SioxX®-Zero

Microsilica-gel bonded castables

(NCC)
Customer handout

April 2015
1
 Content

• Background

• SioxX®-Zero product description

• Performance and advantages of using gel-bond system with SioxX®-Zero

• Technical evaluation of SioxX®-Zero vs Silica-Sol in Bauxite NCC

• Evaluation of NCCs with different aggregates
• Comparison of Tabular T60 NCC vs Tabular T60 LCC
• Explosion testing
• Thermal gravimetric analysis (TGA) of SioxX®-Zero in Bauxite NCC
• Applications

2
 Background
• Silica-Sol bonded cement-free castables is considered the state-of-art in the
refractory industries.
• However, their use have been limited, mainly due to the following challenges:
• Long set-time/complex set-behaviour
• Inadequate green-strength leading to handling problems

• Microsilica as gel-binder for refractory castables have been studied for many years.
The major advantages of using microsilica as a binder system (compared to a
cement binder) can be summarised as follows
• Fast heating-up profile after drying since no cement hydrates are present
• Improved high-temperature properties (hot-MOR) due to mullite formation
between microsilica and alumina at high temperature

• An Elkem speciality product (SioxX®-Zero) has recently been developed based on

more than 20 years of experience with microsilica-gel bond in castables.

3
 SioxX®-Zero: Product description

Technical features:
• SioxX-Zero is a new Elkem specialty product for alumina based NCC
• The product is based on the SioxX family concept and mainly designed for
microsilica-gel bonded systems (No Cement Castables)

• SioxX-Zero will:
• Improve the workability which is crucial and a challenge for the NCC system
• Reduce the water demand (increase the flow at the same water addition) vs.
Silica-Sol
• Control the working and demoulding time
• Develop high green-strength at room temperature
• Develop adequate mechanical strength at intermediate temperatures and better
hot-properties (hot-MOR, RUL) at elevated temperatures (1400-1500ºC)
compared to LCC
• Allow quick drying process after the free water is removed

4
Basics of microsilica gel-bond system with SioxX-Zero

• 3% SioxX-Zero
• 3-6% high quality microsilica
• 0,5% Gelling initiator – Polyvalent Cation (CAC70)
• Min. 10% calcined alumina
• 10 - 20% alumina source (combined calcined and milled) for mullite formation
• No additional hydratable alumina (or max. 0.5%)
• No other magic ingredients or “minor quantities” which require high precision
weighing

• Can be shotcreted using waterglass solution (or alternative external additive) as

accelerator

5
A brief explanation of microsilica-gel bond in alumina-castables

• Even though the overall composition of microsilica is SiO2, the surface of a

microsilica particle consists not only of siloxane functional groups, but is also
partially hydroxylated and hydrated.

• The presence of the silanol groups makes the microsilica easy to disperse in
aqueous systems. Depending on the pH, a fraction of the silanol groups dissociate
(to H+ and –O-) resulting in a negatively charged surface (hydroxyl groups (Si-OH))

6
 A brief explanation of microsilica-gel bond in alumina castables

• The negative charge on the surface of the microsilica makes gel bonding possible

• Negative sites can react with a cation and polyvalent cations may bridge two
adjacent microsilica particles

• A gelling (or stiffening) of the microsilica-containing viscous phase takes place

creating a three-dimensional network of silicate hydrates

• Addition of SioxX-Zero may facilitate further dissolution of the cement by removing

aluminates from the water. Then, more of the cement is dissolved and the setting
proceeds faster and to a higher extent.

7
 Illustration of microsilica surface with negative charges being
linked (gelled) by Ca2+

Microsilica-gel bond acts by gelling of the microsilica slurry and not primarily by
hydration of cement .The 0.5% cement serves as a “retarded gelling agent” supplying
Ca2+ that makes the microsilica-gel.

8
 Illustration of microsilica surface with negative charges being
linked (coagulating) by MgO

Reference:
N. Hamedani Golshan, H. Sarpoolaky and A. R. Souri:
MICROSTRUCTURE AND PROPERTIES OF COLLOIDAL SILICA BONDED MAGNESITE CASTABLE REFRACTORIES
Iranian Journal of Materials Science & Engineering Vol. 8, Number 1, Winter 2011

Schematic representation of silica consolidation through the coagulating

mechanism:
(a) microsilica particle surface
(b) reaction between the cation and silica surface
(c) Mg2+ acting as a bridge by reacting with two particles siloxane bonding (–Si–
O–Si–)

10
 Advantages of microsilica-gel bond system:
Permeability and porosity

• In microsilica-gel bonded castables, the water is not chemically bound, most water
in the gel structure (more than 90%) will be removed at low temperatures (<160°C)
• The lack of hydration phases results in higher permeability and easier gas and
liquid passage at drying temperatures
• Once the physical water has been removed, the porosity remains relatively constant
to much higher temperatures
• The relatively low porosity at intermediate temperatures (as compared to LCC)
leaves the microsilica-gel bonded refractory more resistant to oxidation, gas attack
and slag attack
• The removal of most of the water at low temperature results in linings that are much
less susceptible to steam spalling at high heating rates. The dry-out schedules can
be much quicker, allowing faster vessel turnaround. In some cases, the dry-out
times may be reduced to half using gel bonded refractories.
• A very small quantity of water in the form of attached hydroxyl groups can still be
removed at much higher temperatures. This removal of water, although nearly
undetectable, results in the formation of additional Si-O-Si bonds that further
enhance strength development

11
 Advantages of microsilica gel-bond system:
Strength and thermal shock resistance

• Although the microsilica-gel bonded castables show a lower initial strength

compared to cement bonded materials, the progression in strength development is
good and quickly equals that of the cement bonded materials at moderate
temperatures (<600°C).
• At elevated temperatures, the strength differences become more dramatic. Low-
melting-temperature CaO-Al2O3-SiO2 phases associated with CAC castables are
responsible for liquid phase formation and the resulting lower hot strengths.
• Because the microsilica-gel bonded castables are CaO-free, they do not generate
these low melting phases and typically exhibit higher hot strengths, which results in
better in-service erosion resistance
• Glassy phase formation and volume instability associated with CAC castables often
cause degradation of properties upon thermal cycling. Gel bonded castables
generally show better performance in cyclic applications.
• Normally, after only a few cycles, the CAC material shows a loss of over 85% of its
initial strength, while the Microsilica-gel bonded material loses strength much more
slowly and at a steady, predictable rate.

12
 Advantages of microsilica-gel bond system with SioxX-Zero

• SioxX-Zero is a new Elkem specialty product designed for NCC

• Although Colloidal Silica/Silica-Sol is currently used in gel bonded systems/NCC, set-

time and low green-strength are still the major challenges. In addition the two-
component system requires liquid transportation and handling.

• NCC with SioxX-Zero in combination with microsilica provides

• better flowability
• better workability
• improved mechanical properties at room temperature
• fast firing (energy/money saving)
• better hot-properties (Hot-MOR, RUL) at elevated temperatures (1400-1500oC)
than LCC
• none of the disadvantages involved when using Colloidal Silica/Silica-Sol (see
next slide)

13
 Disadvantages of Silica-Sol

Silica-Sol is often also called Sol or Colloidal Silica.

• Silica-Sol is based on stable water-based suspensions of fine amorphous silica particles
(containing up to 50 wt% spherical particles with diameter less than 100 nanometers).

• Extra component: Silica-Sol needs to be added separately to the mix and to be

transported and stored in time at site.

• Suspension must be stored at 5-35ºC. If subjected to freezing conditions, it can lose its
stability and precipitate. Elevated temperatures may accelerate the growth of micro-
organisms and/or decrease the long-term stability.

• Production problems
• Suitable mixing equipment necessary
• Silica-Sol is more viscous than water. Difficult to mix.
• Low flowability and workability
• Low green-strength and sometimes crack formation during setting

• Higher cost compared to cement bonded systems based on similar raw materials, and
normally more expensive than Microsilica-gel bonded system with SioxX-Zero.

14
 Why is microsilica-gel bonded castables with SioxX-Zero better
than Silica-Sol system?

“Add water only” NCC with excellent flow, controllable setting and quick dry-out and
heating:

• “All in the bag”

• Higher permeability
Microsilica-gel bond • Increased green-strength

Dry system • Quick dry-out and heating

with microsilica
H 2O

• Flowability
• Mixing
• Working time
SioxX®-Zero • Controlled set-behaviour
• Easy placement

15
 SioxX-Zero vs. Silica-Sol in a NCC bauxite castable

weight %
Components
SioxX-Zero Silica-Sol
Bauxite Diff. sizes 68 68
BFA Fines 12 12
Raw Kyanite -100 mesh 2 2
Calcined Alumina d50: 3-4 µm 10,5 11,5
Cement 70% alumina 0,5
Elkem Microsilica 971U 4 2,7
SioxX-Zero 3
Silica-Sol 8,3
Others (Polyvalent Cations….) 0,5
Total 100 105
Water to add 5,0 0
Total Water 5,0 5,0

16
 SioxX-Zero vs. Silica-Sol in a NCC bauxite castable
245
Flowability: Cold MOR (MPa) at 20ºC
Vibra-flow with EN cone (80 mm) 3,0
300
2,5
108% 2,5
200 2,0
250
1,5
23% 245
1,0 1,2
200
0,5
200
0,0
150 Silica-Sol SioxX-Zero

100 14,0 Cold C.C.S. (MPa) at 20ºC

12,0 13,0
50
10,0
8,0 136%
0
Silica-Sol SioxX-Zero 6,0
4,0 5,5
2,0
0,0
Silica-Sol SioxX-Zero

17
 Technical evaluation of SioxX-Zero vs Silica-
sol in Bauxite NCC

• Microsilica-gel bonded bauxite NCCs vs silica-sol bonded NCCs

• Green strength and setting process of micosilica-gel bonded bauxite based

non-cement castables (NCC): SioxX-Zero vs other dispersants.

• Effect of the installation temperatures on setting behaviours of bauxite NCC

• Shelf-life of microsilica-gel bonded bauxite NCCs with SioxX-Zero

18 07.05.2015
Bauxite NCCs: SioxX-Zero versus Silica-sol

SiOxX-Zero Silica Sol

Components A B A B

Bauxite 0-5mm 78 78 78 78
Calcined Alumina fines 12,5 12,5 13,2 14,2
Microsilica THV 971U 6 6 4,6 4,6
Silica-sol 40/130 8 8
SioxX-Zero 3 3
Dispersant PCE 0,05 0,05
Hydrable alumina 0,5
Cement 70% alumina 0,5 0,5 0,5
Gelling agent/MgO Fines - 100 0,1
Total 100 100 104,9 104,9
Water to add 4,5 5 0,2 0,2
Total Water 4,5 5 5 5
Properties tested

• Wet-out time
• Flow Decay (0, 30, 60, 90, 120 min)
• Cold Crushing Strength (CCS)
• Cold Modulus of Rupture (CMOR) at room
temperature,100, 300, 600 and 800ºC
• Hot Modulus of Rupture (HMOR) at 1400ºC
• Refractoriness under Load (RUL)

20
 Videos of mixes

SioxX-Zero-B

Silica-Sol-A Silica-Sol-B

21
Set-time of bauxite NCC

• The microsilica-gel bonded castable A with SioxX-zero has a much quicker and more
“defined” set than the others.
Flow decay: SioxX versus Silica-sol/0.5%CA versus 0.1%MgO

SioxX-Zero provide higher flowability at

same water addition as Silica-Sol
system.
Green strength: SioxX-zero vs silica-sol

<1MPa

Bauxite NCC with SioxX-Zero shows much higher green-strength than the those with
Silica-sol.
CMOR: microsilica-gel bonded with SioxX-Zero vs Silica-sol

The bauxite NCCs with SioxX-Zero at 4.5% water shows similar strength as the one with
Silica-sol.
Hot MOR: SioxX versus Silica-sol

The Hot-MOR of bauxite NCCs with SioxX-Zero is higher than those using Silica-Sol at test
temperature range from 1100-1400 oC.
RUL after prefiring at 1000ºC/24hrs: SioxX versus Silica-sol

The RUL results of bauxite NCCs with SioxX-Zero is comparable with the Silica-Sol bonded
NCCs.
Summary: SioxX-Zero vs Silica-Sol in Bauxite NCC

• Castables with SioxX-Zero are easier to mix and provides higher flowability at
same water addition vs Silica-Sol system

• SioxX-Zero provides reasonably short initial set-time, approximately 2-3 hrs.

• The microsilica-gel bonded castable with SioxX-zero has a much quicker and more
“defined” set, which leads to much higher green-strength than the Silica-Sol system

• Hot-MOR of bauxite mixes with SioxX-Zero is higher in the temperature range from
1100-1400oC, otherwise mechanical properties are comparable with Silica-Sol
system
Compositions of bauxites NCCs with various dispersants

Microsilica-gel bonded
Silica-sol bonded
SioxX-Zero Dips.B Dips.C Dips.B
Bauxite, 0-5mm 78 78 78 78
Calcined alumina
fines 12,5 13 13 13,2
Elkem 971U 6 8 8 4,6
Silica-sol, 40/130 * 8
SioxX-Zero 3
Dispersant-B 0,05 0,05
Dispersant-C 0,23
Hydratable alumina 0,5 0,5
70% CAC 0,5 0,5 0,5
Gelling agent 0,1
Water content 5

The particle size distributions (PSDs) of microsilica-gel bonded refractory NCCs

were calculated using the EMMA program. The q-value was 0.25 for all mixes.
Flowability of bauxite NCcs with various dispersants
 (a) SioxX-Zero, SF:113%

(b) Dips. C, SF: 50%

(c) Silica-sol,
SF:83%

33
 Setting and hardening process of bauxite NCCs

A: SioxX-Zero
C: Disp.C

• The microsilica-gel bonded castable A with SioxX-zero has a much quicker and
more “defined” set than the others.
• Time to final strength is in the order of 5 hours while the one using Disp. C did not
set completely after two-day curing in the molds.

34
 Mechanical strength of bauxite NCCs with various dispersants

Not Set after 2 day

Not Set after 2 day

The green strength of the castable A with SioxX-zero is much stronger than the
others. The C.C.S after demoulding is up to ~ 11 Mpa while the silica-sol bonded one
is ~4.0MPa.

35
Summary: bauxites NCCs with various dispersants

• The types of dispersants has strong impact on setting and hardening

process of microsilica-gel bonded NCCs.

• The microsilica-gel bonded NCCs with SioxX-Zero not only show higher self-
flow but also provides with higher green strength those using other
dispersants.

• In comparison with silica-sol bonded NCC, the setting behavior and green
strength of the microsilica-gel bonded have been substantially improved.

• The microsilica-gel NCCs with SioxX-Zero have been developed, exhibiting

improved setting behavior and mechanical properties
 Installation/curing temperatures vs setting behavior (ongoing)

Components
NCC
Variables:
Bauxite 0-5mm 78
Calcined
12,5 • Three different installation temperatures
Alumina (5, 20 and 35 Celsius degree) were
Cement 70% alumina 0,5 tested.

Microsilica THV 971U 6 • Three different dispersants: SioxX-Zero,

Disp.B and C.

SioxX-Zero 3
100
Water to add 5,0
Total (%) 100

37
 Setting behavior of NCCs with different dispersants at 5º Celcius

38
 Initial set-time of bauxite NCCs under different temperatures
>1440min

• At 5º Celsius, the initial set-time of bauxite NCCs with SioxX-Zero was extended, but it
set and demoulded after one day; while the others with Disp. B and C was still wet after
two-day curing in the molds..

39
 Mechanical properties of Bauxite NCCs with SioxX-Zero vs
installation/curing temperatures

After demoulding 110 ºC/24hrs

The microsilica-gel NCCs with SioxX-Zero have been developed, exhibiting

improved setting behavior and mechanical properties

40
 Shelf-Life of bauxite Ncc with SioxX-Zero (ongoing)

Components
NCC
Bauxite 0-5mm 78 Warehouse in Kristiansand
Calcined • Full mixes in plastic bags
12,5 • Test intervals: fresh, 1, 2, 3 and 6 months
Alumina
Cement 70% alumina 0,5

Microsilica THV 971U 6

SioxX-Zero 3
100
Water to add 5,0
Total (%) 100

Test properties: wet-out time, flowability, set-time, green strength and strength after dry at 110oC

41
 Setting behavior of full mixes of Bauxitte NCC with SioxX-Zero in
platic bags

The set-behavior of microsilica-gel bonded bauxite NCC with SioxX-Zero remains the same after
two-month storage in the plastic bags.

42
 Properties Full mix of bauxite NCC with SioxX-Zero after stored in
plastic bag for two months

CMOR 20oC/24hr CMOR

Wet-out (sec.) SF (%) MPa 110/24h MPa
Fresh 10 118 2,45 6,71
14 days - - - -
1 mth 10 120 2,34 6,32
2 mth 10 118 2,30 5,15
3 mth
6 mth

Test properties: wet-out time, flowability, set-time, green strength and strength after dry at 110oC

After two months in plastic bag, no ageing of full mix bauxite NCC was
observed.

43
Summary: Effect of installation temperature and storage time on
properties of microsilica-gel bonded NCCs

• Installation temperatures has strong influences on setting process.

• At cold condition like 5oC, Microsiica-gel bonded NCC with SioxX-Zero sets and
can be demoulded after one-day, while the ones using Disp.B and C did not set
after two-day curing.

• The SioxX-Zero after stored in open bag in 85% RH at 20 oC for one month, the
final set-time is extended to 10 hrs and the green strength and the strength after
drying are still fine.

• The intermediate results show that the bauxite NCCs with SioxX-Zero are
fine after two-month storage in the plastic bags.
 Evaluation of NCCs with different aggregates

45 07.05.2015
Compatability of SioxX-Zero with various aggregates in
Microsilica-gel bonded NCCs

Bauxite WFA BSA T60

Bauxite 0-5mm 78
WFA 0-5mm 80
BSA 0-6mm 83
Tabular 60 (T 60) 0-5mm 84,5
Calcined alumina fines 12,5 10,5 9 7
Elkem 971U 6 6 5 5
SioxX-Zero 3 3 3 3
70% CAC 0,5 0,5 0,5 0,5
Total Water 4,5 4,15 4,0 4,5

The q-value was 0.25 for all mixes

 Flowability of NCC with various aggregates using SioxX-Zero

Water addition 4,5 4,15 4,0 4,5

Self-flowing NCCs have been produced at low water addition (4,0 – 4,5%) with a range
of aggregate systems

47
 Setting and hardening process

48 07.05.2015
 Flow decay of NCC with various aggregates

49
 Green-strength of NCC with various aggregates

≥ 9,5 MPa

All NCCs with SioxX-Zero have

high green-strength after 24 hrs at
20 oC
≥3,0 MPa

50
 Mechnical strength of NCCs with different aggregates

51 07.05.2015
 Hot MOR of NCCs with different aggregates

T60 NCC and WFA NCC exhibit much higher hot-MOR 1400ºC, up to 20MPa, while the
NCCs with bauxite and BSA have lower H.MOR, about 5MPa.

52 07.05.2015
Refractoriness under loading (RUL) after prefring at 1000ºC for
24hrs : NCC with different aggregates

Mullite formation was clearly indicated in the WFA, T60 and BSA NCC samples.

HP 07.05.2015
Refractoriness under loading (RUL) after prefiring at 1500ºC:
NCC with different aggregates

HP 07.05.2015
 RUL of gel bond NCC vs LCC with WFA aggregates

RUL (0,2 MPa, predried at 110oC)

2

1
Expansion [%]

0
0.5% cement 8% MS
6% cement 8% MS
6% cement , 0% MS
-1

-2
0 500 1000 1500 2000
Temperature [°C]

Gel-bond NCC not only outperforms the LCC with 8% microsilica, but is also
better than the silica-free LCC

55
 Summary: SioxX-Zero in NCCs with various aggregates

• NCCs with four different aggregates; Bauxite, WFA, BSA and Tabular,
have been tested with SioxX-Zero

• Self-flowing NCCs have been produced at water addition of 4,0 – 4,5%

• All NCCs have high green-strength after 24 hrs at room temperature

• The types of aggregates have significantly impact on hot-properties.

• T60 NCC and WFA NCC exhibit much better hot-properties than the
bauxite and BSA NCCs above 1400oC, and even better hot-properties
(RUL) above 1400oC than either LCC’s or silica-free LCCs.

56
 Comparison of Tabular T60 NCC vs Tabular
T60 LCC

57 07.05.2015
 T60 NCC vs T60 LCC

% T60 NCC T60 LCC

2-5 mm 23 23
1-2 mm 13 13
0,5-1 mm 14,5 14
T 60
0,2-0,6mm 8 8
0-0,2mm 24 23,5
20um 2
Calcined Alumina D50: 3 -4 micron 7 6
Cement 70% Alumina 0,5 5
Microsilica THV 971U 5 5,5
SioxX-Zero 3
SioxX 2
Water 4,5 4,5

58 07.05.2015
 Flow decay of tabular based NCCs and LCC

Self-flowing NCC and LCC have been produced at a lower water addition of 4.5%.
The flow-decay of T60 NCC with SioxX-zero is faster than that of T60 LCC with SioxX.
(The flowability at 90min was forgotten to measure).

59 07.05.2015
 Comparison of cold strength of of T60 NCC and LCC

T60 NCC with SioxX-Zero shows lower cold strength at the test temperature
range from 20 to 800oC.

60 07.05.2015
 Hot MOR of T60 NCC and LCC

250%

600%

At temperature of1400ºC, the hot M.O.R of T60 NCC is 14.6MPa, being 250% higher than
that of T60 LCC (4,2MPa).

61 07.05.2015
 Refractoriness under loading (RUL) after prefiring at 1000ºC for
24hrs: NCC with SioxX-zero vs LCC

The RUL curve indicates that the much higher deformation temperature of T60-NCC is
attributed to the mullite formation at Temp. above 1400oC.

62 07.05.2015
 Refractoriness under loading (RUL) after prefiring at 1500ºC for
24hrs: NCC with SioxX-zero vs LCC

T60 LCC T60 NCC

Def. 0,5% at °C 1458 1624
Def. 1% at °C 1473 1689
Def. 2% at °C 1493 1749

The temp. at deformation level of 2% of T60 NCC is about 256oC higher than that of T60 NCC.
T60 NCC exhibits better hot-properties (hot-MOR, RUL) at elevated temperatures (1400-1500ºC)
compared to LCC.

63 07.05.2015
 Conditions for mullite formation – Mullite formation and
precipitation
0.5%CA+7%MS
microsilica

5%CA+7%MS

Peritectic composition approximately

50% cement +50% Microsilica 1512°C

° i.e. 5% CA+5% MS

Alumina castables 4-8%

MS, 0-8% CA cement

64 07.05.2015
CA cement
 Summary: Tabular T60 NCC vs LCC

• Self-flowing T60 NCC and LCC have been tested.

• As expected, T60 NCC with SioxX-Zero shows adequate green strength

and mechanical strength at intermediate temperatures, while being lower
than that of T60 LCC tested at the same test temperaures.

• T60 NCC exhibits much better hot-properties (hot-MOR, RUL) at elevated

temperatures (1400-1500ºC) compared to LCC.

65 07.05.2015
 Explosion testing

66 07.05.2015
 Weight loss as a function of drying/firing, NCC vs LCC

Gel-bonded WFA NCC - 4.15% water LCC - 6% cement

Microsilica-gel bonded NCC will have higher permeability than LCC after drying at
110ºC, makes faster heat-up without spalling problems possible.

67
 CAC: Dehydration, thermal decomposition and phases formed

68
 Explosion resistance of microsilica-gel bonded NCC vs LCC
LCC with 6% cement
Explosion resistance testing according to Chinese standard YB/T 4117-2003: 50mm
un-dried (green) cubes are placed into a furnace at test temperature for 30 minutes.

Test "Green" Dried at 110 oC

temperature
[oC] LCC NCC LCC NCC
200 ☺
250 ☺
300 ☺
350 x
400 ☺ x ☺ ☺
500 ☺ x
550 ☺
600 x x ☺
800 ☺
1000 ☺
1200 ☺

☺ - passed
x - failed

The apparent lower explosion resistance of “green” NCC is attributed to the lower green-strength compared to the LCC.
After drying at 110ºC the gel-bonded NCC has gained strength and contains less water than the LCC resulting in
superior explosion-resistance compared to LCC.

69
 Predried piece – Explosion test set-up

200 kg of pre-dried microsilica-gel bonded castable.

Explosion resistance test passed without problems.

70 07.05.2015
 Example: Heat-up program for a rotary kiln
1000
36 hrs program for LCC
900
24 hrs program for microsilica-gel bond system
800

700 50ºC/h
>75ºC/h

600
550ºC
500

400 50ºC/h

300ºC
300

200 50ºC/h
160ºC
20ºC/h
100
120ºC
15ºC/h
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

For microsilica-gel bond castable some 90% of the water will evaporate during drying at
low temperature. The lack of hydration phases results in higher permeability and easier
gas passage at drying temperatures → fast heat-u

71
 Thermal gravimetric analysis (TGA)
of SioxX-Zero in Bauxite NCC

72 07.05.2015
Thermal gravimetric analysis (TGA) of ULCC and NCC with SioxX-Zero
Temperature
ULCC NCC ULCC NCC
[ºC]
3-6 mm 20 20 20 48,6 22,7
Bauxite 1-3 mm 30 30 110 97,7 28,5
CCS
0-1 mm 20 20 1000 110,2 130,0
1500 79,0 114,8
Kerphalite 0-0,16 mm 5 7,5
20 8,3 2,3
BFA 0-0,2 mm 5 5
110 15,4 5,2
Calcined Alumina D50: 3-4 micron 10 10 CMOR
1000 15,8 18,6
Cement 70% alumina 3 0,5 1500 9,3 13,6
Microsilica 971U 4 4 20 2,82 2,81
SioxX-Zero 3 3 BD 110 2,74 2,70
(Bulk Density) 1000 2,66 2,68
Total 100 100
1500 2,73 2,66
Fibres 6 mm PP 0,05 0,05
20 0 0
PLC
Water 5 5 110 0 -0,02
(Permanent Linear
Change) 1000 -0,23 -0,05
Vibration-flow 120 125 1500 0,03 0,4
Set-time <1 hr <3 hrs

73
TGA of ULCC and NCC with SioxX-Zero
100% 700

Temperature (ºC)
90%
80% ULCC 600
ULCC
Weight loss %

70% 500

60% 400
50%
300
40%
30% 200
20%
100 External Temperature
10% Internal Temperature
0
0%
0 100 200 300 400 500 600 700 0 3 20000
6 9 40000
12 15 60000
18
Internal Temperature (ºC) Time (hrs)

100% 700
90%
NCC 600 NCC

Temperature (ºC)
80%
70% 500
Weight loss %

60%
400
50%
40% 300

30%
200
20%
100 External Temperature
10%
Internal Temperature
0% 0
0 100 200 300 400 500 600 700 0 3 20000
6 9 40000
12 15 60000
18
Internal Temperature (ºC)
Time hrs)

74
 Applications of Microsilica-gel bonded
castables & Summary

76 07.05.2015
 Applications of microsilica-gel bond castables / pumpables

Microsilica-gel bond castables/ pumpables give benefits both in terms of ease

of application and technical properties in a variety of industries:
• Cement industry - high temperature rotary kiln burning zone, rotary kiln
incinerator lining, Burner tilt, TAD off Take, Raiser Duct, Coolers…
• Glass industry - outside the glass melting tank furnace, sidewalls and
roofs
• Iron & Steel
• In blast furnace troughs - because of better workability lining can be installed
by a pump reducing installation time
• In torpedo cars and other transfer ladles, tundish back-up lining, electric
arc furnace (EAF) deltas and runners
• In secondary operations - Reheating furnace hearth, roof.
Gel bond castables/pumpables have shown significant improvement especially
in reheating furnace roof areas, both during installation and drying (which take
about 60% less time than conventional ramming mixes & plastics)

77
 Applications of microsilica-gel bond castables

Cupola Furnace castable

based on SioxX-Zero

78
 Applications of microsilica-gel bond castables

Video Delta Section

Delta Section based on SioxX-Zero

79
 Advantages of microsilica-gel bond system with SioxX®-Zero
• Lack of chemically bound water (i.e. by cement)
• No curing time necessary and Improved mechanical properties at room temperature
• Improved permeability (to vapor) at lower temperatures allows for faster heat-up and
shorter drying and reduces heating problems (e.g. spalling)
• Higher oxidation and acid resistance (infiltration, slag resistance)
• Superior thermal shock resistance
• Excellent hot properties: significantly improved HMOR and RUL will extend life-time
and allow higher service temperatures than LCC, because of:
• the absence of low-melting phases (CA, CA2, C12A7, C2AS, C4AF)
• the mullite formation from microsilica and alumina fines
• Flexible installation by self-flow, casting, vibrating, pumping or shotcreting.
• Faster installation, increased production and equipment utilization
• More environmentally friendly, reduced energy requirement and lower CO2 emission
• Drying and heating can be performed significantly faster compared to standard
castables
 LCC Microsilica-Gel Bond
 ULCC Fast Dry NCC

80
 Thank you for your attention!

More technical papers from Elkem:

http://www.elkem.com/en/Silicon-materials/Products/Refractories/