Rene von der Heyde,

RHIAG, Germany,
introduces two case
studies from TitanCement,
Egypt, with input from
HossamTaha and
WaelSadek, Production
Managers at the BeniSuef
and Alexandria plants,
respectively.

Abstract

RHIs cement-free, sol-bonded castables were first introduced

to the cement industry in 2010. Due to their completely new
bonding system, sol gel bonded castables offer a variety of
advantages, easy pre-drying and heating properties. The option
for rapid heat-up is of the highest importance especially
in times of high cement demand. Additionally, in the case
of economic depression, the fact that these castables do not
require a specific pre-drying procedure helps to reduce costs by
minimising the fuel requirements for pre-drying and heating
periods. Furthermore, due to their technological properties, sol
gel castables have also proved to be a solution for critical lining
areas. In the following paper Hossam Taha, ProductionManager
of Titan Beni Suef, and Wael Sadek, ProductionManager of
TitanAlexandria, report their experiences with sol-bonded
castables as the solution for the most critical areas, such as the
nose ring and burner.

Reprinted from World Cement

[August 13]

Introduction

The Titan Group is an independent multi-regional producer

of cement and other related building materials, founded in
1902. Headquartered in Greece, the TitanGroups vertically
integrated activities span 13countries, with clinker production
plants in Greece, Bulgaria, Serbia, Macedonia, Kosovo, Albania,
Turkey, Egypt and the US.
The first kiln at Beni Suef was commissioned in 1993.
Formerly a joint venture between Lafarge and Titan, ownership
Figure 1. Severely damaged monolithic outlet lining after
3 months in operation.

Figure 2. Sketch of the outlet solution for Titan Cement

Beni Suef based on CARSIT SOL M10-6.

Reprinted from World Cement

[August 13]

passed to Titan in 2008. The second kiln was commissioned in

2010.
In 2011, the Titan plants in Egypt approached RHI AG
for technical support related to problems with monolithic
installations in the nose zones and burners at its Beni Suef and
Alexandria plants.

Titan Beni Suef: nose zone

Titan Cement Beni Suef, located in Central Egypt, operates two

kilns. Kiln 1 is a 4.6 m dia. precalciner kiln with a capacity of
4400tpd, erected by Kobe Steel Co. Kiln2 is also a precalciner
kiln, with a diameter of 4.5m and a 4000tpd capacity,
manufactured by FivesFCB. As in many kilns, the outlet
area is a critical lining section. The simultaneous presence of
multiple wear mechanisms often leads to a reduced lining life
in this area. The nose ring area is exposed to severe stresses
from hot secondary air loaded with clinker dust that causes
abrasive attack on the lining. In addition, thermal shock has
to be considered, as well as mechanical stresses originating
from lining thrust and/or ovality stresses and possible kiln
shell deformations. After evaluating the conditions observed,
mechanical stresses were concluded to be the main issue. This
was also indicated by the brickwork damage in front of the
monolithic outlet section, which showed twisting and crushing
of the first brick rows. Furthermore, pre-drying and heating
was a potential additional issue, causing pre-damage of the
monolithic installation. The short service life of 23months,
caused by heavy cracking and spalling (Figure1), was a
constant threat to continuous production. Using mid-term
patching, the nose ring life could be extended to a maximum of
6months.
Together with Titan Cement, RHI developed a lining
concept for the outlet section, focusing on a solution that could
deal with high mechanical stresses, which were the obvious
reason for the encountered problems. The finally developed
solution not only included selection of a completely new
castable, but also modification of the lining concept, optimising
the expansion allowance and field arrangements. A particularly
challenging area, the retaining ring, was integrated into the first
part of the nose ring (Figures2 and3).
The triangular cross-section retaining ring had already been
embedded in the concrete panel in line2. In line1, the retaining
ring was embedded into the fields of CARSIT SOL M10-6
without implementing any expansion joints (Figure3). The
installation was carried out by the Egyptian installation
company Elseify under RHI supervision. The time frame given
by TitanCement was 48hours; however, due to some delays
caused by the shuttering work preparation, steel shell cleaning
and anchor welding, this had to be extended to 72hours. A
realistic future target is 60hours.
As previously mentioned, part of the solution was to use
a completely new cement-free castable, CARSITL SOL M10-6.
This is one of the products from the range of so-called
sol bonded castables. Developed in 2008, the product
range is based on various raw materials, including fireclay,
mullite, bauxite, and tabular alumina with or without silicon
carbide. The reason for selecting this new product type is the
outstanding advantages it offers, related to the new bonding
system. The absence of hydrate phases on one side but also

a different pore size distribution facilitates the expulsion of

the water that is present in sol-bonded mixes. Furthermore,
the water is present only in free form and is not chemically
bonded. As a result, sol-bonded castables can be dried very
quickly. These properties allow the sol castables to be heated
with the usual heating curve applied to rotary kilns. The heat
development during the usual recommended heating schedule
of 36hours is enough to properly dry this kind of castable.
Accordingly, no additional heating is necessary. Furthermore,
the physical and chemical properties are significantly improved
compared to conventional and also low-cement castables
thanks to the cement substitution. Therefore, it has been
possible to improve the flexibility, refractoriness and resistance
to chemical attack by sulfur, as well as alkalies and other
corrosive components. An additional benefit of sol-bonded
castables is the very long shelf life of up to 18months.
These two compound no-cement castables are especially
designed for difficult to heat areas such as the nose ring, kiln
hood, cooler and burner. The superior technical properties
are also beneficial in other challenging areas, such as the riser
duct, inlet chamber, inlet cone and calciner. Together with the
dry mix, a liquid binder is delivered and added instead of
water. The equipment used for installation and the processing
procedure are the same as those required for common cementbonded castables.
The complete nose ring was installed with approximately
17t of CARSIT SOL M10-6 in accordance with the diagram
in Figure2. Setting times of 24hours were easily achieved.
Since sol-bonded materials require no curing time, very short
de-moulding times can be realised without compromising the
final physical properties. Since curing and separate pre-drying
is not required for sol-bonded castables, the burner was lit only
6hours after the last panels were cast.

Performance

Furthermore, CARSIT SOL M10-6 will be used to replace a

worn kiln inlet arch during the next stop.

Titan Alexandria: burner pipe

Titan Alexandria operates a single 71m long precalciner kiln

with a diameter of 4.55m and a capacity of 4800tpd. The
burner is a 100% gas-fired FLSmidth burner.
Similar to the nose ring, the burner also represents a
critical area due to the simultaneous presence of multiple
wear mechanisms. The dust-loaded hot secondary air affects
the burner pipe lining in addition to the overall high thermal
Figure 3. Installation of CARSIT SOL M10-6. The retaining
ring is simply integrated into the monolithic fields.

Figure 4. CARSIT SOL M10-6 still in good condition after

12 months in operation.

The concept developed in close cooperation between

Titan Cement Beni Suef and RHI proved very successful
and resulted in a nose ring lining life of 12months, without
any interim repair. As a result of the considerable residual
thickness (no visible wear) and good condition of the nose
ring (Figure4), the lining could have remained operational
for a further 612months. However, for safety reasons it was
relined in March2013 using the same material. In the future,
1824month campaigns seem easily achievable with this
material, which would improve the refractory life in this part
of the kiln by almost tenfold compared to previous lining
lifetimes. The main reason for this is the improved heating
properties that do not cause any premature damage to the
monolithic lining. Furthermore, the very flexible microstructure
and excellent thermal shock resistance, which result from the
new bonding system, were a particular advantage in view of
the specific wear pattern.
The results with RHIs castable solution have proved very
successful and we are convinced of the outstanding properties
of this new product type, said Hossam Taha, Production
Manager of Titan Beni Suef. Subsequently, as a result of the
outstanding performance, the plant has also lined the nose
ring of line2 with CARSIT SOL M10-6 and has installed this
material in the critical cooler areas of the roof and bullnose.

Reprinted from World Cement

[August 13]

load and chemical attack from infiltrating alkali salts. The

burner pipe was cast in a vertical position in 1m sections
predominant wear mechanism is often difficult to define
during day shifts over a total of 3.5days. This position is
because of the complexity of stresses acting at the same
recommended in order to achieve the best possible refractory
time. TitanCementAlexandria had already tried different
concrete compaction. At the most critical area the burner
refractory mixes to counteract these stresses. Principally,
tip the panel size was reduced to 50cm. Setting times of
high-alumina low-cement (LC) products with a raw material
approximately 3hours enabled rapid de-moulding and a fast
base ranging from bauxite to tabular alumina were installed,
installation procedure, whilst retaining optimal final product
explained Wael Sadek, Production Manager of Titan
properties.
Cement Alexandria. However, the
maximum lifetime was limited to
Burner pipe performance
Figure 5a. Original high-alumina low23months. In particular, the first
After 6months in service, the
cement burner pipe lining after 2 months
metre of the burner lining showed
kiln was stopped for scheduled
in operation with severe damage at the
very intense crack formation
maintenance. At this time the
burner tip.
(Figure5a). After the refractory had
burner and particularly the
spalled off, the anchors and steel
tip showed only minor wear
shell were seriously damaged. In
(Figures5a and5b). The steel parts
view of the unsatisfactory results,
of the burner were not damaged
which suppliers were not able to
and the remaining refractory
improve, Titan Cement Alexandria
material showed no crack formation
approached RHI to discuss and find
and no steel parts were exposed. In
an appropriate solution.
view of past experiences, the result
achieved represents an excellent
improvement. The very easy
Solution
castable drying behaviour, as well
After technical discussions between
as good stress-absorbing properties,
Titan Cement Alexandria and RHI
combined with excellent strength
to evaluate past performances and
and abrasion resistance were the
the current lining design, it was
reasons for doubling the previous
decided to optimise the burner
service life. The results achieved
tip installation by decreasing the
convinced Wael Sadek to further
filled section size at the tip. The
extend the collaboration with RHI
application area in this critical zone
Figure 5b. CARSIT SOL M10-6 after
and install sol-bonded castables in
was reduced from 100to50cm
6 months in operation. It was taken
other critical areas.
and CARSIT SOL M10-6 was
out of operation due to a scheduled
used. This sol castable had already
maintenance stop. The main part of the
Conclusion
proved successful in other burner
front lining was still in good condition
The experiences at Titan Cement
pipe installations. The use of a
with the exception of a small section at
Beni Suef and Alexandria with
mullite-based monolithic provided
about 5 oclock. This represents a huge
improvement compared to the previous
RHI have encouraged Titan Egypt
sufficient refractoriness combined
situation.
to further extend the cooperation
with the necessary high resistance
with RHI as well as use sol-bonded
to alkali attack. Furthermore, the
castables in other critical areas.
cement-free castable achieves
The results described are just
higher thermal resistance since the
calcium aluminate components
part of numerous successful
originating from cement that cause
installations achieved with
low melting reactions are not
sol-bonded castables. Besides the
present. As previously described, the
successful and fruitful cooperation
substitution of calcium aluminate
between Titan Cement and RHI,
cement leads to product property
the keys to improvement were the
improvements such as mechanical
optimised lining design, as well as
strength, refractoriness and chemical
the best possible installation and
resistance. In this burner application,
application of the sol castable and
the excellent abrasion resistance
its superior properties.
and mechanical properties at high
The excellent results were the
temperatures are a further technical
starting point to further extend
advantage.
the product range of sol-bonded
The installation was carried
castables. Gunning and shotcreting
out by Titan Cement Alexandria
mixes have also been successfully
personnel under RHI supervision
introduced and applied in numerous
in November2011. The entire 9m
cement plants.

Reprinted from World Cement

[August 13]