MgO Spinel Spinel + Zirconia 1750oC

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Sample A: Alumina – Zirconia

Composite

Sample B: Spinel – Zirconia

Composite

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Thermal Shock Resistance [TSR] to determine the effect of

repeated heating and cooling.

Pyrometric Cone Equivalent : To Determine the refractoriness

Scanning Electron Microscopy [SEM] – EDAX Analysis: To

identify the phase morphology

Tests carried out :

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Results of Thermal Shock Resistance [TSR] at 1000 Deg C

Sample # Air Quenching (Cycle) Water Quenching (Cycle)

Sample A + 150 19

Sample B + 150 22

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Results of Pyrometric Cone Equivalent

Orton Cone 38

Sample A Sample B

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Scanning Electron Microscopy [SEM] – Sample A

Homogeneous distribution of Zirconia in Matrix

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Scanning Electron Microscopy [SEM] – Sample B

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004

004

1.0 mm1.0 mm1.0 mm1.0 mm1.0 mm

0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00

keV

004

0

40

80

120

160

200

240

280

320

360

400

Co

un

ts

OK

a

MgK

aA

lKa

Scanning Electron Microscopy [SEM] – EDAX

Analaysis Sample B

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002002 1.0 mm1.0 mm1.0 mm1.0 mm1.0 mm

0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00

keV

002

0

100

200

300

400

500

600

700

800

900

1000

Co

un

ts

OK

a

MgK

aA

lKa

ZrL

lZ

rLa

Scanning Electron Microscopy [SEM] – EDAX

Analaysis Sample B

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High Resolution Optical Micrography Sample B

Zirconia Particle Distribution in matrix

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From the Scanning Electron Microscopy [SEM] study, Uniform Zirconia

distribution in matrix in sample A.

SEM – EDAX study on Spinel – Zirconia, Observed uniform distribution of

zirconia in matrix in Sample B.

Both Alumina – Zirconia and Spinel – Zirconia refractoriness observed to

be Orton Cone 38+. At present we are unable to do refractoriness test at

2000 Deg.C. In future, we are planning to do refractoriness test at 2000

Deg.C for both Sample A and Sample B.

Thermal Shock Resistance of Spinel – Zirconia observed to be superior

when compared with Alumina – Zirconia.

Inference of the Study

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From the study, it is found that sample A [CUMILOX 95AZ SPL] is more

stable & suitable product for the severe application as hot face refractory

in hard black reactor for application temperatures below 1850 Deg.C

Sample B ( CUMILOX MA 26 ) to be analyzed for grain growth stability

studies in repeated cycles at elevated temperature.

Zirconia enhances the thermal shock resistance

Observed Spinel based refractory possesses better thermal shock

resistance compared to Alumina – Zirconia.

Conclusion

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Refractory Application in Hard Black Reactor (Typical Diagram)

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APPLICATION AREA REFRACTORY

HARD BLACK HIGH TEMPERATURE REACTOR TEMPERATURE 1700 oC -1850oC

HEAD SECTION - WORKING LINING CUMILOX 101 HB (99.5% ALUMINA DENSE SHAPE) / CUMILOX 95 AZ SPL

HEAD SECTION - BACK UP LINING CUMICRETE CA 66 (94% ALUMINA DENSE CASTABLE)

HEAD SECTION - INSULATION CUMICRETE CA 58 (94% ALUMINA INS. CASTABLE)

CHOKE SECTION - WORKING LINING CUMILOX 101 HB(99.5% ALUMINA DENSE SHAPE)

CHOKE SECTION - BACK UP LINING CUMICRETE CA 66(94% ALUMINA DENSE CASTABLE)

CHOKE SECTION - INSULATION CUMICRETE CA 58(94% ALUMINA INS. CASTABLE)

COOLER CUMILOX 101 HB(99.5% ALUMINA DENSE SHAPE)

BREACHING SECTION - WORKING LINING

CUMIHICAST EXTRA (80% ALUMINA LCC)

BREACHING SECTION - INSULATION CUMICRETE C9 G (30% ALUMINA VERMICULTE BASED INS. CASTABLE)

Refractory Application in Hard Black Reactor – Recommendation from CUMI

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APPLICATION AREA REFRACTORY

HARD BLACK HIGH TEMPERATURE REACTOR TEMPERATURE (1900 - 2000 Deg.C)

HEAD SECTION - WORKING LINING Spinel Zirconia Composite

HEAD SECTION - BACK UP LINING CUMICRETE CA 66 (94% ALUMINA DENSE CASTABLE)

HEAD SECTION - INSULATION CUMICRETE CA 58 (94% ALUMINA INS. CASTABLE)

CHOKE SECTION - WORKING LINING CUMILOX 101 HB(99.5% ALUMINA DENSE SHAPE)

CHOKE SECTION - BACK UP LINING CUMICRETE CA 66(94% ALUMINA DENSE CASTABLE)

CHOKE SECTION - INSULATION CUMICRETE CA 58(94% ALUMINA INS. CASTABLE)

COOLER CUMILOX 101 HB(99.5% ALUMINA DENSE SHAPE)

BREACHING SECTION - WORKING LINING

CUMIHICAST EXTRA (80% ALUMINA LCC)

BREACHING SECTION - INSULATION CUMICRETE C9 G (30% ALUMINA VERMICULTE BASED INS. CASTABLE)

Refractory Application in Hard Black Reactor – Recommendation from CUMI

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APPLICATION AREA REFRACTORY

HARD BLACK CONVENTIONAL REACTOR TEMPERATURE 1650oC - 1700 oC

WORKING LINING CUMILOX 101 HB (99.5% ALUMINA DENSE SHAPE, CUMILOX 201HF / CUMILITE 90 (90% ALUMINA DENSE SHAPE)

QUENCH SECTION CUMILOX 201 HF(90% ALUMINA DENSE SHAPE)

BREACHING SECTION - WORKING LINING CUMIHICAST 70 (70% ALUMINA LCC)

BREACHING SECTION - BACK UP CUMIHICAST SUPER(45% ALUMINA LCC)

HARD BLACK CONVENTIONAL REACTOR TEMPERATURE 1600oC

WORKING LINING CUMILOX 201HF / CUMILITE 90, (90% ALUMINA DENSE SHAPE), CUMILITE WHF (FUSED MULLITE BASED 76% ALUMINA)

BACK UP LINING & END PORTION CUMICRETE CK 588 (60% ALUMINA HIGH PURITY DENSE CASTABLE), CUMICRETE CK14 (50% ALUMINA HIGH PURITY DENSE CASTABLE)

HARD BLACK CONVENTIONAL REACTOR TEMPERATURE 1550oC

WORKING LINING CUMILITE HF / WHF (FUSED MULLITE BASED 90 & 76% ALUMINA)

INSULATION BACK UP CUMICRETE CK14 (50% ALUMINA HIGH PURITY DENSE CASTABLE)

Refractory Application in Hard Black Reactor – Recommendation from CUMI

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Refractory Application in Soft Black Reactor (Typical Diagram of Carcass Reactor)

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REACTOR TYPE APPLICATION AREA REFRACTORY LINING

SOFT BLACK REACTOR TEMPERATURE 1600 - 1650oC

WORKING LINING CUMILOX 95 AZ / CUMILOX 101 HB (99.5% ALUMINA DENSE SHAPE / BRICK)

BACK UP LINING & END PORTION

CUMILITE WHF (FUSED MULLITE BASED BRICKS / SHAPES) & CUMILAG B101 (98% ALUMINA INS. BRICK / SHAPES)

SOFT BLACK REACTOR TEMPERATURE 1500 -1600oC

WORKING LINING CUMILITE HF / WHF ( FUSED ALUMINA BASED 90% AND 76% ALUMINA SHAPES)

BACK UP LINING & END PORTION

CUMICRETE CK 14 (50% ALUMINA HIGH PURITY DENSE CASTABLE)

Refractory Application in Soft Black Reactor – Recommendation from CUMI

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Alumina – Zirconia Composite : Choke

Assembly for Hard Black Reactor Spinel – Zirconia composite / Zirconia

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Refractory Application in Rotary Drier

(Typical Diagram)

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Installation Service

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Thank You

Visit us at www.cumi-murugappa.com/refractories/