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Tab. 1. Typical data cf E-SY PUMP 1000 and E-SY PUMP 2000

~E"'

~

0.3 0.112.00.100.04

Na20MgOSiO2Fe2O3

%%%%

0.100.04

-m2fgIJmI

I IJm

3.31.916

Bimodal

3.51.916

Bimodal

BETCilas 050Cilas 090Grain size distribution

Fig. 1. Typical particle size distribution of E-SY Pump 2000, mea-

sured with laser granulometer (Ci las 1064)

Fig. 2. Typical particle size distribution of E-SY Pump 1000, mea-sured with laser granulometer (Ci las 1064)

mersion time of 1 second but blended single reactive alumirmsof similar composition only 3 seconds.

As a first approach, self-flow castables were used für pumpingtrials. However, the experience was thattheir rheology was taodilatant and that they could not be pumped at all. Detailed labinvestigations showed that neither vibration nOT self-flow casta-bieg bad a rheology to achieve steadily also pumpable proper-ties. The dilatancy of a castable hag to be low enough to achievepump ability, however, there is no direct link between flow be-haviour and dilatancy.

This observation is also confirmed in the literature [4,5]. Thetheory that low mixing energy is required für pumping was test-ed with a special rheometer [6]. Pumping conditions were simu-lated by a special lid in the rheometer, which leadsto volume re-striction similar to pumping. Pileggi showed t~at gelt flow is nocriteria to judge the pumpability of a castable. In contrary to theexpectation, castables mentioned as "easy mixing castables"showed self-flow or vibration rheology. Low mixing energy andtorque values at high shear rates under volume restriction haveto be achieved to ensure pump ability of a castable composition.

Based on the experience gathered by extended lab trials,E-SY Pump series hag been developed as a solution to providelow dilatancy für high purity (silica free) Tabular and Spinelmixes. It is composed in sucha way that addition of 20-30% ofE-SY Pump to the formulation leads to pumping rheology of acastable.

As a qualitative evaluation of the pumpability of a mix, the socalled ball drop test hag been developed. In the drop test, a steelball (110 g, 30 mm diameter) falls tram one meter above the mixsurface into the mix and the time required tram surface contactto complete submersion of the ball is measured. The measure-ment hag to be conducted in avessei with a depth not less thanthree times greater than the steel sphere diameter. The result isgiven as time in seconds für complete submersion of the ball. Byexperience, acastable with a ball drop time of less than 3 sec-onds is considered to be suitable für pumping.

Castable properties with E-SY Pump

Characteristics of E-SY Pump

Based on E-SY Pump 2000 tour different low cement casta-bles were developed tor pumping trials in a low power mortarpump or a double piston pump. The low cement castables con-tain a range of coarse aggregate sizes (T-60/T-64), and up to27% E-SY Pump 2000 and dispersing additives (ADS 3,AUW 1) (see Table 2). Depending on the castable composition,low dilatancy could be achieved with 5.6-7.0 % wateT, which isreflected in a ball drop of 1-2 seconds. From all castables flowproperties were determined with a cone test (lower (2) 100 mm,upper (2) 70 mm, height 80 mm). The castable setting time hagbeen measured by the EXO method, recording the temperaturedevelopment during setting. Test pieces have been prepared andtested according to the European standard ENV 1402 "Un-shaped refractory products", Part 5 and Part 6. Hot properties(HMOR), density wateT absorption and open porosity weremeasured by DIFK, Bonn, Germany. Further details on sampiepreparation are described in a previous paper [1]. Physical prop-erties of the castables are compiled in Table 3.

For trials in a low power mortar pump, castables Top 2 LPPand Top 1 LPP were used. Top 2 LPP contains coarse aggregatesup to 2 mm and has a low dilatancy with 20% E-SY Pump 2000and 6.6% wateT. The rheology of the castable with a top cutof1 mm is similar when 25% E-SY Pump 2000 and 7% wateT areused (TOP 1 LPP). Both castables have a flow at 30 minutes

1\vo different E-SY Pump products are available, which differin their mineralogical composition. E-SY Pump 1000 is purealumina based, whereas E-SY Pump 2000 contains alumina andalumina rich spinei. Both products are bimodal reactive alumi-nas, with typical d50 and BET of 1.9 J.lm and 3.3 m2/g (E-SYPump 1000) and 1.9 l.IIn and 3.5 m2/g (E-SY Pump 2000). Chem-ical and physical properties are summarized in Table 1, a typicalParticle Size Distribution (PSD) of E-SY Pump 2000 is shown inFigure 1 and of E-SY Pump 1000 in Figure 2.

E-SY Pump is, like other multimodal reactive aluminas, pro-duced by co-grinding which gives higher homogeneity and im-proved rheological behaviour compared to single componentformulations. The advantage of co-grinding can also be seen inthe results of the ball drop test, where E-SY Pump gives an im-

88

ogy of vibration and self-flow castables can be irnproved byIE-SY Pump by exchanging same reactive aluminas für E-SY

Pump products. Further studies are ong.oing inclu.ding also noncement castables, based on the calCla free bInder Alpha-bond 500. (F 14)

using the low power mortar pump and easy pumpability wasachieved with only 5.6% wateT. The lower wateT content resultsin higher strength of the castable sampies compared to sampiesfrom the mortar pump trial. E.g. the CCS at 1500 °C raises from165 MPa (Top 1 LPP) to more than 300 MPa (Top 6 DPP) andthe HMOR rises to 22 MPa.

All castables and pump trials have been performed with theSpinel containing E-SY Pump 2000. However, they could alsohave been done with the high alumina based E-SY Pump 1000.

References

Conclusions and Outlook

[1] Kriechbaum, G. W.; Gnauck V.; Laurich, J. 0.; Stinnessen, I.;Routschka, G.; van der Heijden, J.: The Matrix AdvantageSystem, a new approach to low moisture LC selfleveling andalumina rich spinel castables, Proc. 39. International Collo-quium on Refractories, Aachen, Germany, 1996,211-218.

[2] Laurich, J. 0.; Buhr, A.: Synthetic Alumina Raw Materials-Key Elements für Refractory Innovations, Unitecr '99,Berlin, Germany, 348-355.

[3] Kriechbaum, G. W.; Gnauck, V.; Routschka, G.: The influ-ence of SiOz and on the Hot properties of High AluminaLow Cement, Proc. 37. International Colloquium on Refrac-tories, Aachen, Germany, 1994, 150-159.

[4] Peleggi, R. G.; Marques, Y. A.; Vasques Filho, D.; Pandofel-li, V. C.: Shotcrete Performance of Refractory Castables,Refractories Applications and News Val. 8, 2003, No. 3,15-20.

[5] Pileggi, R. G.; Pandofelli, V. C.: Rheology and Particle SizeDistribution of Pumpable Refractory Castables, Am. Cer-am. Soc. Bull. Val. 80, 2001, No. 10,52.

[6] Pileggi, R. G.; Paiva, A. E.; Gallo, J.; Pandofelli, V.C.: Nov-el Rheometer für Refractory Castables, Am. Ceram. Soc.Bull, Val. 79, 2000, No. 1,54-58.

The trend towards monolithic lining requires state of the artequipment and appropriate castables formulations. The dilatan-cy of high purity vibration and self-flowing castables hampersthe pumping application, especially when double piston pumpsare used. Initial formulations used silica turne in superfine ma-trix hut with anegative impact on refractoriness and thermome-chanical strength. With the E-SY Pump 1000 (pure alumina)and 2000 (Spinel containing) two types of high purity ReactiveAluminas are available which allow the composition of low dila-tancy castable formulations. Several castables compositionsbased on E-SY Pump 2000 gave a reduced dilatancy comparedto self-flowing castables. Field trials showed that E-SY Pumpcastables are pumpable both with simple low power mortarpumps and double piston pumps, which are very demandingwith respect to the castable rheology. Castables could be easilypumped over a distance of 50 m though several hoses with di-ameter of 50 mm and 38 mm.

Besides pumping, dilatant castables are difficult to install inmanyapplications. Initial lab trials show that the general rheol-

90