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.

 

UHPC custom made rotor and stator elements for a grinding systems

One of our customers has a very special grinding system consisting of a rotor and stator made of a very
special stone. 

This grinding system is no longer built today. We were asked if we could rebuild the elements from UHPC for this grinding system, preferably from better wear-resistant material. 14 sets were to be manufactured, as the customer has seven such grinding systems in permanent operation.
We were provided with the only unused rotor and the stator element for measuring. 

 

We made an exact mould from hard plastic, each for the rotor and the stator. We chose a very resistant mixture with silicon carbide ceramics as the UHPC wear protection material. The mixture was very fine, highly flowable, highly pressure-resistant and fast-curing.
All our castings were almost perfect, required no reworking and could be used without any problems.
With this special mixture, we were able to increase the operating time fivefold.

 

 

WPE DK International

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

UHPC Spray Projects in a Northern European Ore Mine

An ore mine operator in Northern Europe has commissioned one of our customers to install a UHPC wear lining on several cyclones. 

The installation was to take place on site at the ore mine. A UHPC wear protection layer of 25 mm was to be installed. The time frame for the installation was very tight due to the mine. For this reason, a UHPC spray installation was chosen. UHPC spray wear protection is sprayed on using a wet process. This has the very great advantage of a controlled and uniform material quality. Since UHPC spray only produces a maximum rebound of less than 2%, there was also no material loss during the spray installation.

Our customer first sprayed half the circumference of the cyclone parts on site and then the other circumference of the cyclone parts. Due to the ambient temperatures, the lined parts could be transported and installed without any problems after 48 hours. directly after installation, this part of the plant could go into operation.

 

 

WPE DK International

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

UHPC Wear Protection lined pipe components produced in Vietnam

 Peter Severin, our UHPC partner for Vietnam, in cooperation with a Vietnamese steel construction
company, will offer UHPC wear protection lined pipeline segments in all sizes and geometries. Peter and the steel construction company have many years of experience in the production of piping elements for hydraulic and pneumatic conveying. These pipeline components have been used in power plants, steel mills, cement works and mines for decades. 

WPE DK International

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

UHPC silicon carbide custom-made burner elements for an ALSTOM coal-fired power plant project

The company ALSTOM wanted us to place an order for the supply and lining of very special burner parts
for a coal-fired power station. Due to the coal composition, the specially required flow conveyance and the very high temperatures, our customer had specified silicon carbide as the wear protection material. After we had calculated the costs of the material and the production, the responsible project managers at ALSTOM almost had a heart attack. The costs were very far over the planned budget and the delivery time for the custom-made silicon carbide elements was almost three times as long as ALSTOM had planned. 

We then offered ALSTOM a lining with a silicon carbide UHPC wear-resistant concrete as an alternative. The material costs were reduced by more than 50% and the delivery time of the elements manufactured by us was reduced by more than 70% compared to the elements made of silicon carbide ceramics. As we had already supplied many UHPC linings for ALSTOM over the past decades, the project managers had complete confidence in our proposed solution.

The production of the burner elements was carried out according to our time schedule and the elements
have fulfilled their purpose until today. 

In the meantime, other burner suppliers for coal-fired power plants have also successfully used this solution worldwide.

 

 

WPE DK International

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

 

UHPC flooring for the most extreme loads

UHPC Phalt and UHPC TopLayer are floor coverings for the toughest environmental, temperature, corrosion, load, wear and tear, extreme loads from special vehicles and their movements and the combination of all these loads.

UHPC Phalt is a semi-flexible overlay, a combination of UHPC mortar and asphalt.
The pavement is laid without joints, similar to an asphalt pavement, using the same machines.

 

 

 UHPC TopLayer systems are UHPC grout concrete floor coverings for extreme loads, wear and corrosion. As a special UHPC TopLayer system, we produce high-temperature resistant floor coverings for industry. Which can be subjected to continuous temperatures far above 800°C.

WPE DK International

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

UHPC Aggregate - Mining of Nature Corundum in Zimbabwe

After a hard day in the corundum mine, blasting, grinding and transporting, we earned a cold beer by the river. 

 

 

 

 

 

Of course, with a proper distance from the shore. Some river dwellers can really be very unpleasant. On
the way to the river we found some interesting minerals here and there.

 

 

 

 

 

 WPE DK International

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

                                                                                         

UHPC Wear Protection installation for a Austrian mining company

For an Austrian mining company, we are to supply raw parts lined with UHPC wear protection and special ceramics. The pipe parts and their wear protection lining were not standard. The delivery was under extreme delivery pressure. Most of the conveyor system was already fully assembled and the customer was only waiting for our special parts to be able to put the conveyor system into operation. WPE DK fitters lined part of the system with UHPC wear protection on site in Austria. An assembly hall was built especially for this purpose. The other pipe parts were lined in the WPE DK workshop. The entire order was delivered on schedule. 

More than 40 tonnes of UHPC wear protection were installed.The average layer thickness was 25 mm.

 

 WPE DK International

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

Repair with UHPC wear protection systems

UHPC wear protection material has been used for over 25 years in all industrial sectors worldwide, such
as the cement industry, power plant industry, steel industry and mining industry. A large part of the projects we carry out are repair orders. In recent years, the share of repair orders has risen sharply. Our customers want fast, flexible and cost-effective repairs. A decisive advantage for UHPC wear protection material is the very high protective function against wear and corrosion, the high flexibility in layer thickness and the simple. Assembly. With UHPC wear protection, existing wear protection systems can be quickly repaired. There is no need to order special plates or cylinders with long delivery times. No installation plan is requested.

More and more of our customers order UHPC wear protection in 25 kg paper bags and process the material themselves in order to have the greatest possible flexibility and very short downtimes for the repair.
We define our wear protection material for plants and floor areas. UHPc wear protection material can be processed as mortar, castable and shotcrete.

You need detailed information? Please contact us via: info@wpe-dk.dk

UHPC Wear protection lining in a titan ore grinding system

After more than 15 years of grinding operations,

the first repair on the UHPC wear protection lining

are now necessary.

More than 15 years ago, the classifier housing and

the fine material discharge of the vertical roller

grinding system were lined with a UHPC wear

protection lining. The grinding system grinds a

special titanium ore for prigment production.

Originally, very little wear was expected and no

wear protection system was planned. However,

the regrind was extremely wear-resistant and after

a very short time after the vertical roller grinding

system was put into operation, the sheet metal 

construction showed considerable wear.

For fluidic reasons, only a layer thickness of 15 mm

for wear protection could be permitted.  The

UHPC wear protection work was started quickly

and was completed within a few days. The

grinding plant was put back into operation after

six days of inactivity.

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 Wear protection for an ore pallet plant in Bahrain

We have an order to supply and install a UHPC wear protection liner in a new grinding system at an ore processing plant in Bahrain. The new grinding system was designed and delivered by a large German plant manufacturer.

UHPC wear protection was specified by this plant manufacturer as wear protection for his system.

The contract included the lining of pipelines, cyclones and separator systems. The assembly of a 25 mm / 1 inch UHPC wear protection liner with a total area of over 600 sq / 6450 sq ft was performed by a local installation company under the supervision of one of our supervisors.

24 hours after the individual plant elements were lined, they could be mounted in the ore processing plant.

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