REFRASUD INTERNATIONAL S.R.L.

COMPANY PRESENTATION

REFRASUD INTERNATIONAL S.R.L.

of 11

Jul. ’12 Rev.08

PRODUCTS BASED ON CARBONXIDE®

The company Refrasud International S.r.l. (hereafter referred to as Refrasud), works

in refractory field and offers different qualities of products. For their production it is

used a special chemical conditioner called CARBONXIDE®, which gives the finished

product specific chemical and physical characteristics.

During the sintering phase CARBONXIDE® facilitates the formation of a better

distributed and widespread microstructure and microporosity (see Photo n. 1-3-5

pag.2), compared to standard refractory products (see Photo n. 2-4-6 pag.2).

Advantages to be underlined:

1) Energy costs reduction

2) Longer life of refractory products

3) Minor maintenance costs

Thanks to the introduction on the market of this conditioner that can be used in almost

all the refractory products (except of refractory cements and castables containing

aluminum phosphate or chemically bonded alumina bricks), Refrasud is able to

improve and increase performances of these products in terms of thermal capacity and

duration.

A major part of the merit of this innovation lies in a special attention that Refrasud has

always paid to Research, placing continued testing programs as a center of its

activities.

Taranto Head Office Workshop – Legal Office Phone +39(0) 99 7798914 P.I. IT02243040736

Via Speziale 10 Via Cesare Battisti, 5280 Fax +39(0) 99 7798923

74100-Taranto (Italy) 74100-Taranto (Italy)

of 11

Jul. ’12 Rev.08

Quality microanalysis or a refractory structure with CARBONXIDE®

Quality microanalysis of a STANDARD refractory structure

Pic. 1 Pic. 2

Detail of a refractory material structure where the detected porosity holes are smaller viewed at the

same scale.

Detail of a refractory material structure where the detected porosity holes are bigger viewed at the

same scale.

Pic. 3 Pic. 4

The microcomponents detected have small dimensions viewed at the same scale

The microcomponents detected have much bigger dimensions viewed at the same scale

Pic. 5 Pic. 6

The grain dimensions detected are small viewed at the same scale.

The grain dimensions detected are bigger viewed at the same scale.




of 11

Jul. ’12 Rev.08

The additive goes into action during the sintering phase and/or ceramization

phase preventing from rising of grain sizes and favoring a notable increase in

quantity of pores with a smaller diameter.

Products treated with additives based on CARBONXIDE have a particular

structure characterized by a total porosity equal to a standard products porosity

but with a much bigger number of pores per cm3 (of 30÷40%) with smaller

diameter (of 30÷50%) [see Table 1 and Photos 1 and 2]

The data reported below show results of a research performed by Mechanical

Engineering of the University of Lecce on two samples of alumina bricks of

quality ZH 85 A containing 82% of alumina: the first with additive and second one

without additive.

The table given below evidences the differences between the two samples:

Table 1

Values of porosity, pores diameter and bulk density of the samples measured using mercury porosimetry

(CERTIFICATE N.1)




PropertiesBrick ZH 85

without additive

Brick ZH 85 A with

CARBONXIDE

Average pore radius (Micron) :

0.83±0.02 0.53±0.02

Total porosity (%) : 20.0±0.6 21.0±0.6

Bulk density (g/cm3): 2.70±0.05 2.69±0.05

of 11

Jul. ’12 Rev.08

It could be deducted that the microporous formation obtained through the use of

CARBONXIDE® is more favorable to a "discharge" of a tension and more

appropriate for improving of a compactness and a thermo-mechanical resistance

of produced materials.

The following characteristics are noted:

• Greater Specific Heat (20%÷30%)

• Lower Thermal conductivity (10%÷20%)

• Lower Thermal Diffusivity (30%÷50%)

• Better Thermal Shock resistance

• Better Hot Crushing Strenght (1300÷1600°C) (20%÷30%)

• Lower thermal expansion (10%÷20%)

The above-mentioned characteristics have been confirmed by a numerous

laboratory tests performed by Societè Francaise de Ceramique (France),

University of Lecce (Italy), Salentec Laboratory(Italy) and some other Italian and

overseas laboratories situated within refractory manufacturers plants.

The laboratory tests have been carried out on insulating bricks and refractory

bricks and castables, some of the results are reported below.

A refractory lining produced with additive by the mean of this technology permits

to obtain a much lower Thermal Diffusivity value compared to standard

refractory linings.




of 11

Jul. ’12 Rev.08

Example of differences between Thermal Diffusivity values of two alumina bricks containing 70% Al2O3

STANDARD BRICK(70% Al2O3)

BRICK WITH ADDITIVE (70% Al2O3)

α =λ

=2,3

= 0,7149 α =λ

=1,886

= 0,4591CpxPs 1,214 x 2,65 CpxPs 1,55 x 2,65

where

α = thermal diffusivity [m2/s] = 0,7149 α = thermal diffusivity [m2/s] = 0,4591

Cp = specific heat [J/KgK] = 1,214 Cp = specific heat [J/KgK] = 1,55

Ps = density [Kg/m3] = 2,65 Ps = density [Kg/m3] = 2,65

λ = thermal conductivity [W/mK] = 2,3 λ = thermal conductivity [W/mK] = 1,886

TABLE OF MATERIALS AND THEIR PROPERTIES.Nature of materials

λ(W/mK)

CkJ/kg K

ρKg/m3

αm2/hx3,6 x 10 3

A(λ. ρ. C)1/2

Steel 50 0,795 7 10 3 32,3 10 3 527,5Bauxite 2 1,214 2,8 10 3 2,12 10 3 82,5Bauxite + additive 1,7 1,578 2,15 10 3 1,385 10 3 86,7Chamotte (fire clay) 1,2 1,214 2,15 10 3 1,65 10 3 56Chamotte + additive 1,02 1,578 2,15 10 3 1,08 10 3 58,8Dolomite 2,9 1 2,81 10 3 3,73 10 3 90,1Magnesite 4 1,32 3 10 3 3,60 125,8Insulation brickt< 10.000 0,465 1,09 1 10 3 1,54 10 3 22,5Insulation brickt ─ 1.400 0,581 1,92 10 3 25,2Baux + additive 2 x 0,85─ 1,214 x 1,3─ 2,8 10 3 1,385 10 3 86,7

1,70 1,578Cham.+ additive 1,02 1,578 2,15 10 3 1,082 10 3 58,8

α. = is the quickness by which the material adapts its temperature in accordance with the thermal gradient.

it could be noticed that a lower value of λ in the numerator and a simultaneous increase of

the value of Cp in the denominator causes a decrease of the thermal diffusivity value that

presents a quickness of the thermal loss and its measure is [m2/s].




of 11

Jul. ’12 Rev.08

CERTIFICAZIONS

THERMAL CONDUCTIVITY

Hereafter the table with laboratory tests results performed by “Société Francaise de Céramique” on two insulation bricks of quality JM26: the first a standard one and the second one with CARBONXIDE®, both with the same specific weight and total porosity.

STANDARD BRICK BRICK WITH CARBONXIDE®

AVERAGE TEMP. °C W / Mk AVERAGE TEMP. °C W / Mk 540 0.281 552 0.240 1083 0.335 1108 0.285

Certificati SFR (Sociètè Francaise de Cèramique) n.88939 e n.88938 (ex Ifintur) (CERTIFICATE N.2 and CERTIFICATE N.3)

THERMAL CONDUCTIVITY

Hereafter the table with laboratory tests results performed by “Société Francaise de Céramique” on two samples of refractory castable Carbovibro 50 LI produced by Refrasud, both with the same specific weight and total porosity.

CARBOVIBRO 50 LI (N) WITHOUT ADDITIVE CARBOVIBRO 50 LI (A) WITH CARBONXIDE®

AVERAGE TEMP. °C W / Mk AVERAGE TEMP. °C W / Mk 208 0.92 286 0.73 1105 1.08 1177 1.01

Certificates SFR (Sociètè Francaise de Cèramique) n.97061 e n.97060 (ex Ifintur)(CERTIFICATE N.4 and CERTIFICATE N.5)

SPECIFIC HEA T

Hereafter the table with laboratory tests results performed on two samples (one with additive and another without additive) both with the same specific weight and total porosity.


AVERAGE TEMP. °C J / kGK A AVERAGE TEMP. °C J / kGK 1250 1197 1250 1313 1300 1242 1300 1381 1350 1239 1350 1451 1400 1276 1400 1554

Certificates SFR (Sociètè Francaise de Cèramique) n. 97482 e n.97483 (ex Ifintur)(CERTIFICATE N.6 and CERTIFICATE N.7)




of 11

Jul. ’12 Rev.08

COMPARATIVE TESTING OF HEAT DISSIPATION

In order to demonstrate the difference during a time period between two alumina based refractory castables (one with CARBONXIDE® and the other without additive), we can evidence the laboratory results carried out by the Refrasud laboratory on two castable samples with the same values of specific weight and total porosity. The both samples have been fired in a furnace at 600°C and 900°C for 20 hours and measured till the total cooling off.

CASTABLE WITHOUT ADDITIVE CASTABLE WITH CARBONXIDE®Furnace temperature: 600°C - Environment temperature: 29°C

Time point Temperature Time point TemperatureImmediately after firing 303°C Immediately after firing 313°C

after 10 minutes 218°C after 10 minutes 227°Cafter 20 minutes 145°C after 20 minutes 147°C

Certificate Refrasud International n. 2378/11

(CERTIFICATE N.8)

CASTABLE WITHOUT ADDITIVE CASTABLE WITH CARBONXIDE®Furnace temperature: 900°C - Environment temperature: 34°C

Immediately after firing Temperature Immediately after firing TemperatureImmediately after firing 435°C Immediately after firing 468°C

after 10 minutes 280°C after 10 minutes 318°Cafter 20 minutes 184°C after 20 minutes 215°C

Certificate Refrasud International n. 2380/11

(CERTIFICATE N.9)

HMOR (HOT MODULUS OF RUPTURE) (1500°C)

Laboratory tests results performed on two samples (one with additive and another without additive) both with the same specific weight and total porosity.


TEST MPA TEST MPA 1 0.91 1 1.10 2 0.80 2 1.15 3 0.69 3 0.92

AVERAGE 0.80 AVERAGE 1.06

CertificatiesSFR (Sociètè Francaise de Cèramique) n.97442 e n.97441 (ex Ifintur)

(CERTIFICATE N.10 and CERTIFICATE N.11)




of 11

Jul. ’12 Rev.08

Products based on CARBONXIDE®

Chemical conditioners CARBONXIDE® (innovative liquid and powder additives)

conveniently mixed with refractory products are able to give to a finished product better

thermal and mechanical properties compared to standard products.

They can be used for:

• Refractory mortars;

• Insulating bricks;

• Refractory bricks (aluminous and basics);

• Refractory castables;

• Preshaped refractory modules;

• Refractory spray materials.

As to liquid additives, the percentage to add to refractory mixture is about 0,1% - 0,5%

of the total weight of the mixture to be treated.

As to the powder additive, the percentage to add is about 1,5%-3%.




of 11

Jul. ’12 Rev.08

APPLICATION FIELDS

REFRASUD TECHNOLOGY FOR REFRACTORY PRODUCTS

FOR:

• Steel Ladles (REPORT N.1 Siviere acciaio (Lay-out tipico));

• Tundish (REPORT N.2 Paniere (Tundish));

• Torpedo ladle cars (REPORT N.3 Carri siluro);

• Cokery doors (REPORT N.4 Porte cokerie);

• Heating furnaces (cooling piping – walls – roofs – bottoms – burners)

(REPORT N.5 Forni da riscaldo: moduli prefabbricati per tubazioni interne e rivestimenti

refrattari);

• Cement Rotary Furnaces;

• Other.

All the above-mentioned application fields have been described in a more

detailed way in the following pages, evidencing characteristics and advantages of

implementing of Refrasud technology.

REFERENCES

The Refrasud delivers its products both on the Italian and foreign markets, its main

clients are:

*0 ThyssenKrupp Acciai Speciali Terni S.p.A. – Italia *1 EZDK Al Ezz Dekheila Steel Co – Egitto *2 Duferco, La Louvière – Belgium




of 11

Jul. ’12 Rev.08

*3 Carsid, Marcinelle – Belgium *4 Acciaierie Valbruna S.p.A. – Vicenza – Italia *5 Lucchini S.p.A. – Piombino – Italia *6 Loi Italimpianti Tenova – Genova – Italia *7 Metinvest Trametal – Udine – Italia *8 Green Project srl – Genova – Italia *9 ILVA S.p.A. – Riva Group – Taranto – Italia *10 ABS Acciaierie Bertoli Safau S.p.A. – Cargnacco – Italia *11 Grigoli S.p.A. – Verona – Italia (ora NLMK Verona S.p.A.)*12 Verona Steel S.p.A. – Verona – Italia (ora NLMK Verona S.P.A.)*13 Mobarakeh Steel Co. – Iran *14 DANIELI – ABS Acciaierie Bertoli Safau S.p.A. – Cargnacco – Italia *15 DANIELI – ACINDAR – Argentina*16 DANIELI – Duferco, La Louvière – Belgium*17 TECHINT – BHUSHAN – India

*18 Forno Walking Beam, SIDMAR, Gent – Belgium *19 Forno Walking Beam, DUFERCO, Clabecq – Belgium *20 Forno Walking Beam, Techint – Lucchini, Piombino *21 Forno a spinta, THYSSENKRUPP, Stahl Edelsthalwerk Witten – Germania*22 Forno Walking Beam, Techint - DUFERCO, La Louvière – Belgium*23 Forno Walking Beam, Techint – TATA STEEL, Jamshedpur – India *24 Forno a spinta, Techint – SSAB, Oxelösund – Sweden *25 Forno Walking Beam, Techint – STOMANIA, Pernik – Bulgaria *26 Forno Walking Beam, Techint – HKMK, Novokuznetsk – Russian *27 Forno Walking Beam, Techint/Vai – HADEED F2, Al Jubail – KSA *28 Forno Walking Beam, Techint – SIDERAR, San Nicolas – Argentina *29 Forno Walking Beam, Techint – HYLSA, Mexico 2006 *30 Forno Walking Beam, Techint – ACRONI – Slovenia

PLAYERS/PA RTNERS

Among the players / partners of Refrasud we have:

*31 TRL Krosaki Refractories Limited – INDIA (mattoni dolomite zona bagno – mattoni in magnesite)

*32 Refraco s.r.o. – SLOVAKIA (mattoni in magnesite – mattoni in allumina)*33 Thermal Ceramics Italiana s.r.l. – LODI (calcestruzzo – mattoni isolanti)*34 Alexandria Co. For Refractories – CAIRO (mattoni in allumina –

calcestruzzo)*35 Sheffield Refractorie Ltd – UK (calcestruzzo)




REFRASUD INTERNATIONAL S.R.L.

Documents

Transcript of REFRASUD INTERNATIONAL S.R.L.