Dr. V. Wagner, M. Louen; Calderys Germany, In der Sohl 122, 56564 Neuwied, Almanya C. Léfevre; Calderys France; Route de Troyes, 51120 Sézanne, Fransa Emre Özkurt ; Calderys Turkey, Lizbon Cad. No:33/1 Öveçler, Çankaya, Ankara, Türkiye
Introduction
Modern refractory materials for the cement industry must withstand all kind of stresses. Besides high temperatures, which require a high refractoriness, these materials must have enough strength and abrasion resistance, a high elasticity and finally they must be resistant against chemical attack resulting from raw materials, clinker phases and the influence from alkalis, sulphur and chlorine.
Proper low cement castables provide all these properties. For many years these materials were the only available refractories having a low porosity as well as a high density. Low cement castables are based on calcium aluminate cement and deflocculents.
In 1999 the unique gunning solution LPGM (low porosity gunning materials) has been presented during the Unitecr in Berlin (1). These LPGM products have been introduced as equivalents to the existing low cement castables. They are gunned and therefore installed significantly quicker than the respective castables. This is essential especially if the downtime must be as short as possible.
Refractory Concept Optimization
Consequently, there were always two different, but similar materials: One castable, one gunning mix (e.g. CALDE® CAST LA 50 SZ and CALDE® GUN LA 50 SZ). In many plants both products can be found in the warehouse. Both materials have very similar physical and chemical properties.
Just the way of applying the refractory materials is different. The question is obvious: Isn’t it possible to unify both materials into one? This makes not only storage management easier; it gives the installer freedom in selecting the most appropriate installation method when a repair is necessary.
LPGM gunning materials are dry gunning mixes. The required equipment is simple and easy.
UniverCEM® – The Combination
Extensive analyses in our labs have finally led to the unification of low cement castables and low cement gunning materials. The new materials have received a new name: UniverCEM®.
Summary
UniverCEM® products combine the installation speed of dry gunning with the excellent properties of low cement castables in one material. This leads to less downtime and simultaneously to a high performance and a long refractory lifetime.
In terms of storage management less space is required, which also means lower inventory costs. UniverCEM® provides a high flexibility to the installation team.
Currently UniverCEM® is already applied in many cement plants world-wide: Germany, Poland, Greece, France.
Calderys is the only refractory producer in the world who serves the market with deflocculated dry gunning materials for multiple applications.
