cement industry - shivlal & sons · pdf filelances, and clinker cooler have allowed...

Monolithic

concept

solutions for

Cement

Industry

Monolithic Refractories in Cement Industry

Introduction of modern heat exchangers, calciner &

tertiary air ducts, rotary systems for the sintering zone,

discharge sections with the kiln hood and burner

lances, and clinker cooler have allowed Calderys to

implement innovative, state-of-the-art monolithic

products and de-sign solutions, which have proven to be superior to brick linings in the Cement Industry. Progress has been made through the development of in-

novative solutions such as LCC (low cement castables)

and ULCC (ultra low cement castables) that are alkaline

resistant and specially dedicated to cement production

conditions. The combination of recent product design with

modern installation techniques, such as Spraycast

(shotcrete) and low porosity gunning allows Calderys to

be a pioneer in refractory technology and solutions.

These solutions, developed in partnership with our customers, extend the reliability and the

availability of the installations. Calderys’ own team of experienced engineers can provide

total monolithic refractory lining solutions,

including custom-designed anchoring systems, selection of correct materials, professional

supervision and installation/project management. A modern cement unit includes a cyclone pre-heater, a calciner with tertiary air duct, a

rotary system and a clinker cooler.

Calderys relies on decades of ex-

perience in the complete monolithic

refractory lining of “static” areas but

also provides solutions for the “dy-

namic” parts such as the inlet cone

and the nose ring of the kiln or

rotary cooler.

Our engineering solutions are well-known and trusted both by plant operators and design-

ers, many of whom cooperate closely with Calderys for their day-to-day refractory needs.

Calderys is well-known and respected for its high quality products and services. Our pre-

sence in local markets is essential in helping our customers to meet ever-increasing

produc-tion demands. Decades of experience in refractory technology and development,

coupled with modern production facilities, means that Calderys can truly be regarded as a

high quality, reliable supplier.

Stresses in cement units

Higher temperatures

Better chemical resistance:

New products need to be not only resistant to high temperatures but also chemically inert to alkali and

sulphur and have a maximum infiltration resistance. The cement industry has undergone a change in

the use of fuel from oil and natural gas to low-grade coal and combustion of waste materials including

rubber tyres, plastics, solvents, coke, wood, used oil etc. Selecting the most suitable monolithic material requires experience and knowledge of existing produc-

tion conditions to avoid further reaction or chemical infiltration.

Alkali resistant Alkali non resistant Bursting effect

Calderys monolithic products selection will have a strong impact on reducing the build up effect in the

different parts of cement unit.

Alternative fuels and the Low Cement castables pore size: Depending on the composition of the alternative fuels, compounds containing alkalis, chlorine

and sulphur, etc… are introduced into the kiln system. Salt compounds are also used in coal-

fired cement kilns. The use of alternative fuels results in increased salt concentration in the structure of the

refractory lining, depending on the temperature level. Materials with the lowest pore size and

permeability have to be considered to avoid excessive infiltration of chemicals. Compared to

bricks, properly de-signed monolithic materials will develop these densification properties

resulting in very small pores.

Low Cement Castable: GIBRAM – after firing at 800°C Standard bricks

Installation technique:

The introduction of gas suspension pre-heaters andcal-

ciners, with their complex geometry, has further encour-

aged the installation of monolithic refractories in place of

brick linings. In these new installations, sections of the

cyclones, pipe lines, inlet chamber, kiln hood and the

cooler were installed with the LCC castables. Monolithic solution simplify thermal control of the

lining, result in increased efficiency, faster delivery

times and ultimately a reduction in the total cost of

installation. The most economical option is achieved

by applying a combination of dry or wet gunning

products together with conventional castables, self-

flowing castables and LC castables.

Solutions for the Monolithic Installations Concepts Dense gunning & Spraycast solution Due to the fast development of the thermal industries and high increase of

the demand coming from our customers, Calderys was the first to came to

the market with the new range of products like: Spraycast and Low Porosity

Gunning Mixes. Those products are Low Cement containing materials,

combining high chemical and mechanical resistance with cost effective

installation. In most situations, by using a wet gunning option, it is possible to achieve in-

stallation rates which are 3-10 times faster compared to traditional products,

whilst still achieving a service life which is similar to, or above that of regular

castables. An additional advantage is a limited amount of rebounds, no dust

during installation, no moulds required and most importantly, these products

can be applied as wet gunning material, castable as well as pumping material.

Global rates of up to 2.5 T/h (including

preparation, gunning, cleaning...) can be

achieved by dry dense gunning (Low

Poros-ity Gunning Mixes = LPGM) or up to

10T/H by wet gunning Spraycast

(shotcrete), compared to a maximum 1T/h

for standard gunning. Products installed

using standard gunning techniques also

achieve good performan-ces and can be installed 2-3 times faste than traditional

brick linings.

MID. CYCLONES

AH 404 | AH 410 | SPRAYCAST F 50 R

LOWER CYCLONES AH 405 | AH 410 | AH 411 |

AH 413 | SPRAYCAST F 50 R

KERLITE | PLICAST LW-Mix |

BASACAST ISO AS INSULATION

INLET CHAMBER

AH 411 | SPRAYCAST F 40 S30 | SPRAYCAST F 50 R

MEAL PIPE

TERTIARY AIR DUCT

SPRAYCAST F 50 R AH 404 | SPRAYCAST F 50 R

(cast)

PRECALCINER NOSE-RING AH 405 | AH 410 | SH 411 | AH 13 |

SPRAYCAST F 50 R |

SPRAYCAST F 50 R | SPRAYCAST F 40 S30 SPRAYCAST BX

85

ELBOW


FIRING-HOOD AH 405

| AH 410 | AH 420 | SPRAYCAST F 50 R |

SPRAYCAST BX 85

COOLER TOP AH 411 | SPRAYCAST F 50 R

FEED TILE

SPRAYCAST F 40 S30 (cast) | SPRAYCAST F 50 R

CHUTE-WALL

AH 410 | SH 420 | SPRAYCAST F 50 R |

SPRAYCAST BX 85

BULL-NOSE

AH 411 | SPRAYCAST F 50 R |

SPRAYCAST BX 85

CONUS

AH 411 SR | SPRAYCAST F 50 R

COOLER-MID BOTTOM


COOLER BOTTOM END

AH 404 | SPRAYCAST F 50

Solutions for the

Preheater Tower Cyclones - Gas Ducts - Meal Pipes Meal enters through the uppermost hot air duct and is

preheated within the various levels of the cyclones by hot

combustion gas coming from the rotary kiln. In these

cyclones, temperatures vary from 300°C (upper part) to

930°C (lower part). The choice of the appropriate monolithic lining material is

made according to thermal and chemical conditions expe-

rienced in the area. The wall installation may have several

layers of castables with an appropriate anchoring system.

The following installation methods can be applied:

Casting with: PLICAST, PHLOCAST, BASACAST, INTRACAST, ULTRACAST, GIBRAM

Standard gunning with: PLIGUN, KERGUN, BASAGUN

Dense gunning with: SPRAYCAST or LPGM (AH/SH/HC products)

UPPER CYCLONES/ GAS DUCTS

Standard PLICAST 18 C/G and severe KERGUN C 20 SR conditions

MID CYCLONES/ GAS DUCTS/MEAL PIPES

All PLIGUN Strong-Mix conditions PLICAST Strong-Mix

KERGUN C 28 HR SR

PHLOCAST M 28 HR SR

INSULATING MATERIALS

BASACAST ISO

PLICAST LW-Mix 124 C/G


LOWER CYCLONES/ GAS

DUCTS/MEAL PIPES Standard PLIGUN FL 40 conditions PLICAST FL 40

PHLOCAST M 28 HR SR

KERGUN C 28 HR SR

Severe BASACAST LC 35-407

conditions PLICAST LZ 106

PHLOCAST SiC 30 SR

BASAGUN 40-407

SPRAYCAST & LPGM (AH products)

Solutions for the

Preheater Tower Calciner - Combustion Chamber - Riser Duct The installation of a calciner in the cyclone heat

exchanger enables preheating and calcination of the

cement dust using for burning different kind of

combustion materials, therefore resulting in a reduction of

the entire combustion process. In these areas, due to a high temperature process of

about 1100 - 1250°C, as well as chlorine-alkali

circulation, the re-fractory material is exposed to severe

thermal and chemical conditions. Here, alkali-resistant products are required:

COMBUSTION CHAMBER

RISER DUCT

CALCINER

Standard PLICAST FL 40 conditions PHLOCAST M 28 HR SR

PLIGUN FL 40

KERGUN C 28 HR SR

Severe PLICAST ML 55 S5 conditions BASACAST LC 35-407

PLIGUN MM 55 S5

BASAGUN 40-407

PLISTIX Zircon

PLIBRICO Redd Ram



Standard

and severe

conditions

BASACAST ISO 13-135 0-5 PLICAST LW-Mix 124 C/G PLICAST LW-Mix 106 C/G

Solutions for the

Preheater Tower Inlet Chamber - Kiln Inlet Due to the fast development in the cement industry, furnace builders have to consider new construction

concepts with much more sophisticated design. The

best and the most flexible solution is to apply

monolithic refractories. The most intricated part is the inlet arch with the

skewback transition to the intake chute. The mix runner profile is cut into the back wall to allow

precise guiding of the raw meal. Due to the complex

shape of the casing and to the angular arrangements

around the shock blower nozzle, this type of lining can

only be carried out with a monolithic refractory product

in : cast, gunning and spraycasting version.

INLET CHAMBER

FEED TILE

KILN INLET

Standard PLICAST FL 40

PHLOCAST M 28 HR SR

conditions

PLIGUN FL 40

KERGUN C 28 HR SR

Severe PLICAST LZ 106

conditions INTRACAST 440 SR

BASACAST LC 35-407

PHLOCAST SiC 30 SR

MONROX SiC 60 SR

PLISTIX Zircon

PLISTIX ZM 30 S15

PLIGUN MM 55 S5

BASAGUN 40-407 0-6

BASAGUN 40-205

SPRAYCAST & LPGM

(AH products)


Standard BASACAST ISO

and severe PLICAST LW-Mix 124 C/G

conditions


Solutions for the

Kiln Hood & Cooler Burner Lance - Nose Ring

Areas such as nose ring, burner lances, kiln hoods and cooler ducts, lined with

monolithic material, operateunder the most

severe conditions. The use of multi-fuel burners is becoming more common practice in cement plants, a

pattern that is likely to increase in the near

future due to the large amount of alternative

and residual fuels available. Unfortunately,

these emerging problems influence coating

formation, clinker quality and refractory life-

time. The combustion problems in a cement

kiln are very complex and affected by a lot of

factors.

BURNER PIPE

Standard PLICAST ML 55 S5

and severe BASACAST LC 60-717 F

conditions

GIBRAM SR

MONROX AX SR

PLIFLOW A 50 Z/S

PLIBRICO Superal-X AB

PLIBRICO 90 AB

The burner lance tips, for example, are always

exposed to alkalis corrosion and abrasion by

the clinker. They also experience vibration and

exposure to high temperature. Calderys solutions concerning the choice of

material, dimensioning, anchoring and

instal-lation technique guaranty long lasting

opera-tion time.

NOSE RING

Standard PLICAST LX 68

and severe GIBRAM SR

conditions

BASACAST MC 55-305 F 0-6

BASACAST LC 60-717 F

Solutions for the

Kiln Hood & Cooler Kiln Hood - Tertiary Air Duct The proper selection of the refractory material for the

kiln hood is of the highest importance. Due to the big

temperature differences and to avoid erosion caused

by the coming clinker, a high abrasion, thermal shock

and chemical resistant materials should be applied. Calderys long-term experience allows providing you

with the solutions combining: the right selection of the

materials – depending on the chemical problems, the

actual speed of the kiln and the temperature level;

detailed design, anchoring system and installation

techniques to guarantee future long service life.

KILL HOOD

Standard PLICAST LX 58 conditions PHLOCAST M 28 HR SR

PLIGUN MM 55 S5

KERGUN C 28 HR SR

BASAGUN 60-500

Severe BASACAST LC 60-717 F conditions PLICAST LZ 106

PLICAST ML 55 S5

KERGUN C 28 HR SR

PLIGUN MM 55 S5

PLIGUN GX A 60 S7


TERTIARY AIR DUCT

All KERGUN C 28 HR SR conditions BASAGUN 55-503

PLIGUN FL 40

PLIGUN MM 55 S5


TAD ELBOW

Severe PLIGUN MM 55 S5 conditions GIBRAM SR





conditions


Solutions for the

Kiln Hood & Cooler Grate Cooler - Hot Zone The function of the clinker cooler is to cool clinker from 1300°C down to near 100°C and to com-

plete its 3 CaO SiO2 transformations to the main component of Portland cement. In this area, the refractory material is exposed to high temperature changes, difficult mechanical

conditions in the sidewalls (high wear), and severe chemical attack due to the presence of

alkalis released by the clinker cooling process.

COOLER WALL/ROOF

Standard PLICAST FL 40 conditions PHLOCAST M 28 HR SR

KERGUN C 28 HR SR

BASAGUN 60-500

PLIGUN FL 40

Severe BASACAST MC 55-305 F conditions BASACAST LC 60-717 F

ULTRACAST SiC 30 SR

PLICAST LX A-51 S 5

PLIGUN GX A-60 S 7


IMPACT ZONE

Standard ULTRACAST 387 SR

and severe PLICAST LX 58 W2

conditions

GIBRAM SR




conditions


Solutions for the

Kiln Hood & Cooler Grate Cooler

BULL NOSE Standard

& severe

conditions

PLICAST LX A-51 S 5 BASACAST MC 55-305 F GIBRAM SR BASACAST 50-501 PLIGUN GX A-60 S 7 SPRAYCAST &

LPGM (AH products)

COOLER COLD ZONE

Standard KERGUN C 20 HR SR & severe PLICAST 18 C/G conditions

COOLER MID. ZONE Standard PLICAST FL 40

& severe PHLOCAST M 28 HR SR

conditions

KERGUN C 28 HR SR

PLIGUN FL 40

SPRAYCAST & LPGM

(AH products)


BASACAST ISO



Solutions for the

Kiln Hood & Cooler Planetary Cooler For the monolithic lining of grate, rotary and planetary

coolers, Calderys offers advanced materials like:

CAST, GUN or SPRAYCAST, which are the most

suitable for this application.

PLANETARY COOLER INLET

Standard GIBRAM SR PLANETARY COOLER -

REST

& severe BASACAST LC 60-717 F

conditions

Standard

BASACAST MC 55-305 F PHLOCAST M 28 HR SR

MONROX B SR & severe PLIGUN MM 55 S5

conditions

SPRAYCAST & LPGM SPRAYCAST & LPGM

(AH products) (AH products)

Products characteristics by type of installation

Product name

Raw Material Working Chemical Analysis (%)

Density CCS 110° C

Type Temperature

(base)

(g/cm3) (Mpa)

(°C)

Al2O3 SiC ZrO2

Castable

BASACAST LC 35-407 LCC chamotte 1350 44 na na 2.3 95

BASACAST LC 60-717 F LCC bauxite 1600 76 na na 2.8 50

BASACAST MC 55-305 F LCC chamotte 1550 31 35 na 2.4 120

INTRACAST 440 SR LCC andalusite 1650 50 10 10 2.85 120

GIBRAM SR LCC bauxite 1600 82 na na 2.95 125

PHLOCAST M 28 HR SR LCC chamotte 1550 46 na na 2.25 100

PHLOCAST SiC 30 SR MC SIC 1500 33 na 2.35 95

PLICAST FL 40 LCC chamotte 1450 40 na na 2.26 70

PLICAST LX 58 LCC andalusite 1650 57 na na 2.5 95

PLICAST LX A-51 S 5 LCC andalusite 1600 51 5.0 na 2.42 90

PLICAST LZ 106 ULCC zircon 1600 29 na 43 3.2 50

PLICAST ML 55 S5 LCC High Alumina 1550 55 5.0 na 2.48 95

PLICAST Strong-Mix ULCC Chamote 1320 40 na na 2.0 65

ULTRACAST 387 SR ULCC Tabluar Alumina 1750 92 na na 3.2 120

ULTRACAST SiC 30 SR ULCC SIC 1500 34 31 na 2.46 60

Self-flow

PLIFLOW A 50 Z/S LCC zircon 1650 60 10 10 2.79 90

MONROX AX SR LCC andalusite 1650 52 10 9 2.78 110

MONROX B SR LCC bauxite 1600 85 na na 2.85 60

MONROX SiC 30 SR LCC SIC 1500 33 35 na 2.42 80

MONROX SiC 60 SR LCC SIC 1500 25.5 59.5 na 2.55 85

Product name

Raw Material Working Chemical Analysis (%)

Density CCS 110° C

Type Temperature

(base)

(g/cm3) (Mpa)

(°C)

Al2O3 SiC ZrO2

Standard Gunning

PLICAST 18 C/G MC chamotte 1300 34 na na 1.87 30

PLIGUN FL 40 LCC chamotte 1450 42 na na 2.08 30

PLIGUN GX A-60 S 7 LCC andalusite 1550 51 7 na 2.17 28

PLIGUN MM 55 S5 MC High Alumina 1500 57 5 na 2.35 90

PLIGUN Strong Mix C/G R chamotte 1320 37 na na 1.95 60

BASAGUN 20-305 R chamotte 1200 35 17 na 2.2 40

BASAGUN 40-205 MC SIC 1400 26 52 na 2.3 55

BASAGUN 40-407 0-6 MC chamotte 1400 43 na na 2.1 45

BASAGUN 55-503 MC chamotte 1550 55 na na 2.3 70

BASAGUN 60-500 MC High Alumina 1600 57 na na 2.25 70

KERGUN C 20 SR MC chamotte 1350 38 na na 2.05 40

KERGUN SiC 30 HR SR MC chamotte 1400 35 34 na 2.25 80

KERGUN C 28 HR SR MC chamotte 1500 53 na na 2.17 90

PLISTIX Zircon MC zircon 1350 37 na 30 2.8 40

PLISTIX ZM 30 S15 MC zircon 1350 31 14 26 2.8 40

Dense Gunning & Shotcrete

AH 404 SR LCC chamotte 1500 48 na na 2.25 60

AH 410 SR LCC andalusite 1650 58 na 10 2.7 98

AH 411 SR LCC andalusite 1650 51 10 10 6.7 70

AH 413 SR LCC chamotte 1500 43 10 na 2.2 70

SH 420 SR LCC SIC 1500 31 na 2.35 63

SPRAYCAST F 50 R LCC chamotte 1550 51 na na 2.4 45

SPRAYCAST BX 85 ULCC bauxite 1700 84 na na 2.9 50

SPRAYCAST F 40 S30 LCC chamotte 1600 44 30 na 2.45 60

Ramming

PLIBRICO 90 AB ceramic Corundum 1750 90 na na 2.77 15

PLIBRICO Redd Ram ceramic High Alumina 1650 69 na na 2.5 44

PLIBRICO Superal-X AB ceramic bauxite 1650 73 na na 2.42 13

NOTES: CALDERYS does not warrant the accuracy, fitness for purpose or update of any information disclosed herein. The recipient shal l refer to instructions

and advice provided under any technical documentation. This document and the information contained herein are the exclusive property of CALDERYS.

Reproduction, alteration, copy, release, publication or distribution, in whole or in part, is not allowed. References, trademarks and specifications of the products may change according to the geographical area to be supplied. Please check the availability of

the products with the sales area manager.

cement industry - shivlal & sons · pdf filelances, and clinker cooler have allowed...

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