OVERVIEW OF SAINT GOBAIN AND INTRODUCTION TO...

HIGH-PERFORMANCE REFRACTORIES

OVERVIEW

OF

SAINT GOBAIN

AND

INTRODUCTION TO

REFRACTORY SOLUTIONS

FOR GASIFICATION

BY

SHAILESH DOSHI

CERAMIC MATERIALS

1 /

HIGH-PERFORMANCE REFRACTORIES 2

Saint-Gobain: History and Overview

Sectors of Activity

Refractory solutions for Gasification

AG

EN

DA


Saint Gobain History

1665 : creation of the Saint-

Gobain Group, on industrial basis

19th century, the beginnings of

the European scope

20th and 21st century, the

transformation of the Group

Other applications

Other building materials

Other high-performance materials

Distribution of building materials

3 business sectors today

http://upload.wikimedia.org/wikipedia/en/b/b6/1665C.jpg


2016 net sales

€39.1 BN

KEY FIGURES

4

Present in

67 countries

One of the top100 industrial

groups in the world with around

950 production sites

More than170,000 employees

and 100+ nationalities represented

Around 4,100sales outlets

Created more than

350 years ago

More than 80% of sales

are made in the habitat markets:

construction, renovation,

infrastructures and civil

engineering


21 %

12 %

43 %

8 %

16 %

THE GROUP’S MARKETS

5

AS A % OF NET SALES

New residential construction

New non-residential construction

Renovation

Civil engineering and infrastructure

Industry


Cavaillon France

Aubervilliers France

Shanghai China

Chantereine France

Herzogenrath Germany

Chennai India

Capivari Brazil

Northboro USA

6

INNOVATION MINDSET

* Source: Clarivate Analytics

3,700 people

8 cross-business

R&D centers

One of the top 100Global Innovators*

390 patents filed in

2016

Partnerships with universities

and start-ups

About 100development centers

3 months in average:

the usage time its takes

for our insulation solutions

to offset the CO2

emissions attributable to

their production

1 product out of 4 sold by Saint-Gobain today didn’t exist 5 years ago


INNOVATIVE MATERIALS

7

The four cockpit windows and 32 passenger

windows of the Falcon 8X are supplied

by Saint-Gobain Sully

Novelio Nature

Range of fiberglass wall coverings from

Saint-Gobain Adfors

NORTON I-HD

New technology from Saint-Gobain

Abrasives that is revolutionizing the

market for diamond tools

MAIN BRANDS PRODUCTS AND ARCHITECTURAL PROJECTS

FLAT GLASS

CONTRAFLAM®

Fire-retardant and anti-UV glazing by Vetrotech in the

futuristic boarders’ residence in Le Rosey, Geneva,

designed by Bernard Tschumi

AUTOMOTIVE GLAZING

ABRASIVES

FLEXIBLE TUBING

BEARINGS

POLYMER SEALS

TECHNICAL TEXTILES

FIRE RESISTANT GLASS

WINDOW FILM

ARCHITECTURAL

MEMBRANES

ADHESIVE FOAMS

CERAMICS FOR ENERGY

REFRACTORIES

ELECTROCHROMIC GLASS


6 large R&D multi-business centers, many dedicated centers and local teams

8


Ceramic Materials

68 manufacturing facilities in 18 countries

7,500 employees

Products:

All divisions produce grains and powders, ceramic components and refractories,

specialty crystals and associated systems.

9

Silicon Carbide (SiC)

Abrasive materials

ZirPro – Zirconia beads and powders

NorPro – ceramic solutions for oil and gas exploration and catalyst bed supports

Ceramic refractories (SEFPRO for glass-making furnaces and HPR for other applications)

Particle filters for Diesel engines

Photonics – sapphire wafers for LED, optical windows, medical and industrial lasers

Scintillators – radiation detectors

Quartz - products based upon synthetic silica and fused quartz (crucibles, fibers, rods, tubes)


Saint-Gobain Ceramic Materials manufacturing facilities

10

Rödental

Bollène Le Pontet Avignon

Courtenay

Mudanjiang

Worcester, MA

SiC

Abrasive Materials

ZirPro

NorPro

SEFPRO

HPR

DPF

Crystals

Quartz

Puerto Ordaz

Barbacena

Tirupati

Shanghai

Xining

Phuentsholing

Hody Anaheim, CA Beijing Handan Deng

Feng

Brisbane

Bryant, AR Daisy, TN

Huntsville, AL

Steinefrenz

Guanghan

Vénissieux Gières

Bangalore

Vinhedo

Rainford

Düsseldorf Weilerswist

Thomastown

Northampton, MA

Provins

Lillesand

Arendal

Niagara Falls

Niagara Falls, NY

Wheatfield, NY Amherst, NY

Fort Smith, AR

Buckhannon, WV Olyphant, PA Latrobe, PA

Mezzocorona

Palakkad

Sakai

Chiba

Linyi Lianyungang Jinzhou

Nemours

Larchant

Vallauris

Milford, NH

Hiram/Newbury, OH Canton, OH

Boulder, CO

Riverport, KY

Stow, OH

Bryan, TX

10


Innovative Materials

Construction Products

Packaging

Building Distribution

SAINT-GOBAIN GROUP, HPR DIVISION

Flat Glass

High Performance Materials

Abrasives Crystals Textile

Solutions Plastics

Ceramics

Grains &

Powders

Ceramic Materials

High Performance Refractories Division


WTE Gas Turbines

Iron

Gasification

Aluminium Steel

Foundry Petrochemical

Kiln Furniture Firing Systems Insulators

WRT

Process

Components HX

Armor

Muffles

Norfoam Liquid Filtration

REFRACTORIES ENGINEERED CERAMICS

HIGH PERFORMANCE REFRACTORIES MARKETS SERVED


# 13

Industrial footprint – 2017

Niagara Falls

Vénissieux

Worcester

Vinhedo

Rodental

Latrobe

Rainford

Bangalore

Seto

Shanghaï

11 High Performance Refractories locations

* 6 locations shared with Sefpro for Electrofused products

Halol

Pallakad *

Perundurai *

Bejing * Mezzocorana *

Le Pontet *

SGTM *


14

Reforming CarbonBlack

Fertilizers Chemicals

Alternative Energies Nuclear

14

Gasification


REFRACTORY SOLUTIONS

FOR GASIFICATION

CERAMIC MATERIALS

15 /


GASIFICATION TECHNOLOGIES

16

E Gas

by P 66


ENTRAINED FLOW GASIFIER TYPICAL LININGS

17

Refractory lined option available, but less popular


ENTRAINED FLOW GASIFIER LININGS - SCHEMATIC

18

(Or bricks)

Back up

(Chrome

or

Alumina) Alumina Or


GASIFICATION SYSTEMS

Refractory solutions for slagging and non-slagging gasifiers Texaco / GE E-Gas Siemens

Material qualitites for various feedstocks Natural gas Oil Coal Petcoke Biomass Municipal waste


TECHNICAL SOLUTIONS - GASIFICATION

Solids gasification High chromia refractories

Liquids gasification High alumina refractories

Design / Calculation

/ Supervision

AH199, AL100 1st layer Zirchrom

MS2R 2nd layer Chromcor

AN599,RI34,SiC,MS6 3rd layer

MS6,RI34, SiC


Refractory solutions from A Z

Full refractory design

Thermal Calculations

FEM analyses

R&D support for refractory analyses and

assessment

Product preassembly and inspection

Installation supervision

Individual package solutions for each customer


LABORATORY TESTS-CORROSION

SAINT-GOBAIN R&D CENTER CAPABILITIES

Crucibles Test

(50 x50 x 20)

-Isotherm, static

Multiple cycles

Dimensional before and after corrosion

Finger test

(180 x 25 x25)

-Material corrosion by dynamic molten slag under reducing atmosphere

-Tmax: 1600°C

-3 samples/1 reference material

-Dimensional before/after corrosion (triple point or immerged part)

-2-10 rpm

Rotary kiln

(Arch brick 33 x 200)

-Evaluation of slag infiltration by dynamic molten slag

-Presence of thermal gradient

-Determination of wear > 1%

-T: 1600-1650°C

Hot abrasion test

-Evaluation of abrasion I nhot medium and impact on wear

-Tmax: 1600°C

22


LABORATORY TESTS-CORROSION

SAINT-GOBAIN R&D CENTER CAPABILITIES

Wettability Test

- Determination of Slag Melting temperature

- Comparative refractory analysis

- Impact of additives on Slag Viscosity

Thermal Shock testing

- Thermal shock in air

Thermal shock in water

- Determination of residual strength

- Comparative analyses

Strength

- Cold crushing strength

- Hot MoR (T=1400°C)

- MoR (20°C)

Material analyes

- Chemical composition

- Crystal structure

- XrayDefraction

- Hot Xray Deflection

- SEM

- Mircorprobe

23


Chromium oxide products

Zirchrom®

(chrome-zirconia):

Zirchrom®30V

Zirchrom®400

Zirchrom®60/60V

Zirchrom®750

Zirchrom®85V

Zirchrom®90

Zirchrom®900

(chrome-alumina)

Chromcor®12

Monochromcor® 10

Chrpmcor® B/B10/BDAK

Aluminium oxide products

AL100

AL102 / AL102V

MS2R

MS4

MS6

Alundum® AH199H

Alundum® AH191

Alundum® AN599

Allfrax® 101HF

Mullfrax®202HF

Mlullfrax® 201

Zirconium oxide products

Ziral14

Ziral94M

ZiA95

ZH192

ZH392

ZS739

Sh

ap

es

Bricks

Monolithics

Ramming&Towelling mix

Pro

ce

ss

Automatic press

Maxibrator press

Vibrocasting

Slipcasting 24


Complicated shapes Maxibrator shaping

25


Large shapes Vibrocasting

Chromia Qualities

Alumina Qualities

Up to 1500kg/pce

26


Big series Automatic Press

27


Al203 – Cr2O3 – ZrO2 system

ZrO2

Cr2O3

Thermal shock

resistance Hot mechanical

strength

Corrosion resistance (slag, glass)

Impurities

(SiO2 < 10%)

Ziral 14/AH199BZ

Al2 O3

ZC 900

ZC 85V

ZC 60

AL100/ AH199 Ziral 94M/ZA95 CC B10 CC BDAK

ZC30V

AL102

ZC400

ZC 90

ZC 750

CC12


AL100 family Product Al2O3 SiO2 Fe2O3 CaO Alkalins P2O5 Others

% % % % % % %

AL100 99.5 0.1 0.1 - - - <0.3

AL102 96.0 1.2 0.1 ZrO2 2.5

- - <0.2

MS2R 87.0 12.4 0.1 0.2 - - <0.3

MS4 70.0 29.5 0.3 - - - <0.2

MS6 62.0 36.5 0.9 TiO2 0.25

- - <0.3

RI34 98.5 0.7 0.1 - - - <0.3

Product Density Porosity Max service temp

Thermal conductivity

g/cm3 % °C W/mK

AL100 3.32 16.0 1800 3.8

AL102 3.30 15.5 1800 -

MS2R 3.05 14.0 1650 -

MS4 2.5 18.0 1650 2.2

MS6 2.53 14.0 1600 1.85

RI34 1.50 - 1800 1.25

29


30

Alfrax® Family

AL 100

Product Al2O3 SiO2 Fe2O3 CaO Alkalins P2O5 Others

% % % % % % %

Alfrax 101 98.7 0.1 0.1 0.1 0.25 - <0.5

Alfrax 201P 92 5 0.5 0.5 0.3 2.8 <0.5

Alfrax 301P 91.5 3.5 0.5 0.1 0.2 0.5 <2.0

Alfrax B101 98.4 1.3 0.1 0.1 0.3 - <0.5

Alfrax B202 81 17 0.3 (TiO2 0.2)

0.9 - <0.5

Mullfrax 201 78 21 0.2 - 0.4 - <0.5

Mullfrax 202 87 12 0.1 (TiO2 0.1)

0.5 0.5

Product Density Porosity Max service temp

Thermal conductivity

g/cm3 % °C W/mK

Alfrax 101 3.00 22 1800 2.7

Alfrax 201P 3.05 11 1800 2.8

Alfrax 01P 3.10 13 1800 3.4

Alfrax B101 1.48 58 1800 -

Alfrax B202 1.44 49 1800 1.1

Mullfrax 201 2.60 18 1750 1.6

Mullfrax 202 2.80 18 1800 2.0


31

ZirchromTM/ChromcorTM family

AL 100

Product Al2O3 SiO2 Cr2O3 ZrO2 Others

% % % % %

Chromcor BDAK 80.0 6.0 10.0 4.0 <0.3

Chromcor 12 87.0 - 12.5 - <0.5

Zirchrom 30 41.8 10.0 30.0 18.2 <0,3

Zirchrom 400 43.5 6.5 39.0 10.0 <1.0 (0.8 Fe2O3)

Zirchrom 60 17.0 9.0 62.0 12.0 <0.3

Zirchrom 750 11.0 9.0 71.0 7.5 <1.0 (0.7 Fe2O3)

Zirchrom 900 - 5.0 88.0 7.0 <0.3

Product Density Porosity Max service temp Thermal conductivity

g/cm3 % °C W/mK

Chromcor BDAK 3.55 12 1800 -

Chromcor 12 3.35 17 1750 4.4

Zirchrom 30 3.45 14 1750 2.9

Zirchrom 400 3.72 13 1800 -

Zirchrom 60 3.84 10.0 1800 2.9

Zirchrom 750 4.05 12.0 1800 -

Zirchrom 900 4.15 12.0 1800 -


Technical solutions - Gasification Production of syngas (CO + H2 ) from hydrocarbons

For ammonia, methanol production, synfuels, energy

High process temperature (Tmax 1600°C)

Various feedstock:

Natural gas

Oil

Coal

Petcoke

Biomass

Municipal waste

Heavy oil

Energy

Flame

Plasma torch

Low CO2 emissions

Lot of molton ash

No or very few molton ash

Refractory lined:

Withstand high temperature

Insure corrosion resistance

Insure thermal shock resistance

Optimize process and maintenance 33


Technical solutions - Gasification Burner

Feedstock inlet

Dome

Reaction zone

1st refractory layer 2nd refractory layer 3rd refractory layer

Molton ash deposition Cone

Syngas and

molton ash output

34


Technical solutions - Gasification

Solids gasification High achromia

refractories

Liquids gasification High alumina

refractories


Summary

Refractory experience since more than 60 years

Customizes solutions

Strong R&D support

Worldwide production and support facilities

Access to Saint-Gobain products network

High quality products over a long time


THANK FOR YOUR ATTENTION !

OVERVIEW OF SAINT GOBAIN AND INTRODUCTION TO...

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