Eduardo Reis AFCM Hanoi April

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1 Magnesita Refractory Optimization Model Eduardo Reis AFCM Hanoi April 15

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4 Magnesita Refractory Optimization Model 1 Process Audit Clinker analysis Fuel & Alternative Fuels, Flame Coating area and its stability area KBC - Kiln Brick Chart.

5 2 Post Mortem Analysis What is/are the wear mechanism phenomenon? Is it Thermal, Mechanical, Chemical or combination among them? Hot Face 1 Hot Face 2 Inter. Face Cold Face TDS Distance from hot face mm Apparent Porosity % 11,4 13,5 12,8 11, Bulk Density g/cm 3 3,03 2,97 3,00 3,01 2,96-3,06 Coating Hot face Intermediate Face Cold Face MgO, MA, βc S MgO, C A Elasticity Gpa 15 17,5 18,5 37 X-Ray Diffraction MgO, MA, K 2 SO 4, MA, MgO, MA, MgO, MA, C 12 A KCl,K 2 SO 4, ChemicalAnalysis MgO % 83,1 85,8 83,3 81, Al 2 O 3 % 12,0 12,2 12,2 12,4 10,5-14,5 Na 2 O % 0,0 0,0 0,0 0,0 - K 2 O % 0,16 0,04 0,09 0,28 - SO 3 % 0,14 0,02 0,10 0,17 - CaO % 2,8 0,9 2,6 3,4 < 0,9

6 3 Thermal Mechanical Studies Numerical simulation and finite element analysis

7 4 Computer Aided Design Complete modeling for full clinker process and or separate equipments in order to have total assertiveness on the calculated amount of materials. As well as double checking on the equipments interconnection.

8 4 Computer Aided Design Magnesita Refractory Optimization Model CONECTION DETAIL Rotary Kiln Detail Inlet kiln Inlet kiln Rotary Kiln

9 5 Ovality Analysis Meedon Equation: Ec = 3. Ws. h. Me 4 R 2 Ec : Compression force (N/mm 2 ) Limited by Refractory CCS Ws : Kiln Ovality (mm) h : Lining thickness (mm) R : Kiln Radius Me : Brick Elastic modulus (N/mm 2 )

10 6 Thermo Graphics 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

11 7 Tailored Product Recommendation Refractory Physical & Chemical Properties From which type of raw material? Basic Material : Magnesia-Spinel, Magnesia-Doloma, Doloma Non basic Material : Alumina, Andaluzite, Silicon-Carbite, Bauxite. Which type of physical properties? Density Bulk, Apparent Porosity Cold Crushing Strength Permeability, Elasticity Hot modulus of rupture Thermal conductivity.. Which type of chemical properties?

12 8 Installation Services Kiln inspection Supervision. In house training. Installation techniques. (Method & Equipments)

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14 MAGKOR DB 1

15 - Magkor DB1

16 - Magkor DB1 Suitable for: Severe Thermal overload High abrasion area Low liquid phase viscosity.

17 MAGKOR S5

18 - Magkor S5

19 - Magkor S5 Pertinent Characteristics: Stress (Mpa) Magkor S5 Very Low permeability High mechanical resistance High abrasion resistance Low porosity High refractoriness High Chemical resistance Typical Mag-spinel brick Strain (%) Highly suitable for : High mechanical stress areas No protective coatingg area and unstable ones. Severe alkaline and salt infiltration Low viscosity liquid phase of clinker High abrasion in the outlet and lower transition zones

20 - Product Details BRANDS MAGKOR DB1 MAGKOR S5 Technology AZT LPT Chemical Analysis MgO (%) 85,5 86,5 Al 2 O 3 (%) 11,5 12,0 Fe 2 O 3 (%) 0,5 0,5 SiO 2 (%) 0,3 0,3 CaO (%) 0,8 0,8 ZrO 2 (%) 1,7 - Physical Properties Bulk Density (g/cm 3 ) 3,01 3,03 Apparent Porosity (%) 15,2 14,0 CCS (MPa) 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

21 Calcinations U.T.Z. B. Z. L.T.Z. C.Z.

22 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.

23 Thanks Eduardo Reis Global Technical Assistance Area 55 (31) (31)