fused calight 70 - a report on its functionality in refractory application

1. Introduc)on
Experiment
Comparison
Case Study
4
1
2
3

2. 1
4
3. Diversity and complete pallet of products
2. Supply consistent quality CE and ISO
1. Own production , r&d and product development
2
3
4. Sintered and fused special cements;
CSA – CAC – ACA – GREEN BINDERS

3. raw materials are produced by
selected producers–proofed
over years to have the skills
to produce, control and
supply consistency in
compliance to Caltra
specifications.
We have 2 separate fully
automated packing lines one for pe the
other for paper bags of 20 or 25 kg , a semi-
automated filling station for super sacks of
1,25 mt own weigh station for loading bulk trucks
After control in our own laboratory
and external survey,goods are
adapted to satisfy client needs.
In coöperation with
renowned institutes
and universities we develop
innovative binder
systems and materials.
WHAT WE DO

4. a stable binder in any way used ;castable, gunning, ramming, and
self-flowing
CAC
70
has
a
low
silica
and
iron
content
high
early
strength
under
low
and
normal
temperature
enables
quick
de-­‐molding
through
fusion
a
reduced
water
uptake
1
2
4
fast
con)nious
growth
of
strength
at
increased
temperature
3
6
5
stability
is
a
key
advantage
when
designing
LLC
and
deflocculate
system
castable
7 op)mized
grain
size
distribu)on

6. Mineral
Phases
CA
CA2
High
speed
and
high
degree
of
hydra)on
Sensi've
to
addi'ves
and
hard
to
control
High
degree
of
heat
on
hydra'on
Low
shelf
life
High
reac'vity
,
difficult
to
control
Slow
hydra'on
Low
intensity
Forming
CA6
phase
-­‐
high
temperature
resistance
AH3
phase
,
good
mid-­‐temperature
strength

7. Blaine
Mpa
Formula:
hard
refractory
clay
aggregate
75%,
CA70
25%,
20
℃
op'mum
Optimum Blaine between 2500 to 4500, more fine particle size gives better castable
strength – reduction of strength at higher Blaine

8. C - A - S
A — S C — A
CAC 70
> 5%
CAC 70< 3%
Low Cement
Castable
Improve high
temperature
Performance
Reduce CaO
High
Temperature
phase
A3S2mullite
phase
ULLC
Ultra low
cement
castable
Improve high
temperature
Performance
Reduce SiO2
High
Temperature
Phase
CA6-­‐
hexagonal shape
Alumina Base
LLC
Low cement castable
CAC-70F has excellent performance in both systems
C
=
CaO
A
=
Al2O3
S
=
SiO2

9. Vibra'on
Ramming
Self
Flow
Dry/Wet
Spraying
Methods

10. 0.5% 1% 3%2%1.5% 2.5%
MCCLCCULCC
Semi
Dry
Spray
or
Wet
spray
high
performance
light
weight
castable
8%~20% CA70
Tradi)onal
Medium
Cement
Castable
Deflocculate
Castable
Vibration Casting Self flow Casting Wet Spray
2% CAC
70
5% CAC 70 8%CA70
CaO Content in Castable

11. 1. Chemical
2. Blaine
Typical
Al2O3 70.39
CaO 28.57
SiO2 0.27
Fe2O3 0.26
MgO 0.14
Na2O 0.23
Blaine 4500
cm2/g
>
325
Mesh
(44.5
μm) 7.5%
D50 3.12
µm

12. 3. Physical Data
Comp / Flex (MPa)
6h ≥ 8 / ≥2
24h ≥ 40 / ≥5
Setting Time (min)
Initial ≥ 60
Final ≤ 360
Flow (mm)
10 min ≥ 150
30 min ≥ 140
60 min ≥ 130

13. Castable Type
Corundum
Base
High Alumina
Base
Corundum
Base with
silica fume
℃ 14 14 14
Water % 5.0 5.8 4.8
Flow mm
Initial 150 140 140
30 min 145 140 135
60 min N/A 125 120
Setting Time（min） 112 145 95
Comp / Flex Mpa
20℃ 1d 27.5 / 4.9 40.5 / 5.5 32.75 / 5.2
110℃×24h 67.1 / 10.1 95 / 12.3 98.12 / 14.3
1100℃×3h 83.7 / 13.5 103.6 / 13.5 135 / 18.1
1500℃×3h 120.9 / 18.89 135 / 12.3 156 / 36.5
Linear length change
%
1100℃×3h +0.03 -0.07 -0.08
1500℃×3h +0.45 -0.20 -0.36
Bulk Density g/cm3
110℃×24h 3.1 2.78 3
1500℃×3h 3.0 2.76 2.9

14. Date
Blaine
cm2/g
325
Mesh
(44.5μm)
w/c
flow
mm
Begin
min
End
min
6h
Comp/Flex
MPa
24h
Comp/Flex
MPa
2014.4 4588 5.5 0.4 145 105 195 15.7 / 3.8 90.85 / 12.3
2014.1 4510 6.1 0.4 140 98 170 19.3 / 4.1 97.3 / 12.5

15. Date of Production 2014.4 2014.1
Temperature℃ 14 14
Water % 6.0 6.0
Flow mm 145 140
Setting time（min） 160 150
Comp / Flex Mpa
20℃ x 1d 38.5 / 5.2 41.2 / 5.5
110℃×24h 88.0 / 10.3 90.3 / 10.5
1100℃×3h 100.6 / 13.5 105.5 / 13.3
1500℃×3h 129.5 / 13.8 135.3 / 13.5
Linear length change %
1100℃×3h -0.07 -0.05
1500℃×3h -0.22 -0.20
Bulk Density g/cm3
110℃×24h 2.78 2.78
1500℃×3h 2.76 2.76

16. Type Al2O3 CaO SiO2 Fe2O3 MgO Na2O
CAC-­‐70F 70.59 28.57 0.26 0.15 0.14 0.21
CA-­‐270
(ALMATIS)
72.32 26.43 0.41 0.15 0.23 0.22
SECAR71
(KERNEOS)
69.14 29.35 0.38 0.16 0.44 0.34

17. Type > 325 Mesh
(44.5μm)
Blaine D50 Color
CAC-­‐70F 6.2% 4558 3.12 Grey
white
CA-­‐270 12% 4017 5.95 Grey
white
SECAR-­‐71 9.5% 4253 5.49
Light
yellow-­‐
white

18. Type w/c
flow
mm
Begin Set
min
End Set
min
6h
Comp/Flex
MPa
24h
Comp/Flex
MPa
CAC-70F 0.40 140 110 172 20.5 / 4.3 95.5 / 11.5
CA-270 0.43 145 140 195 17.4 / 3.2 65.2 / 8.1
SECAR-71 0.43 140 130 185 19.6 / 3.6 60.7 / 8.2

19. Type ℃ water（%）
Initial Setting
（h : min)
Final Setting
(h : min)
CA-70 20 25 3 ：30 4 ：50
CA-270 20 25 3 ：20 5 ：10
SECAR-71 20 25 4 ：10 7 ：20

20. Type CAC-­‐70F CA-­‐270 SECAR-­‐71
10
min 200 180 210
30
min 200 170 200
60
min 190 170 195

21. Type CAC-­‐70F CA-­‐270 SECAR-­‐71
℃ 14 14 14
Water
% 5.0 5.0 5.0
Flow
mm
ini)al 150 150 150
30
min 145 145 135
Seeng
)me（min） 112 135 165
Comp
/
Flex
Mpa
20℃
-­‐
1d 27.5
/
4.9 21.62
/
3.1 19.5
/
2.8
110℃×24h 67.1
/
10.1 60.5
/
10 68.7
/
11
1100℃×3h 83.7
/
13.5 80.2
/
12.3 88.7
/
14
1500℃×3h 120.9
/
18.89 119.4
/
17.6 110.5
/
19.7
Linear
length
change
%
1100℃×3h +0.03 +0.03 +0.05
1500℃×3h +0.45 +0.50 +0.52
Bulk
Density
g/cm3
110℃×24h 3.1 3.1 3.1
1500℃×3h 3.0 3.0 3.0

22. Type CAC-­‐70F CA-­‐270 SECAR-­‐71
℃ 14 14 14
Water
% 5.8 5.8 5.8
Flow
mm
ini)al 140 140 140
30
min 140 140 135
60
min 125 130 120
Seeng
)me（min） 145 160 185
Comp
/
Flex
Mpa
20℃
-­‐
1d 40.5
/
5.5 33
/
4.9 30.84
/
3.1
110℃×24h 95
/
12.3 87.3
/
10.3 83.8
/
11.4
1100℃×3h 103.6
/
13.5 97.5
/
12.3 100
/
11.3
1500℃×3h 135
/
12.3 124.3
/
13.3 128.1
/
15.2
Linear
length
change
%
1100℃×3h -­‐0.07 -­‐0.06 -­‐0.11
1500℃×3h -­‐0.20 0.22 -­‐0.25
Bulk
Density
g/cm3
110℃×24h 2.78 2.78 2.78
1500℃×3h 2.76 2.76 2.75

23. Type CA-­‐70 CA-­‐270 SECAR-­‐71
℃ 14 14 14
Water
% 4.8 4.8 4.8
Flow
mm
Ini)al 140 140 135
30
min 135 135 130
60
min 120 120 120
Seeng
)me（min） 95 100 110
Comp
/
Flex
Mpa
20℃
-­‐
1d 32.75
/
5.2 28.05
/
4.9 25.95
/
2.5
110℃×24h 98.12
/
14.3 97.7
/
13.5 88.6
/
10.2
1100℃×3h 135
/
18.1 126.8
/
17.76 130.55
/
14.5
1500℃×3h 156
/
36.5 145
/
30 150.2
/
27
Linear
length
change
%
1100℃×3h -­‐0.08 -­‐0.10 -­‐0.07
1500℃×3h -­‐0.36 -­‐0.40 -­‐0.33
Bulk
Density
g/cm3
110℃×24h 3 3 3
1500℃×3h 2.9 2.9 2.9

24. SECAR71 CAC-­‐70F DF ZZ
Bulk
Density
g/cm3
110℃,
24h 3.24
3.29
3.28
3.14
1000℃,
3h 3.17
3.22
3.23 3.08
1300℃,
3h 3.15
3.19
3.20
3.04
1600℃,
3h 3.12
3.16
3.15
3.08
Porosity
%
110℃,
24h 12.3
11.9
12.0
15.8
1000℃,
3h 15.2
14.7 14.5
18.1
1300℃,
3h 16.2
16.1 14.9 19.2
1600℃,
3h 18.0
17.9 17.4 18.8
Linear
length
change
%
110℃,
24h -­‐0.03
-­‐0.03 -­‐0.03
-­‐0.03
1000℃,
3h +0.12
+0.13
+0.08
+0.20
1300℃,
3h +0.50
+0.57 +0.09
+0.45
1600℃,
3h +0.67
+0.60
+0.53
+0.01
Flexural
20℃
MPa
110℃,
24h 11.2
10.5
11.4
3.4
1000℃,
3h 15.8
14.6
14.3
3.0
1300℃,
3h 32.4
28.4
27.3
13.7
1600℃,
3h 31.2
33.0
29.4
25.4

25. SECAR71 CA70 DF ZZ
Comp
strength
MPa
20℃
110℃,
24h 76.6
76.2
76.8
26.6
1000℃,
3h 85.9
92.5
91.7
36.2
1300℃,
3h 99.6
97.9
69.2 39.1
1600℃,
3h 121.8
127.1
69.5
102.8
Flex
strength
MPa
20℃
1450℃,
1h 8.23 8.15 6.96 2.68
Water
（%） 4.3 4.3 4.3 5.3
flow（mm） 198 206 202 188

26. 1
4
3. Improved granular size distribution
2. low silica and low calcium content gives
CA6-hexagonal shaped crystal
1. CAC-70F proofs to be a good alternative to other
70 grade refractory cements in the market
2
3
4. Fusion gives low water / cement ratio and
improved flowability
Castable
micro-­‐structure
STM（X3000）