REFRACTORY

INSTALLATION
FOR PT. MAKMUR SEJAHTERA WISESA

2016
2x126 TPH COAL FIRED STEAM POWER PLANT TANJUNG TABALONG

TABLE OF CONTENTS
Contents
ALUMINA MONOLITHICS _____________________________________________________ 1
GENERAL INFORMATION _____________________________________________________ 1
INSTALLATION _______________________________________________________________ 5
IMPROVEMENT _______________________________________________________________ 9
CONTACT INFORMATION _____________________________________________________ 9

Refractory Guide Installation Reference - PT.MSW

I. ALUMINA MONOLITHICS

2.1 Cement bonded castablesoverview and

Alumina Monolithics are castables made out

of raw materials that fit in the Al2O3-SiO2
system, but can have other raw material
bases

like

Zircon,

Silicon

Carbide

or

Chromium added for special features.

Alumina based castables can be divided
using :
Installation method
Bonding type

classification
Cement bonded castables are the most
commonly used type of alumina based
castables. The different types of cement
bonded castables are:
(CC, CaO>2,5%)
(LCC, CaO1,02,5%)
(ULCC,
CaO0,2-1,0%)
(NCC, CaO<0,2%)

Raw material base

Application

II.GENERAL INFORMATION

are a wide range of

products with very different bonding types.
2.1.1 CC Conventional Castables

2.1 Cement Bonded Castables -Overview

Commonly used castables with high cement

and Classification :

content (resulting in higher water demand ~10

-Conventional Castables

litres/ 100 kg)

-Low-Cement Castables
-Ultra-Low-Cement Castables

Advantages
in

No-Cement Castables
terms

of

installation
2.2 Special Application Mixes

water

demand

temperature

behaviour.

Disadvantages
-Flowing Castables
density
chemical attack resistance
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and

dosage,

and

setting

Refractory Guide Installation Reference - PT.MSW

2.1.2 LCC Low-Cement Castables

Widely used type of mix with lower cement

higher temperatures

content.
Disadvantages
Advantages
(e.g. dispersing additive) are necessary,
conventional castables (decreased water

therefore the workability is more difficult and

demand 5-8 litres/ 100 kg)

shelf life reduced

ntent 4 lower porosity and

higher density, fibresadded

good mixing equipment necessary

chemical attack resistance

2.1.4 NCC No-Cement Castables (general)

Cement free castables, use of external

higher temperatures

binders (e.g. phosphates). Can be very

different types of binding, application etc).

Disadvantages
Advantages
mix for an easier handling. That make them
susceptible

to

errors

and

bad

mixing

ery

fast

and

simple

heating

up

procedures, high storage limits

equipment and decreases the shelf life (8-9

month).

density

2.1.3 ULCC Ultra-Low-Cement Castables

resistance (e.g. sulphur).

Further reduction of cement compared to

other castables and therefore lowered water

Disadvantages

demand (below 5 litres / 100 kg)

(installation and workability)
Advantages
up necessary.
higher density 4 plastic fibres necessary in
the mix for a proper heating-up

necessary (e.g. phosphoric acid or other

binders) and fibres, in general more difficult

chemical resistance
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workability (exception possible).

Refractory Guide Installation Reference - PT.MSW

2.1.5 Compac Sol / Carsit Sol NCCs

Disadvantages

NC-castables, bonding based upon Si-O-Si

pressure vessel)
Advantages
bound (high material loss compared
phases very fast, save and easy heating up

to casting, up to 30% for roofs)

procedures (heating finished at 150C or

even below)

installation and low rebound

dry mix easy and

simple workability, low equipment (mixer)

2.2.2 Dense Gunning

requirements

Based upon dry gunning mixes, installation

technique the same as for dry gunning (with

alkaline-,

acid-,

sulphurand

chemical

exception of the nozzle)

resistances
Advantages
distribution
its possible to use LCC material (reason for
Disadvantages

better mixing: additional air at nozzle).

sensible to frost
density

irreversible destroyed when freezed

2.2 Special Application Mixes

n
gunning application.

2.2.1 Dry Gunning

Dry gunning, mainly high cement content,

Disadvantages

cold gunning but hot gunning possible as well.

conventional gunning.
Advantages
installations (only a minimum of moulds are

2.2.3 Shotkasting

necessary)

Wet gunning application (developed out of

LCC)

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Refractory Guide Installation Reference - PT.MSW

Advantages
density difficult to heat up, even if fibres are
material is already mixed and has only be

added

accelerated (with sodium silicate).

because a complete mould can run empty
mouldingdemand) and high engine output (up

even through a small gap

to 10t/h)
, almost zero
rebound (compared to dry gunning)

2.2.5 Insulating Castables

Insulating castables can be casted, poured or
gunned but are not allowed to vibrate or

Disadvantages

gunned with high air pressures, because they

need a certain porosity to give the right

equipment (costs) and working space (not

insulating properties. They are made of very

suitable for small jobs <20t)

different light materials, resulting in different

densities,application temperatures and heat
conductivities:

nozzle (sodium silicate)

2.2.4 Free-Flowing Castables
LCC Wet gunning application (developed out
of LCC)
Advantages
-vibration
castables but compaction is done without
vibration, because of that secure and good
properties.

Most of the insulating castables have low

ery high CCS and density

strength and abrasion resistance with the

exception of Litecast 44G, which is high

Disadvantages

strength and abrasion resistance gunning mix

designed for special use in preheater and

(needs strong engine)

cyclone areas. General properties: Bonding:

Portland cement or CA-cements (20 40%,

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Refractory Guide Installation Reference - PT.MSW

cement rich) Material properties: TC: 0,2 1,0

W/mK OP = 30 70% Density: 0,5 1,9

easily be drained away to avoid dampness

t/m3Application Temp. Limit 1000C 1800C

from the ground.

III. INSTALLATION
All necessary information is given in the
Operating Instruction manuals

shelf life.
3.2.Casting
The most important types of proccessing /
installation of castables is casting-vibrating
and several gunning applications.
1.Moulding (including expansion)

Ambient & material temperature

Dry mixing & time mixing

Water required base on TDS

(Demin water is better to use).
MSW already have demin water
stock.

Wet mixing & time mixing.

Casting with vibration.

3.1 Storage General

completely dry and frost free at an ideal
temperature of 15 to 25C (if possible
indoors).

3.Vibrating
4.Setting
5.Demoulding
6.Drying/Heat up Step 2 and 3 are replaced
by the gunning process incase of gunning
application techniques
3.2.1 Mixing -General
it has decisive influence on the final quality of
the lining.
equipment, observe the mixing time and use
the right amount of mixing liquid.

rain or water.
condensation ensure sufficient
ventilation. No stay in container for long time.
Please replace if PT. MSW have new place
for cover refractory with ventilation.
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2.Mixing

material will most likely not provide the

service properties you expect.
tory castable are generally mixed in
apaddle mixer because only this mixer type
will ensure good blending of the binder.

Refractory Guide Installation Reference - PT.MSW

Mixer can be made by custum from MSW.

Self Fabrication, motor spesification, plate
spesification, etc.
Mixing by hand is not allowed
3.2.2 Key figures for good mixing water
1.pH-value between 6,5 and 9,5
2.Electrical conductivity
3.Visually clean
4.No special smell or taste

Slowly flows apart concrete has the optimum

consistency

3.2.3 Mixing Unit

Custom of mixer
3.2.4 Ball in hand-Test

Flows apart quickly the concrete was mixed

with too much water
3.3 Compaction / Vibration
Mixed castables content a relatively high
amount of air as small bubbles. To reach the
final properties for dense castables the air
must be removed. Pouring
porosity)

Crumbles the concrete is too dry

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metallic stick Vibrating

Refractory Guide Installation Reference - PT.MSW

3.5 Dry Gunning

exception of free flowing castables
Gunning)
vibrator
Advantages
necessary to vibrate (excep. free flowing)!
Disadvantages
bubbles escape from the mix
quality

casting 15-25%)
en the mix starts to

seggregate.

low density, low CCS)

3.4 Compaction Vibrators

installation

Rule of thumb: The diameter of the vibrator

should be at least 1/6 of the lining thickness
but the bigger the better!
Installation of side walls: The refractory
concrete is installed in different portions one
after another Vibrate during the whole casting
in the upper most 10 to 15 cm of the castable
Installation of bottom fields: Make sure that,
in case of a horizontal and closed shuttering,
the escaping air can be released by drilling
small holes in the shuttering (roof part).

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-2 t/h) (but more as for casting)

Refractory Guide Installation Reference - PT.MSW

-Cyclone/Cone Shuttering Desain

-Straight Wall Shuttering Desain

3.6 Moulding/Form Work/Shuttering Design

MSW can make self desain for shuttering for
one boiler. And material can be use by plate.
So, if boiler shutdown and need to refractory
repair, no need many job for carpenter to
make the shuttering. Because the shuttering
is ready. And make the code for all shuttering.
Refractory repair should be panel by panel.
Because need to have bonding in panel.
- Cyclone shuttering

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-Opening Shuttering Desain

Refractory Guide Installation Reference - PT.MSW

IV. IMPROVEMENT
Make sure all of component of refractory
(preparation, installation, supervision, desain,
method of work and material) approved by
MSW before start working and needed
assesment before it.
Personal in Charge (PIC) from MSW for
refractory repair is required for controlling and
inspection during installation by contractor.

V. CONTACT INFORMATION
Name : Indra Purnama R
Tittle : Refractory Engineer

Tel :
+62 8212 664 1246
+62 8231 569 7124
Email :
indra_purnama1987@yahoo.co.id
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References : RHI AG
End Report
Tanjung Tabalong May-2016