Installation With Mortar

Dr. Reinhard Umlauf

REFRA-Training, Göttingen 2015
Content

• Refractory mortars: characteristics and implications

• Mortars for lining rotary kilns and static vessels
• Practical demonstration
Lining With Mortar

Generally
• Compensates differences in brick dimensions
• Yields a virtually gas-tight monolithic unit

In rotary kilns
• Distributes mechanical loads more uniformly over the entire lining,
reducing brick hot face spalling
Demands on Refractory Mortars

• Physically and chemically compatible with brick composition

• Provides a strong joint between the bricks from cold to service temperature

• Resistant to abrasion and corrosion

• Good workability
Classification of Mortars

Mode of mixing Mode of setting

• Ready-to-use mortars • Heat setting (clays…)

• Dry mortars • Air setting (chemical binders)
• Ready mixed dry mortars
Mortar composition Mortar type

• Aggregate (magnesia, fireclay, corundum, etc.) • Aggregate (magnesia, fireclay, bauxite)

• Stabiliser (plastic clay, organic stabiliser, etc.) • Binder (water glass)
• Binder (hydraulic or chemical binder, resin, etc.)

MgO + Na2O x 3SiO2 Mg2 SiO4 (1890 o C ≈ 3434 o F)

Al2O3 x SiO2 + Na2O x 3SiO2 NaAlSiO4 (1526 o C ≈ 2779 o F)

Basic lining Basic mortar

Fireclay lining Fireclay mortar
High alumina lining High alumina mortar
!! No fireclay mortar with basic lining !!
Water Glass Characteristics

Na2O x n SiO2
(n = 1.0-3.5)

SiO2/Na2O = 3.46 wt%

titel

Colloidal solution: pH 10-13 !! Protection of skin and eyes !!

Hardening Sol-Gel transition

• Drying
• Neutralisation: CO3—
• Ions: Ca++, Mg++, Al+++

!! Only clean water should be used as mixing water !!

Freezing point: -2 o C (28.4 o F) Limit of working: +5 o C (41 o F)

!! No application of mortar nor storage of liquid water glass at temperatures below the freezing point !!
Characteristics of Mortars for Lining …

Rotary kilns Static vessels

• Low max. grain size • Medium max. grain size

• Longer time for corrections • Shorter time for corrections
Mortars for Lining Rotary Kilns

PX-R Mortar AG-R Mortar OX-R Mortar CX-R Mortar CX-R Mortar

PERILEX  ALMAG REFRATHERM 150 KRONEX 20 KRONEX 50

FERROMAG KRONEX 25
MAGNUM KRONEX 35 (> 45 % Al2O3)
MAGPURE KRONEX 40
REFRAMAG
TOPMAG (< 45 % Al2O3)
FORMAG 
Mortars for Lining Static Vessels

CS-R Mortar KS-R Mortar AS-R Mortar

KRONEX 20 KRONEX 50 .... ALMAG

KRONEX 25 KRONAL 63 AR .... FERROMAG
KRONEX 35 REFRALUSIT MAGNUM
KRONEX 40
(> 45 % Al2O3)
(< 45 % Al2O3)
Setting of Water Glass Mortars

1. Drying of water glass: rising viscosity (min, h)

2. Chemical setting by silica precipitation

Water glass mortar requires porous materials.

When applied between brick and kiln shell max. thickness 8-12 mm
Normal Setting of Water Glass Mortars
Incorrect Setting of Water Glass Mortars
Mixing of Refractory Mortars

High shear mixing tool

Sufficient mixing time

Water addition following the data sheet

Additional water will make the consistency of the mortar too soft !
Drilling Machine
Mixer

Rotary Mixer Concrete Mixer

Data Sheet of AG-R Mortar