MINTEQ INTERNATIONAL, INC. Advanced Self-Flow & Shotcrete Materials Compared to Traditional Gunnite
GUNNITE NOZZLE Dry Material is pnuematically conveyed through large hose. Water is introduced and mixed with material at the nozzle via a water ring. Water addition is controlled via a valve at the nozzle.
Refractory Gunnite Features Simple Equipment, Easy Set Up Nozzle can be up to 1000 ft. horizontally or 500 ft. vertically from the gun Water added at the nozzle Water addition ( and product quality ) is controlled by the nozzle operator. Highly variable. Subject to operator expertise. Water / Material Mix time Very dusty Allows for castable refractory to be installed without forms High Rebound & Waste ( 15 – 20 % ) Slow Installation Rates Average 2 tons per hour out of one machine if working efficiently Physical properties very limited
LOW MOISTURE, LOW ACCELERANT SHOTCRETE CASTABLES PRODUCT TECHNOLOGY OPTISHOT LOW MOISTURE, LOW ACCELERANT SHOTCRETE CASTABLES
THE SHOTCRETE PROCESS Thoroughly Mix Material Pump Material Add Air/Accelerator at Nozzle Nozzle/Application Technique Curing/Dryout
Shotcrete System mixer/pump Dry Material + Measured Water Added to Mixer NO DUST, Minimal Rebound at Nozzle accelerator pump mixer/pump 750 cfm air
SHOTCRETE NOZZLE Castable is mixed with pre-measured water in a high intensity pan style mixer and conveyed to the nozzle via a high pressure concrete pump. At the nozzle, compressed air and minimal accelerator are introduced to the material.
MINTEQ Refractory "Shotcrete" Technology Most Advanced Dispersant Technology Critical Raw Material Selection Reduced H20 resulting in: lower porosity improved physical properties Whatever you need to remember to say
WATER LEVEL IMPLICATIONS High Water Levels Required to Install Gunnite and Competitive Shotcrete Materials Reduce Strength and Increase Porosity High Water Levels Require High Accelerator Levels
OPTISHOT PRODUCTS Low Water Demand Equates to Very Low Accelerator Demand Minteq’s Shotcrete Materials Retain Their Cast Properties Minteq’s Materials Were Designed as Shotcrete Materials From The Start
OPTISHOT PRODUCTS Lowest Water Content Lowest Porosity Highest Strength Best Abrasion Resistance Best Chemical Corrosion Resistance
Higher Water Contents Create Higher porosity has a negative effect on: Strength Corrosion Resistance Alkali Penetration
REFRACTORY TECHNOLOGY Why Does Minteq Material Succeed When Competitors Fail? Superior Technology Products OPTISHOT MATERIALS STARSLICK System PROCESS CONTROL ENGINEERED INSTALLATION EQUIPMENT & FIELD EXPERIENCE
SHOTCRETE PROCESS CURING/DRYOUT Low Moisture Castable 12-24 Hour Cure at Room Temperature (60-90°F) (not necessarily ambient) Standard, Controlled Dryout Dryout Schedule With Hold Points FAST FIRE Shotcrete products allow for rapid dry-out / no hold periods
MINTEQ Shotcrete Features Rapid Installation Rates 8-10 Tons Per Hour Through 1 Pump/nozzle Improved Performance “Cast” Lining System Without The Time Consuming Forms No Dust Minimal Rebound ( typically 2-5 % ) FAST FIRE Shotcrete Products Allow for Reduced Dry-out Time All Products Must Pass a Pumping Test All Products Must Pass A Room Temp Workability Test ( >3 Hours ) All Products Must Pass A Hot Stability Test ( > 90 minutes @ 90 F ) All Technical Data Processed on Actual Pumped & “Shot” Panels
MINTEQ Shotcrete Benefits & Customer Value Improved Refractory Life / Furnace Performance “Cast” Lining System Without The Forms Reduced Refractory Waste During Installation Reduced Furnace / Vessel Downtime Reduced Curing & Dry-out With FAST FIRE Products Increased OEE ( operating equipment efficiencies ) Lower Operating Costs
Shotcrete versus Gunnite – Physical Properties 60 % alumina, low cement OPTISHOT 60 VERSAGUN 60 Water Required ( % ) 5.0 – 5.5 Na Installation Method SHOTCRETE Gunning Manufacturer MINTEQ ANH / RHI / HWR Bulk Density ( pcf ) after 230 F after 1500 F 156 154 148 Modulus of Rupture ( psi ) after 2000 F after 2500 F 2200 3000 1650 1350 Cold Crushing Strength ( psi ) 11700 10100 12400 16700 8600 6700 Permanent Linear Change ( % ) -0.1 -0.4 + 0.1 -0.2 Abrasion Loss ASTM C704 ( cc ) after 2300 F 3.8 4.9 11.0
Kruzite 70 % alumina brick AGGREGATE KILN Kruzite 70 % alumina brick OPTISHOT 60 MINTEQ shotcrete shows 1.5 – 2.0” less wear than a 70 % alumina firebrick after 1 year in the feed end of the kiln. Both materials were installed at the same time.