Castament. Review. BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 1 [Pfad.ppt]

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1 Castament Review BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 1

2 Improving Refractories Material (Fe, Al, Glas,..) Refractoriness Wear resistance Corrosion resistance Slag resistance Application Requirement Raw Material Mix Design CAC-containing High/Low Alumina SiC-SiO2 C -containing Particle size distribution Innovative new refractories require an integrated approach, to be successful Dispersing Wetting Rheology Density / Voids Porosity Water Chemicals Workability Placement Wetout Time Mixing Energy Free-/ Vibrational-Flow Working time Strength Development BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 2

3 What is the Castament Series About The Castament family are polymeric dispersants for castables containing calcium aluminate cement, reactive aluminas, microsilica and aggregates. Water Reduction Improved physical properties Reduced Porosity Increased Density Increased Strength Prolonged Lifetime Castament Additive Wetting Self / Vibra Flow Improved Workability Pumpability Easy Placement Setting Retardation Acceleration Economy of Time BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 3

4 Effects of Castament Flow / Spread with Castament 2 1 Reference withtraditional polyacrylate Water content of system 1 Plastification 2 = improved workability Water reduction = improved physical properties BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 4

5 Effects of Castament added to a refractory mix The addition of Castament changes the rheological behaviour significantly with 0,2 % CASTAMENT FS 10 freeflowing, homogeneous mass Raw Material Particle size Content (%) Tabular Alumina ¼ - 8 mesh mesh mesh mesh mesh 5-20 μm 20 Reactiv Alumina Bi-modal 10 CAC Cement 70% Al 2 O Water 4,2 % Dispering Aid 0,2% Recipe plus 4,2 % water without CASTAMENT FS 10 humid, crumbly mass BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 5

6 Evaluation of Castament in a self-flowing Castable Castament FS 10 was compared to a commonly used polyacrylate in a selfflowing micro-silica free castable containing: Tabular Alumina 85% Reactive Alumina CL 370 C 10% CAC CA 14 M 5% 200 CASTAMENT FS 10 Polyacrylate 200 CASTAMENT FS 10 Polyacrylate Flow [%] 100 Flow [%] ,5 5 5,5 6 Water demand [% bwc] Castament FS 10 Dosage: 0.2 % bwc bwc = by weight of castable 0 0,05 0,1 0,15 0,2 0,25 0,3 Dosage [% bwc] Water content: 5.3 % bwc bwc = by weight of castable BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 6

7 Evaluation of Castament in a self-flowing Castable Castament FS 10 and Castament FW 10 (accelerated version of FS 10) in combination for microsilica-free refractory materials containing CAC (calcium aluminate cement). Castament FS 10 and Castament FW 10 can be mixed at any ratio to optimize workability and set behavior of the refractory mix. This is especially useful for low and high temperature applications. Testing Temperature 5 C Castament Dosage: 0.1 % bwc Water content: 5.3% bwc bwc = by weight of castable Mix Design: Tabular Alumina 85% Reactive Alumina CL 370 C 10% CAC CA14M 5% Testing Temperature 20 C Castament Dosage: 0.1 % bwc Water content: 5.3% bwc bwc = by weight of castable BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 7

8 Evaluation of Castament in a self-flowing Castable Castament FS 20 gives excellent self-flowing properties in MS-containing ULCC mixes. It is either possible to enhance workability properties of the refractory material or to reduce the water content of the mix for better physical properties. Self Flow Value [%] min 30 min 60 min 120 min 90 min Self Flow Value [%] min 30 min 60 min 120 min 90 min 40 Castament FS 20 Polyacrylate 20 Castament FS 20 Polyacrylate Test recipe: Cement (70% Al2O3) 0,5% Hydrated Alumina 0,5% White Fused alumina 84% Calcined Alumina 7% Microsilica 983 U 8% Dispersant 0.05% Water content 4.1% b.w.c. Test recipe: Cement (70% Al2O3) 0,75% Fused silica 84% Microsilica 983 U 16% Dispersant 0.05% Water content 6,5% b.w.c. BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 8

9 Evaluation of Castament in a self-flowing Castable Castament FS 40 is superior in LCC refractory formulations containing microsilica, bi-modal reactive aluminas and low aluminum CAC as a three component binder matrix. Flow Test with a Bauxit Containing Refractory Mass Test recipe: Bauxite 72% Reactive Alumina 10% (Almatis CL 370C - bi-modal resp. CTC 20 - mono-modal) Cement (Lafarge Fondu) 5% Microsilica 971 U 3% Dispersant 0.1% Water content 6% b.w.c. Vibratable Flow [%] FS 20 (CTC 20) FS 40 (CTC 20) FS 20 (CL 370 C) FS 40 (CL 370 C) Elapsed Time [min] BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 9

10 Castament in a self-flow High Alumina Castable Castament FS 30 and Castament FS 60 give improved cold crushing strength (CCS) in LCC castable formulations based on tabular aluminas, reactive alumina and high alumina CAC as binder matrix min 30 min 60 min 90 min Tabular Alumina 3 6 mm 25 % 1 3 mm 5 % 1 2 mm 10 % 0,5 1 mm 11 % 0,2 0,6 mm 6 % 0 0,2 mm 12 % 0 0,45 mm LI 9 % Reactive Alumina Multi-modal 17 % Cement 70% Alumina 5 % 100 % Dispersant Variable 0,2 % Water 4,0 % Flow [cm] CCS = 3,4 N/mm 2 CCS = 26,6 N/mm 2 CCS = 34,3 N/mm 2 CCS = Cold Crushing Strength after 24h 0 FS 10 FS 30 FS 60 BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 10

11 Castament in a self-flow High Alumina Castable Reactive Aluminas (Product: A = multi-modal; B = bi-modal; C = bi-modal; D = mono-modal) strongly influence setting time of castables The use of Castament, in combination with Reactive Alumina allows to adjust setting times in a wide range. Tabular Alumina 3 6 mm 25 % 1 3 mm 5 % 1 2 mm 10 % 0,5 1 mm 11 % 0,2 0,6 mm 6 % 0 0,2 mm 12 % 0 0,45 mm LI 9 % Reactive Alumina Variable 17 % Cement 70% Alumina 5 % 100 % Dispersant Castament FS 60 0,2 % Water 4,4 % FS60 is less retarding than FS30 CCS = Cold Crushing Strength after 24h BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 11 Temp. [ C] Flow [cm] Heat of Hydration as a Function of Time: Castament FS A B C D 17 0:00 12:00 24:00 36:00 48:00 Time [hh:mm] Flow as a Function of Time: Castament FS CCS = 34,3 N/mm 2 CCS = 27,5 N/mm 2 CCS = 26,2 N/mm 2 10 min 30 min 60 min 90 min A B C D CCS = 24,2 N/mm 2

12 Castament in a self-flow High Alumina Castable Reactive Aluminas (Product: A = multi-modal; B = bi-modal; C = bi-modal; D = mono-modal) strongly influence setting time of castables The use of Castament, in combination with Reactive Alumina allows to adjust setting times in a wide range. Tabular Alumina 3 6 mm 25 % 1 3 mm 5 % 1 2 mm 10 % 0,5 1 mm 11 % 0,2 0,6 mm 6 % 0 0,2 mm 12 % 0 0,45 mm LI 9 % Reactive Alumina Variable 17 % Cement 70% Alumina 5 % 100 % Dispersant Castament FS 30 0,2 % Water 4,4 % CCS = Cold Crushing Strength after 24h BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 12 Temp. [ C] Flow [cm] Heat of Hydration as a Function of Time: Castament FS A B C D 17 0:00 12:00 24:00 36:00 48:00 Time [hh:mm] Flow as a Function of Time: Castament FS 30 CCS = 6,1 N/mm 2 CCS = 26,6 N/mm 2 CCS = 12,8 N/mm 2 10 min 30 min 60 min 90 min A B C D CCS = 0 N/mm 2

13 Castament in a self-flow High Alumina Castable Influence of Cement on flow and strength development Tabular Alumina 3 6 mm 25 % 1 3 mm 5 % 1 2 mm 10 % 0,5 1 mm 11 % 0,2 0,6 mm 6 % 0 0,2 mm 12 % 0 0,045 mm LI 9 % Reactive Alumina multimodal 17 % Cement Variable 5 % 100 % Dispersant Variable 0,2 % Water 4,2 % Temp. [ C] Secar71 CA14M CA270 Castament FS 30 0:00 6:00 12:00 18:00 24:00 30:00 36:00 42:00 48:00 Time [h:m] Cement Types have significant influence on set time and strength development after 24 hours Castament FS 60 seems to be more robust Temp. [ C] Castament FS Secar71 CA14M CA :00 6:00 12:00 18:00 24:00 30:00 36:00 42:00 48:00 Time [h:m] BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 13

14 Castament in Vibrational-Flow Test Recipe for MS-containing Low CAC (LCC) Castable Castament FS 60 gives improved vibrational flow in MS-containing designs with low alumina cements. Working time can be adjusted with Castament FW 10. Mulcoa mm 3 6 mm 20 % 1 3 mm 1 3 mm 30 % 0 1 mm 0 1 mm 20 % 0 0,09 mm 0 0,09 mm 5 % Reactive 12,5 % Alumina MS 5 % Cement 50 % Alumina 50 % Alumina 7,5 % Total: 100 % Dispersant Castament FS 60 Castament FS 60 0,2 % Accelerator Castament FW 10 0,05 % Water 6,3% Flow [cm] min 30 min 60 min FS60 FS60 + FW10 BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 14

15 Castament in Self-Flow ULCC and LCC Refractories Al 2 O 3 -content of the Calcium Aluminate Cement (CAC), Reactive Alumina and Microsilica are important details for choosing the most effective Castament Typ for your specific recipe. 80% Al2O3 content in CAC FS 10 FS 30 FS 60 FS 20 (ULCC only) 40% FS 40 FS 60 for vibrational mix design MS = 0% % BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 15

16 Difference in Performance of Castament in High Alumina Castables 80% Al2O3 content in CAC FS 10 FS 30 FS 60 FS 20 (ULCC only) 40% FS 40 FS 60 for vibrational mix design MS = 0% % Recent test results have shown differences of the new Castament types in MS-free mix designs in terms of high alumina CAC (70% Al 2 O 3 ) and reactive aluminas BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 16

17 Castament in Self-Flow MS-free High Aluminate LCC Flow FS 30 FS 30 is more like a water reducer! FS 60 is more like a plasticizer with improved early strength development FS 60 Set Time FS 10 24h Cold Crushing Strength Adjustments are possible by choosing the right CAC + Alumina Binder Mix BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 17

18 Summary: Use of Castament in Self-flow Castables Free-flowing properties of MS-free, high alumina castable mixes are improved by different Castament types Flow increases by Castament FS 10 < Castament FS 60 < Castament FS 30 Reaching a certain flow is depending on the Castament quantity used The particular Set Time and Cold Crushing Strength of the green body refractory may be modified by Castament and the quantity used. Retardation increases with Castament FS 60 < Castament FS 30 < Castament FS hour CCS increases with Castament FS 10 < Castament FS 30 < Castament FS 60 Reactive Alumina influences Set Time as well Retardation increases with multi-modal < bi-modal < mono-modal particle size distribution By Combining particular cement types with different Reactive Aluminas set time and flow of castables can be adjusted to customer needs The selection of the right dispersant is determined by the type of Reactive Alumina All mix designs can be accelerated by using Castament FW 10 BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 18

19 Stabilisation of Castable Mixes Against Segregation Starvis 4302 F; Starvis 3003 F; 0,005-0,05% dosage may prevent segregation and gives a smoother surface to the monolithic castable piece. The products can also be used to reduce bleed in shotcrete castable at 0.25% (BTWR) and 4-6% water. Bleeding Stabilisation Segregation BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 19

20 Typical Use of Castament for Free Flow Applications FS 10 FW 10 (accelerated) FS 20 FS 30 FS 40 FS 60 HCC: CAC; Alumina x x x LCC: CAC; Alumina x x x x x LCC / ULCC; CAC; Alumina x x LCC: Bauxit; CAC x x x LCC: Bauxit, CAC; Alumina x x x LCC: Spinel (MgAl2O4), CAC x x LCC: Bauxit; CAC; MS x x LCC: Alumina; CAC; MS x x ULCC: Bauxit; CAC; MS x ULCC: Alumina; CAC; MS x ULCC: Andalusite; CAC; MS x ULCC: Bauxit; CAC; MS; Alumina x NC: Alumina; MS; SiC; C; synth. binder x x NC: Alumina x x BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 20

21 for further information please contact: BASF Construction Polymers GmbH, Germany P.O. Box Trostberg Dr. J. v. Seyerl Phone: BASF Construction Polymers GmbH * Dr. J. v. Seyerl * March 2008 * 21