UHPC HT and Refractory - The difference

UHPC HT Products

UHPC, Ultra High Performance Concrete, is a combination of a cement, micro particles and wear resistant (very hard) particles. Due to the 

micro particles it is possible to create a perfect physical packing ensuring improved chemical reactions. These chemical reactions secures the formation of minerals with superior properties at room temperature. Hence around 60% of the full strength will be obtained after 48 hours. Final strength of a UHPC is 100-250 MPa / 14500-36250 psi.

Water added to UHPC to secure a proper 

rheology is limited, and shortly after setting there will be no more free water in the system, as all water will be bond in the structure of the chemical reactions.

When heating UHPC HT the risk of cracking due to evaporation of water is limited. However too fast heating of a virgin installation could lead to this. Hence it is recommended to firstly heat up the installation at a rate of 50°C/hr. The heating does not contribute to the strength of the system however it will increase the rate of strength building.

Refractories

Unshaped refractories typically contains an alumina cement as the bonding material and other metallic minerals depending on the 

temperature and environment it is installed. Water is mixed in to create the right rheology for installation. As such this product at ambient 

temperature can be viewed as an ordinary mortar. As such the product is relative porous and strength at ambient temperature is not likely 

to exceed 45 MPa. This system will also reach around 60% of final strength after 48 hours of hydration.

This system will contain free water after installation, hence there is a risk of cracking when heated. Hence it is necessary to heat it at specific heating rate in order to avoid such cracks. In order for refractories to work they need to be heated so that the metallic minerals is calcinated 

and sintered into the wanted minerals with the needed properties.

Comparison

The strength and density of UHPC HT is a lot higher than that of refractories. Hence these products will be better at withstanding inner pressure from internal water evaporation, reducing the risk of cracks and ultimate process destruction of the product.

UHPC HT does not need heat to form the minerals needed in the mix in order to obtain the properties. 

Heat will however increase the rate of property formation.

 

Companies which used UHPC Wear Protection in the last 25 years

 

We are always asked who has been used UHPC
Wear protection for the past 25 years. WPE DK our UHPC wear protection specialist, took the task to compile a list of companies who used UHPC as wear protection during these years.

The list includes plant system supplier and plant operators in
worldwide. The list should give an impression of where
UHPC is already standard as wear protection everywhere. In
In many cases, plant operators have the UHPC material
installed by own fitters.

Here is the list:
The company names can change over the years and some
companies probably have merged with other companies.

A Tech Anlagentechnik GmbH &Co KG, Austria        LOESCHE GmbH 

Aalborg Portland Cement A/S        TASEK Cement, Malaysia       Al Bijjar, UAE

Nigeria Cement        Allgaier Process Technology GmbH        Thung Song, South Korea

Mikropul GmbH        California Cement, USA        Moxba NL                                  

 

Aumund Fördertechnik GmbH            OMYA, Austria

                                         

MULTOTEC, South Africa        Aurubis AG        Nohma, Italy    Engineering Dobersek GmbH   

BES Brandenburger Elektrostahlwerke GmbH        Oschatz GmbH        Babcock Borsig Service GmbH

ÖMAG  GmbH, Austria               Babcock Borsig Steinmüller GmbH       

Phoenix, Australia       

 

Balke Dürr  GmbH        Pilkington GmbH        Bartin Cimento, Turkey        Pioneer Cement, UAE

BASF Antwerpen N.V. , Belgium       Vattenfall Europe Generation AG        Austria Tec S.A., Mexiko

Polysius AG            Bayer Leverkusen        RWE        British Steel   

 

                                  JSW Steel Limited India

       

Binder + Co AG, Austria        Salzgitter Flachstahl GmbH                       Bio Bio Cimento 

 

   Scheuch GmbH                   Paul Wurth, Luxembourg

Italcimenti, Italy      Burmeister Wain Energy a/s, Denmark       Votorantim, Brazil            Schott AG

Cemtec Cement & Mining Technology GmbH        Blue Circle, GB        Siam Cement            

 

Asia Cement

      

CEMEX Cement plants        SMS GmbH        Christian Pfeiffer GmbH 

 

          Titan Cement, Greek            Huyndai Steel, SouthKorea

                           

STAG Austria        Claudius Peters Project GmbH                Colacem, Italy  

 

      SSAB, Sweden

 

Cima Perlis, Malaysia        Cementos Portland Valderrivas    Coperion GmbH

ThyssenKrupp India        KHD GmbH        Shree Cement, India                    NUH Cimento Turkey

Cementir Holding, Italy        TPI Polene, Thailand        DESI Process    voestalpine Steel, Austria

ThyssenKrupp Steel AG        Wacker Chemie AG         

 

E.S.C.H. GmbH                E. Schwenk Ciment

Rautaruuki, Finland        Emscher Aufbereitung GmbH                        EON Power plants        LKAB, Sweden 

 Posco Steel SouthKorea

Eternit GmbH        Lucky Cement, Taiwan        FISIA Babcock GmbH  

  

                                                 FLS Möller GmbH

FLS Pfister GmbH        FLSmidth, Denmark        ALSTOM Power                 Gebr. Pfeiffer SA      

Heidelberger Cement Cement plants         

 

HITACHI Power Europe GmbH

Hoffmeier Industrieanlagen GmbH        HOLCIM Cement Plants                         IBAU Hamburg mbH

IKN GmbH        Intensiv Filter GmbH & Co KG        Kali+Salz AG Werke

Krupp Fördertechnik GmbH        Küttner GmbH & Co KG                           Lafarge Cement plants

WPE DK International

Phone: 0049 176 601 73146
E-mail: ber@wpe-dk.dk
Homepage: www.wpe-dk.com

UHPC Wear protection lining in a granulated slag grinding plant

For a granulated slag grinding plant in Germany, 

the channel between the mill and filter was lined 

with UHPC wear protection. The layer thickness 

of 25 mm / 1 inch has so far been standard in all 

of our granulated slag grinding plants lining 

projects.

For around 20 years, areas of cement-, clinker-,

coal- and slag grinding systems have been lined 

with UHPC wear protection material. 

A particular important advantage alongside many 

other UHPC wear protection devices for slag 

grinding plants is the jointless lining.

The assembly effort compared to the assembly of

ceramic plates or special welded metal sheets is the

simple and quick assembly.

WPE DK International

Phone: 0049 176 601 73146
E-mail: ber@wpe-dk.dk
Homepage: www.wpe-dk.com

UHPC Wear protection for a KHD Sepmaster cement separator system

Today we lined our 60th KHD SEPMASTER

cement separator with UHPC wear protection. 

For a long time UHPC castable wear protection

concrete was specified and standard for all KHD

SEPMASTER separators.

The first KHD SEPMASTER separators were

lined with UHPC wear protection concrete more 

than 25 years ago. In the current project, the 

associated classifiers and chutes were also lined 

with UHPC wear protection mortar. 

The classifier was cast with UHPC castable wear 

protection concrete. The cyclones and

chutes were lined with a 25 mm / 1 inch UHPC

wear protection mortar layer.

Based on the very long experience we now have,

we expect the lifetime of the UHPC lining is15 years.

WPE DK International

Phone: 0049 176 601 73146
E-mail: ber@wpe-dk.dk
Homepage: www.wpe-dk.com

UHPC ThermCombi lining systems

UHPC ThermCombi lining system consists of

a highly effective insulating layer and UHPC

wear protection layer

For a cement plant in Europe, we should

create a technically optimal possibility that
a complicated hot gas line is provided with

wear protection against a very abrasive

material and at the same time the gas

temperature must not drop below 700°C /

1292°F. A similar project we had years ago

for a steel plant in Asia.

In order to meet these customer requirements,

we have chosen a UHPC ThermCombi lining

system.

We reduced the temperature for the steel

structure to 80°C / 176°F. That was no problem

with the insulation material we chose. A high

temperature resistant UHPC wear protection
layer was installed on the insulation layer.

The advantage over a traditional refractory
lining is:
 - The combination lining was about 60% lighter
      in weight than a refractory lining.
 - The total layer thickness of the combination
      lining was 400% less than that of a standard
      refractory solution.
 - This meant that the steel pipe diameter was
      much smaller than with a refractory lining
      and the supports had to carry much less weight.
 - UHPC HT wear protection can withstand

      temperatures of 1200°C / 2192°F, which was

      an additional security in this project.

 - UHPC HT wear protection is several times more
      wear-resistant than refractory concrete, which
      has resulted in a significantly longer service life

      and much less maintenance.

 

Today, the new UHPC ThermCombi systems are not only used in the steel, power plant and cement industries. The construction industry has also recognised the enormous advantages for building structures and façade constructions. It is not only the insulating properties that save energy, the significantly lower material consumption and the very light precast weight - it is especially the fire and heat resistance that makes UHPC ThermCombi building constructions very safe constructions.

 

 

UHPC Hot gas slide system in a cement plant

A customer from the cement industry had permanent problems with a hot gas gate valve. The gate valve was made of a stainless steel construction with a refractory heat protection lining. The average gas temperature is in the pipesystem is 800°/1472°F - 1000°C/1832°F.

The problems in detail were

• Significant wear due to high dust loading in the gas flow
• Heat exchange problems arose as a result of temperature changes and the result was breakdowns in the refractory lining and problems with the movement of the slide.

We engineer a slider made complete of UHPC HT (High Temperature) with the following characteristics

• High thermal shock resistance
• Thermal stability up to 1100°C/2012°F
• Very high wear resistance
• High impact resistance
• There was no metallic reinforcement used, so there was no metallic thermal expansion
• Due to the very high strength values ​​of the UHPC used, the board thickness could be reduced by more than 60% compared to the old refractory construction.
• This resulted in a weight reduction of almost 50%, which also reduce power consumption.
• a drastic reduction of the idle time and better movability of the gate valve resulted in a 16% better production.

Here are a short video to show the impact resistance of the gate plate

www.hhbc-consulting.de
info@hhbc-consulting.de

UHPC Supervisor projects worldwide

Today we completed our 100th Supervisor project

Since the first customer request more than 20 years ago, we have meanwhile completed projects with UHPC materials in more than 35 countries around the world. We looked after offshore, corrosion, wear protection, concrete rehabilitation, architecture, hydraulic engineering, road construction, etc.
On behalf of our customers, we have carried out assembly projects, trained fitters on site, carried out complete assemblies independently, assessed damage, worked out repair solutions, etc.
Our current project was the rehabilitation of 10 km of lanes at Europe's largest flower auctioneer.

Here some impressions of our worldwide jobs

www.hhbc-consulting.de
info@hhbc-consulting.de

UHPC - Wear protection in cement plants

Large quantities of materials like clinker, cement,
lime and granulated slag are handled in a cement
plant. To ensure a constant production, most of
the conveying, storing and production equipment
must lined with wear protection products.

UHPC (Ultra High Performance Concrete)
wear protection systems are engineered for wet
and dry system cement plants, grinding
clinker or grinding slag plants.

Til today the most of the interantional OEMs like
Polysius, FLSmidth, Loesche, FCB, Gebr. Pfeiffer,
KHD, IKN, etc. use UHPC wear protection systems
in their machines.

There is a 25 years long experience in engineering of
UHPC wear protection systems for dynamic and static
seperator systems, clinker cooler and grinding systems,
like hammer mills, vertical roller mill, high pressure
mill and crusher.

Mill systems in which UHPC wear protection 
systems were used

FLS ATOX coal mill

FLS OK mill
Gebr. Pfeifer MPS mill
Claudius Peters EM mill
Polysius QUADROPOL mill
Polysius DOROL mill
Loesche LM mill
Christian Pfeiffer QDK separator
KHD SKS Sepmaster separator
KHD V-Separator
Polysius SEPOL separator

Standard application areas for UHPC 

wear protection systems

Cyclones  Seperator
Pneumatic transports systems

Hydraulic transport systems
Mechanical transport systems
Chutes
Chain conceyor systems
Slide gate valves
Ventilator housing
Coal, cement and clinker mills
Flash dryer system
Coal bunker
Silos
Dedusting systems

WPE DK International

Phone: 0049 176 601 73146
E-mail: info@wpe-dk.dk
Homepage: www.wpe-dk.com

Wear Protection with UHPC wear protection concrete

UHPC is a high wear resistant ultra dense ceramic concrete (Ultra High Performance Concrete). It is a material mix of cement binder, microsilica, superplastiziser and ceramic aggregates (Quarz, Bauxite, Corundum, Silicon carbide).

The combination of high compressive strength, high dense particle packing and extrem hard aggregate, create a flexible and simple to install wear resistant material.

UHPC material can install in any thickness it is needed. It is a jointless lining and over-head-installation is not a problem.

It is produced in a mortar and in a castable material version.
No special underground treatment is required. Steel or concrete surface should be free of loose particles and free of oils and fats. For the installation of such wear protection system it is necessary to install a anchor system. As a standard we recommend follow anchor/reinforcement system:

a) Rhombic wire mesh

b) Honey- or Hexagon mesh

Two UHPC binder versions are produced, one for process 

temperature of max. 450°C/840°F (normal material quality) and 

one for high process temperature of max. 1.200°C/2190°F (high temperature quality)

Advantages

• High wear resistant
• Good impact resistant
• Extreme high compressive strength
• Good corrosion resistant
• Flexible in layer thickness
• Overhead installation is possible
• Thermo shock resistant
• Jointless lining
• Very short curing time

UHPC as a wear protection system has been used worldwide for more than 25 years in cement plants, steel plants, coal fired power plant and mines.

WPE DK International

Phone: 0049 176 601 73146
E-mail: info@wpe-dk.dk
Homepage: www.wpe-dk.com