Innovation future driven

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NEW SILICON CARBIDE CONTAINING REFRACTORY CASTABLE

FOR RESOLVING PROBLEMS IN CEMENT KILN
Chanvit Chawengkul1

(1)

Thanapong Prasertphol 2

Punyoot Huantanom3

Senior Researcher, The Siam Refractory Industry Co. Ltd., Thailand

(2) Researcher, The Siam Refractory Industry Co. Ltd., Thailand
(3) Researcher, The Siam Refractory Industry Co. Ltd., Thailand

ABSTRACT
A major and frequent problem occurring in the outlet zone and burner pipe of cement rotary kilns are thermo-chemical and
mechanical wear which shortens the life of refractory monolithic linings to less than 1 shutdown (4-6 months). The loads generally act on
the refractory lining come from abrasion of clinker ball, abrasion and chemical reaction of clinker dust, and thermal cycling of secondary
air from cooler.
To find a solution to such problem, a new and highly thermal spalling resistance property silicon carbide containing refractory
castable has been developed. It also helps resist chemicals attack of alkali and clinker during the operation, thereby formation of
protective film on surface of lining. The important features of silicon carbide containing refractory castable enabling it to overcome the
problems at the outlet zone and burner pipe of cement rotary kilns are its high level of hardness, outstanding mechanical strength at
elevated temperature, excellent thermal shock resistance etc.
The development of silicon carbide containing refractory castable was started from applying QFD and DOE for finding the
optimum content of silicon carbide in order to help solving problem of refractory in these areas. Silicon Carbide is the main material to
generate thermal spalling resistance property as well as its abrasion resistance. Special additives were studied and experimented to
preserve the good properties of silicon carbide in high oxidation atmosphere. Thermal spalling resistance of silicon carbide containing
refractory castable is relatively higher than other types of refractory castable. The abrasion resistance of this castable has been improved
which also related to amount of silicon carbide in the recipe.
The performance of newly developed silicon carbide containing refractory castable after several trials at SCG cement kilns has
showed an obviously improvement of service life at outlet zone and burner pipe up to 1 shutdown.
Keywords: Thermal spalling, Silicon Carbide containing refractory castable, Monolithic

INTRODUCTION
Regarding high competition of cement market, cement manufacturers must cut down their operating cost and prolong kiln
operation for high productivity. Kiln operation with high running factor is targeted and needed for all cement manufacturers. Frequent
break down time is not preferred. Generally, mechanical and electrical problems are main factors of break down time. Another factor was
shut down of relining refractory bricks which also affected cement production loss. This major relining refractory should be done at
about once a year. Several minor shut down times of refractory works basically must be avoided. So that, these minor works could affect
the running factor of the kiln and need to be resolved.

Surveying customers needs

According to continuous development of refractory materials with advanced technology and TQM concept of Siam Refractory
people, High alumina brick and Magnesia Spinel brick using in cement kiln should last up to one shutdown plan at least. However, some
part of refractory lining at critical area such as outlet and main burner pipe faced short service life and they needed to reline prior the
targeted planned shutdown. The records showed that the relining time of this minor shut down was about 5 days in average of production
loss. Most refractory materials using at outlet and main burner are refractory castable (monolithic) which requires careful setting, curing
and preheating process. So that critical path of minor relining time is the castable works at the outlet of cement kiln. In order to improve
service life of the castable at outlet and burner, Siam Refractory set up a P-team (Product team) which included teammates from Product
development, Quality assurance, Production and Marketing department observing problem and finding solution. By this, observation of
P-team at customers sites was set up in order to see the fact beginning from installation, heating, operation, demolition to disposal.
Details of each step were noted and distinguished customers needs. The interviews with related persons in the route were done such as
masons, contractors, operators, supervisors, engineers and managers. Questionnaires were also prepared and send to customers for
checking and prioritizing their needs. Reverse engineering for failed samples were deeply investigated as well as bench marking of other
products was tested and compared. In doing so, the closed relationship and good communication with customers were simultaneously
developed.
The observation of P-team found that the major and frequent problems occurring in the outlet zone and burner pipe of cement
rotary kilns were thermo-chemical and mechanical wears. The loads generally acted on the refractory lining coming from abrasion of
clinker ball, abrasion and chemical reaction of clinker dust, and strong thermal cycling of secondary air from cooler as showed in figure
1. However, improper installation and installation techniques also affected short service life of them. These fact finding factors need to be
resolved by new development of refractory castable.

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Figure 1: pictures of cement rotary kiln and failed outlet & main burner
Main Problem
( 60% Al2O3 Low Cement Castable )

Thermal &
Mechanical
Spalling

Thermal Shock
Abrasion
Alkali Attack

Nose Ring (Kiln Outlet)

Thermal,
Thermal, Mechanical
Mechanical
And
And Chemical
Chemical Spalling
Spalling

Thermal spalling caused by cold

air from cooler at the boundary
Abrasion of cement clinker
Cracking by mechanical stress
Infiltration of alkali components

Burner Pipe

Quality function Deployment (QFD)

The needs and fact finding were reviewed, grouped and prepared in matrix table. Quality characteristics of product were
related, weighed and considered. Deployment of customers needs and quality characteristics was developed following QFD stages and
QFD tables were prepared as shown.

fast demoulding

long shelflife

good flowing

optimum setting

easy mixing

easy casting

no explosion

Low consumption

Thermal conductivity

Thermal shock resistance

Strength after firing

Reheat test

Refractoriness

Bulk density

Clinker attack test

Strength after installation

Gas permeability

Setting time

Oxidation test

Abrasion test

Alkali attack test

Size distribution

Flow-ability

Binder

Inert

Non-toxic

Quality characteristics

Low TE

Refractoriness

Needs
Installation

Hard

Material

Thermal expansion

Table 1: The QFD table

3
3
4
3
5
7
7
3

4
4

Demanded
Quality
weight

2
4

Long service life

Thermal shock resistance from clinker bed

Thermal shock resistance from air cooling

Thermal shock resistance from main burner

Thermal load resistance at about 1500 C

Thermal load resistance in high oxygen atm.

thermal expansion allowance

4
4

abrasion resistance from dust

resistance to clinker attack

resistance to dust attack

less sticking of snowman

4
4

abrasion resistance from clinker

resistance to alkali attack

9
9
9
4
4
3
7
7
3
4
4
3

Energy saving
Low kiln shell temperature

short preheating

short curing

2
4

2
4

3
9
9

Waste management
easy wrecking

Strong

recycle

non toxic

3
4
4

Weak

Development stage
From above table 1, quality characteristics of products were related with quality of raw materials and processes. Development
plan was set up. Materials and equipments were also prepared for the development.

Planning stage
Most refractory castable are Alumina materials which are widely used by all refractory manufacturers such as Calcined Kaolin,
Calcined Bauxite, Tabular alumina, etc. In order to develop innovative product, selection of new raw materials was a key of development
because the new raw materials should have superior properties than ordinary Alumina materials. Properties of various kinds of raw
materials were studied comparing with the ordinary Alumina materials. Silicon carbide material was found that its properties could cope
with the needs.
From the table 2, Silicon carbide material is inert, high hardness and low thermal expansion material which could generate
excellent properties of castable such as good abrasion resistance, good chemical resistance, excellent thermal shock resistance and high
refractoriness. This could be used in the critical conditions of outlet and burner pipe. However, its resistance to high oxidation
atmosphere at high temperature is poor and its structure could be transformed from Silicon carbide to fluffy Silicon Dioxide which could
be quickly abraded. However, P-team though that this important property could not be compromised. In vice versa, if oxidation resistant

Innovation future driven

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property of Silicon carbide could be developed, it will be an excellent material which suit for using at outlet and burner pipe of cement
kiln. Hence, the development has to be done in experiments.
Table 2: Selection of alternative material technology
Customers needs
Characteristics of products
Ordinary alumina materials
Resist to abrasion of clinker
High abrasion resistance
****
Resist to abrasion of dust
High abrasion resistance
***
Resist to clinker attack
High chemical resistance
***
Resist to dust attack
High chemical resistance
***
Resist to alkali attack
High chemical resistance
**
Resist to thermal cycling
High thermal shock resistance
***
Resist high temperature above
Refractoriness > 1500 C
*****
1500 Degree Celsius
Resist high temperature with
High oxidation resistance
*****
high oxidation atmosphere
Note: * poor
**fair
***good
****very good
*****excellent

Silicon Carbide material

*****
*****
****
****
*****
*****
*****
*

Experiments stage
Designs of Experiments (DOE) were applied to find out the optimum using Silicon carbide materials. Types and amount of
additives for oxidation resistance (additive A, B and C) were also selective and experimented. The design was showed in table 3.

Factor
A
B
C
D

Table 3: The planned experiments

Level 1
Level 2
Level 3
0
30
60
0
2
0
2
3
10
-

Description
% Silicon carbide
Additive A
Additive B
Additive C

Level 4
80
-

From above design, 32 experiments were done and tested in Laboratory and results were analyzed by statistical program.
Analysis results were showed in figure 2, 3, 4 and 5 as followed
Figure 2: test results of abrasion resistance

Figure 3: test results of thermal shock resistance

Main Effects Plot (fitted means) for TSR

Main Effects Plot (fitted means) for Abrasion

Silicon carbide content

Additive1 content

40

30

20

2
0

30
60
Additive2 content

80

2
Additive3 content

Mean of TSR

Mean of Abrasion

Silicon carbide content

Additive1 content

10
0

30
60
Additive2 content

80

2
Additive3 content

40

30

20
10

2
0

10

Figure 4: test results of oxidation resistance

10

Figure 5: test results of interaction of oxidation resistance

Interaction Plot (fitted means) for Oxidation

Main Effects Plot (fitted means) for Oxidation

Silicon carbide content

Additive1 content

10
1.6

0.8

0.0
1.6

Additive2

0.8

Silicon carbide content

0.75

Mean of Oxidation

0.50

0.0
1.6

0.25
Additive1 content

0.00
0

30
60
Additive2 content

80

2
Additive3 content

1.00

0.8

Additive2 content

Silicon
carbide
content
0
30
60
80
Additive1
content
0
2

1.00

content
0
2

0.75
0.0

0.50
0.25

Additive3 content

0.00
0

10

From test results, amount of Silicon Carbide was directly related to castable properties such as abrasion resistance, Thermal
shock resistance and oxidation resistance. Increasing of Silicon carbide (SiC) affected higher abrasion resistance, better thermal shock
resistance but oxidation resistance was poorer. Increasing values of oxidation mean higher oxidation of SiC because Oxygen (O 2)
substituted to molecular structure of Carbon (C) and Silicon Dioxide (SiO 2) was occurred with higher molecular weight than Silicon
Carbide. Despite of prevented Silicon Carbide from the oxidation reaction, additive C must be added about 10% by weight as showed in
figure 4. Both additive A and B could slightly reduce oxidation rate. The experiments also showed that they had no interaction of the
factors.

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Checking stage
The test results were verified and reviewed in QFD table again. Negative effects of using higher percentage of Silicon carbide
were also considered and discussed among P-team such as cost, price per performance, and thermal conductivity values. Higher amount
of Silicon Carbide could generate higher heat loss due to its high thermal conductivity characteristic. If using 80% Silicon Carbide
product is applied, kiln shell and anchor of cement kiln will be destroyed by heat load. So that medium amount of Silicon Carbide
product (60% SiC) was considered.

Action stage
From checked and discussed results, reproduced samples were done and tested again. Test results showed that new refractory
castable with 60% Silicon carbide and 10% additive C gave optimum test values which properly applied to outlet and burner of cement
kiln. Samples of new anti-oxidant Silicon Carbide castable were tested and fired at temperature 1500 Degree Celsius for 5 hours in
oxidation atmosphere comparing with normal Silicon Carbide castable. The fired samples showed that forming of protective film could
be perfectly covered Silicon carbide material and oxidation reaction could be prevented as showed in figure 6. Hence, all excellent
properties of Silicon Carbide could be preserved by new mixes design. New Silicon Carbide containing castable was trialed and launched
to market.
Figure 6: Left; Oxidized general Silicon Carbide castable and Right; Anti-Oxidant Silicon Carbide castable

Customer trials
Marketing materials of new refractory castable were prepared and presented to a customer in order to make trial lot in the real
application. A cement plant in SCG group accepted the concept of development and works trial of new Silicon Carbide containing
castable was produced. New castable was installed at area of outlet and burner tip by 60% Silicon carbide containing castable namely
TufDura S600. It could show outstanding performance after running 1 shut down as showed in figure 7 and 8. This was much
improvement and could satisfy the customer.
Figure 7: outstanding result at burner pipe

Figure 8: outstanding result at outlet

TufDura Castable
TufDura S 600: At one of SRICs customers in Thailand
Normal service life of Low Cement Castable: 3-4 months (90-120 days)
Solution: TufDura S 600 : service life after 200 days

TufDura Castable
Abrasion Resistance Evaluation
Media
: Silicon Carbide size -20+50 mesh, 1 kg.
Condition : Air Pressure 65 psi
Sample : After firing at 1400 oC

Feature of TufDura Castable:

Excellent abrasion and thermal
shock resistance

Trial of refractory profile at burner pipe

Low Cement Castable

TufDuraS 600

Burner tip

TufDura S 600
Abrasion loss 4.0 cc.

LCC, 60% Al2O3

Abrasion loss 8.0 cc.

LCC, 60% Al2O3

TufDura
TufDura S
S 600
600

Bottom Part of Burner pipe

Low Cement High Alumina Castable

TufDuraS 600

Performance of TufDura S 600

at one of SRIC
SRICs customers in
Thailand (after 219 days)

Commercial stage
After finished the first trial, this new castable namely TufDura S600 was launched to world-wide market. Performance of
these castable could satisfy customers due to their tough and durable properties. Siam Refractory sold this type of our products to more
than 10 countries such as Malaysia, The Philippines, Vietnam, India, Pakistan, Nigeria, Indonesia and Australia, etc.

Conclusion
Changing raw material based from Alumina materials to Silicon carbide material could produce higher performance refractory
castable which has excellent thermal shock, chemical and abrasion resistance. Added additive C with certain content could protect
Silicon Carbide from oxidation reaction and preserve excellent characteristics of the same. This type of new refractory castable could
satisfy, resolve problem and fulfill customers needs. The most important step of development is how to find out what customers need
and how developed products or services can satisfy or delight them. These need good vehicles, tools and techniques of TQM such as
QFD, DOE, and other statistical models could help to be easier and faster development. This also was pushed by policy deployment of
top management as well as daily management of teammates. An example of this development of new silicon carbide containing
refractory castable could satisfy the customer trough TQM steps.

Innovation future driven

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References
The Technical Association of Refractories, Japan (1998), Refractories Handbook,The Technical Association of Refractories, Japan
Subrata Banerjee (1998), Monolithic Refractories, World Scientific Publishing Co., Pte.Ltd., Singapore
J.P. Saxena (2003), Refractory Engineering and Kiln Maintenance in Cement Plants, Tech Books International, India
Gerald Routschka (2004), Refractories materials, Vulkan-Verlag Essen, Germany
Shigeru Mizuno, Yoji Akao (1994), QFD The customer-driven approach to quality planning and deployment, Asian Productivity
Organization, Japan