Beruflich Dokumente
Kultur Dokumente
Milan Henek
Průmyslová keramika, spol. s r.o., Rájec-Jestřebí
Miroslav Vajda
RAMIRA PRAHA-ZÁPAD, Třebotov
1. INTRODUCTION
Gunning is a very effective, efficient and relatively simple method of installation of
monolithic refractory linings. There has been dominant the dry (sometimes called semi-dry)
method in the field of castable techniques. There have been known and used conventional
refractory gunning castables for spraying. The refractory mixtures are based on its
composition from conventional casting dense or insulating castables, which means they
contain a high proportion of hydraulic binding material - alumina cement. Thus, there are
brought to the lining all of known deficiencies of ordinary castables, such as high porosity,
decrease of its strength with temperature, poor corrosion resistance of matrix and much more.
Any spraying of quality deflocculated castables with reduced cement content has some
considerable technical and technological difficulties and it hasn´t been wide-spread yet in the
field of castable techniques. The article deals with the real possibilities of application of the
method of dry gunning even used for a group with reduced cement content.
1
difficult can to use gunning method because there the time length from addition of water to
put it in place is calculated in the order of tenths of a second.
2
Chart no. 2 Composition of conventional dense gunning castable DTB
Mixture DTB
Burned kaolin 0-6mm share 65
Melt fireclay under 0,1 mm share 9
Alumina cement 70 % Al2O3 share 25
Comprehensive adhesive ingredient share 1
The conventional castable of defined composition was, within the use of all three
nozzles types, sprayed with test plates which, after hardening, were cut into test specimen and
on its basis defined their basic physic-mechanical properties. The resulting values are entered
in chart no. 3, there are also parameters determined on specimen made from the mixture of
vibration.
Chart no. 3 Comparison of specimen from the mixture made by various gunning nozzles
Temperature DTB-TA DTB-TB DTB-TC DTB-V
of heating
Gunning nozzle Type A Type B Type C vibration
Diverting water l/100 kg 11
Assessment of layer Very good Very good Very good
application
Bulk density 110 kg.m-3 2070 2130 2110 2140
400 kg.m-3 1900 2000 1970 2030
800 kg.m-3 1900 1960 1920 2000
1200 kg.m-3 1900 1970 1920 1990
1400 kg.m-3 1930 2000 2010 1980
1450 kg.m-3 1970 2090 1840 1970
Cold crushing strength 110 MPa 62,8 85,4 95,5 88,3
400 MPa 53,7 77,1 82,6 73,7
800 MPa 44,5 60,9 73,6 57,9
1200 MPa 32,3 42,0 58,9 60,4
1400 MPa 36,2 48,7 40,5 33,3
1450 MPa 29,1 68,4 40,6 93,5
Apparent porosity 400 % 30,5 28,1 29,2 26,7
800 % 32,4 31,3 32,4 28,5
1200 % 33,1 29,2 32,7 29,2
1400 % 25,5 23,3 22,3 25,0
1450 % 23,2 18,5 20,6 21,4
Permanent linear changes 400 ˇ% -0,05 -0,14 -0,26 -0,04
800 % -0,05 -0,16 -0,04 -0,08
1200 % -0,22 -0,17 -0,21 -0,34
1400 % -0,50 -0,77 -1,04 +0,15
1450 % -1,17 -1,05 +0,52 +0,34
3
Abrasion resistance 800 cm 18,2 13,1
The results showed a significant effect of selection gunning nozzle applied to compact the
refractory layer. By using suitable nozzles then it does not arise any significant difference in
quality of covered layer of conventional castables between the one deposited by spraying on
the other hand the second by vibration.
3
3.2. Deflocculated LCC castables
To verify a low-cement spraying castable was prepared a basic recipe of LTB, based on
past occasional experience of spraying a mixture of LCC. At the beginning of this series of
tests were again at the basic mixture LTB injected with all types of gunning nozzles. In the
practice of spraying, however, this method failed of producing the body with a nozzle.
Type C - showed a very narrow passage in regulating the addition of water flowing down of
deposited layer between dusting accompanied by increased waste.
We could testify again a difference between the other two nozzles tested, so any other
body were prepared with guns type B, which create a wall of water across the entire irrigation
ring. The basic recipe LTB allows application mix as well on the walls as on the ceiling, but it
depends on individual assessment of service "is though on the edge." It may therefore appear
problems, such as using a different type of nozzle, or if it was sprayed by less experienced
crew. Therefore, the basic formula was added by some improvers, which are expected to have
an effect of improving the application and adhesion, but also to increase the density and
strength of the applied layer. Composition of the test compounds are shown in the following
Chart no. 4.
The results obtained from this series of spraying gives the following chart no 5. It is
necessary to note that there were far more of the verified ingredients and combinations than
indicated in the chart. Some of them have had no significant effect, while others have
improved adhesion, but also deteriorated compaction as in an example of the formula LTB-8.
There are also values obtained at the basic mixture LTB by vibrating to see a better
comparison.
Looking at the data in the chart, it is clear that gunning method of deflocculated low-
cement castables completely has not reached values as vibrated samples. Gunning materials
(e.g. LTB-3 LTB-5 LTB-6), however, can provide the values that correspond to a high quality
castables. This is concerning to both density and also mechanical strength of castables. With
regard to any application exposed to any abrasion, there has been set an abrasion resistance at
most of the tested mixtures (according to EN 993-20). Specimen for this test was pre-heated
to 800 ° C.
4
Chart no. 5 Comparison of specimen made by gunning of low-cement mixtures
LTB with various ingredients
Temperature LTB- LTB- LTB-3 LTB-5 LTB- LTB- LTB-V
of heating TA TB 6 8
Gunning nozzles Type A Type B Type B Type B Type Type vibrations
B B
Diverting water l/100 6,0
kg
Assessment of the average average Very Very Very Very
layer application good good good good
Bulk density 110 kg.m-3 2050 2150 2160 2160 2160 2070 2230
400 kg.m-3 2010 2110 2090 2110 2100 2030 2180
800 kg.m-3 2020 2120 2100 2100 2100 2030 2190
1200 kg.m-3 1980 2130 2120 2130 2130 2050 2180
1400 kg.m-3 2020 2130 2120 2140 2160 2060 2250
1450 kg.m-3 2070 2160 2150 2140 2140 2080 2250
Cold crushing 110 Mpa 48,1 76,6 68,5 44,6 54,9 32,8 82,4
strength
400 Mpa 53,1 72,6 60,8 72,2 75,1 39,4 118,0
800 Mpa 42,6 84,9 64,8 72,8 83,9 42,7 127,5
1200 Mpa 30,2 72,3 72,2 80,4 73,8 48,6 128,8
1400 Mpa 43,5 69,8 52,1 68,7 68,7 49,7 138,0
1450 Mpa 61,4 103,7 82,2 72,3 57,0 42,0 143,5
Apparent porosity 400 % 22,6 19,1 20,5 17,7 17,8 21,2 12,3
800 % 21,4 18,5 18,3 19,6 19,3 21,0 12,2
1200 % 20,9 16,9 17,9 18,6 18,3 20,2 13,7
1400 % 21,1 18,2 17,5 18,2 18,2 20,0 13,6
1450 % 20,6 17,6 17,8 18,8 18,3 20,4 12,1
Permanent linear 400 ˇ% -0,18 -0,17 +0,02 -0,22 -0,27 -0,26 -0,08
changes
800 % -0,42 -0,31 -0,31 -0,36 -0,27 -0,37 -0,40
1200 % -0,39 -0,44 -0,52 -0,75 -0,78 -0,43 -0,31
1400 % -0,74 -0,78 -0,71 -0,75 -0,88 -0,58 -0,67
1450 % -0,89 -0,87 -0,92 -0,84 -0,96 -0,86 -1,04
3
Abrasion resistance 800 cm 14,4 12,5 11,1 9,7 19,4 8,6
5
We can see in subsequent chapters again the parameters of particular castables set out on
specimen made by gunning. There are always to compare the values of the mixtures of
vibrated bodies, and moreover the values of the material list of castable, which is designed
specifically for the application of vibrating.
6
Chart no. 6 is a castable which in its composition, particularly with the matrix, ensures a
very good resistance to alkali bursting.
4.2. Alkali- resistive LCC fireclay type castable with shares of SiC and zircon
Castable is designed mainly to heat exchange systems of cement kilns. In the following
chart no. 7 are compared catalogue values of gunning LCC castable, the values of the sprayed
body and the body made of vibration. There are again catalogue values of a made castable
presented in the last column, the one produced within the similar composition intended for
building by vibration.
Chart no. 7 Comparing the values of the various made bodies of gunning alkali-resistive
fireclay type castable
Castable Catalogue Vibrated Gunning LCC
values specimen specimen SiC-ZR-RA
Mixture NT-Z-3 NT-Z-3 NT-Z-3 Material
list
Diverting water l/100kg By nozzle 6,2 By nozzle 5,4-6
Bulk density 110°C kgm-3 2310 2440 2360 2380
800°C kgm-3 2280 2370 2280 2370
1000°C kgm-3 2270
ox1450°C kgm-3 2320 2400 2330 2350
re1450°C kgm-3 2410 2290
Cold crushing 110°C MPa 55 100,4 52,4 80
strength
800°C MPa 55 66,1 60,8 80
1000°C MPa 64,6
ox1450°C MPa 50 76,7 56,4 90
re 1450°C MPa 35,5 58,0
Apparent porosity 800°C % 16 18,1 20,2 15
1000°C % 20,3
ox1450°C % 16 15,1 16,2 15
re 1450°C % 15,6 16,4
Permanent linear 800°C % -0,2 -0,28 -0,31 -0,2
changes
1000°C % ¤ -0,70
ox1450°C % -0,5 -0,40 -0,43 -0,4
re1450°C % -0,41 -0,36
ox…firing in common atmosphere re…firing in argon atmosphere
7
density of lining is significantly affected by the used nozzle, particularly its structural system
of perfect water distraction through the dry mixture.
The issue of the operating personnel consists in the fact that the gunning workers have
still been accustomed to work with conventional castables. In there, the high cement content
creates a protective layer that allows quite a wide range of possible variation of the mixing
water amount. Furthermore, aluminous cement itself contributes significantly to the high
adhesion of wet concrete mixture to the basis and it prevents sagging of sprayed layer.