WE PROTECT YOUR PROCESS
n We protect your process customers experience a high and uniform level of
High-temperature processes are demanding and
cost-intensive. These advanced processes make
great demands on the processing equipment used.
All equipment must help to ensure the longest ser-
vice life possible, as well as minimise energy costs
and environmental impact.
At HASLE, we take great pride in developing, manu­
facturing and supplying refractory materials to pro-
tect your process.
Our refractory materials are continuously being de-
veloped in close collaboration with our customers.
We aim to be a market leader in materials specially
designed to resist mechanical impact, chemical at-
tack, shock, build-up and wear – resistance proper-
ties which ensure a long service life for the refractory
lining. The characteristics of our company are qua­lity,
flexibility and quick response times.
Quality – because it is paramount to our custo-
mers that HASLE’s materials function optimally
– every time. We give priority to ensuring that our
2 3
quality with all our products.
Flexibility – because our customers needs
change over time – and from one job to another.
We are ready to assist at all times with advice and
guidance in selecting materials – to ensure the best
results for our customers.
Quick response times – as every customer
inquiry is important to us, we are constantly
focused on ensuring quick responses and short
lead times.
We look forward to protecting your process with
the best refractory materials possible.
Michael Bladt
CEO, Owner
HASLE Refractories A/S
 HASLE castables
are made from the best raw materials
n All our castables are manufactured ac-
cording to our own secret formulas, which
are continuously being developed and im-
proved
Our castables are manufactured at our own factory,
and the entire manufacturing process is designed
to ensure that all our castables have a high level
of uniform quality. We use only the best raw ma-
terials – in other words, we do not use recycled or
semi-manufactured materials from other manufac-
turers. Our comprehensive quality control process
ensures that all finished goods comply with our
high requirements for particle-size distribution,
workability, and physical properties when our
products leave the factory.
Castables are usually grouped as follows: tradi-
tional castables, low-cement castables, insulating
castables, gunning mixes and mortars. These are
described on the following pages.
5
 HASLE castables

HASLE traditional castables
are composed of relatively few, well-known com­
ponents and have been in use for many years.
This type of castable is used for jobs that are not
too demanding – where mechanical and chemical
action on the castable is relatively low.
HASLE low-cement castables
HASLE low-cement castables (LCC) were devel-
oped to create the best combination of mechanical
strength, impact resistance and alkaline corrosion
at high temperatures. LCCs low porosity characte­
ristis reduces the risk of slag attack and corrosion.
Low porosity also helps to make LCCs stronger
than traditional castables. As a result, low-cement
castables are highly resistant to alkaline attack,
such as from sodium and potassium salts – com-
pounds often found in biofuels, waste, etc.
This means that linings made of low-cement casta-
bles have a long service life and excellent durability
and are more economical to use in the long term
than traditional castables.
HASLE low cement gunning mixes
Our low cement mixes for dry gunning are based
on the same high-quality raw materials as our well-
known LC-castables. Hence chemical resistance
and mechanical strength are high and the LC-gun-
ning mixes are suitable as primary linings. The grain-
size distribution of the gunning mixes ensures a
dense packing and low rebound of the material
when sprayed onto the ceiling.
In our product range we also have a pumpable
castable for wet gunning/shotcrete, which also
can be pumped directly into moulds where it levels
without vibration.
HASLE insulating castables
Insulating castables differ from other castables
due to two factors: That the grog is composed
of high-porosity components or that the castable
forms a porous structure when heated. For utili-
sation purposes, insulating castables are a com-
petitive alternative to insulating (porous) bricks.
An insulating castable is a suitable filling material
between a hot face lining and block insulation. The
insulating castable flows into all corners and cracks
leaving no cavities.
Mortars
Mortars were developed to bind bricks together in
bricked linings. Refractory mortars are made from
fire clay, refractory clay and cement, with the particle
size and quality adapted to the desired application.

REFRACTORIES

REFRACTORIES

REFRACTORIES

REFRACTORIES
25 kg net

25 kg net

Hydraulic setting
25 kg net

Hydraulic setting
25 kg net
low-cement castable
Hydraulic setting

low-cement castable
Hydraulic setting

Max service temp:

low-cement castable

Max service temp:

low-cement castable
Bags per m3: 90
Max service temp:

Bags per m3: 90

Max service temp:
PR no:12035478
Water add ltr/bag

PR no:12035478
Water add ltr/bag

PR no:12035478
Water add ltr/bag
Bags per m3: 90

PR no:12035478
Water add ltr/bag
Bags per m3: 90
tories.com
hasle@hasle-refrac-
Fax: +45 5695 3181
Phone: +45 5695 1800
Denmark
DK-3700 Roenne
HASLE Refractories A/S

tories.com
hasle@hasle-refrac-
Fax: +45 5695 3181
Phone: +45 5695 1800
Denmark
DK-3700 Roenne
HASLE Refractories A/S

tories.com
hasle@hasle-refrac-
Fax: +45 5695 3181
Phone: +45 5695 1800
Denmark
DK-3700 Roenne
HASLE Refractories A/S

tories.com
hasle@hasle-refrac-
Fax: +45 5695 3181
Phone: +45 5695 1800
Denmark
DK-3700 Roenne
HASLE Refractories A/S
D52A

D1600SC

D65TA

D1700A
6 7
 HASLE precast elements
The most efficient solution
n An excellent alternative to casting is the For pipelines we offer a precast cylindrical lining
installation of a HASLE precast solution that is installed without anchors. This solution is
HASLE manufactures precast modular elements very fast and safe to install and is combined with
developed by our own technicians. We also offer to insulation material to reduce heat loss from feed
design and manufacture customer-specific element pipes etc.
for linings or functional furnace parts. The design
process takes place in close collaboration with the
customer and is based on requirements like ease of
assembly, durability and thermal conduction.

The combination of a high-quality low-cement

castable with a controlled manufacturing process
ensures a very durable, precise and uniform ele-
ment. Thanks to innovative mould-building tech-
niques, precast elements can be manufactured in
all sorts of shapes and sizes.
Part of Precast Feed Pipe installation
There are many advantages of choosing a refrac-
tory lining made of precast modular elements. The
elements are easy to install, and the user avoids the
drying-out problems that can be experienced by
using castables. The process can be restarted very
quickly without a risk of explosion due to vapour
pressure inside the lining. If an operating kiln sys-
Precast Smoke Chamber tem needs to be renovated, the repair process is
short: the precast elements can quickly be placed
and replaced as no formwork is required.

A precast refractory lining is denser and thus less

vulnerable to chemical attack and build-up forma-
tion. The lining will also have greater mechanical
strength than a lining cast in situ.

HASLE offers modular systems suitable for floors,

Precast Grate Cooler walls and roofs, regardless of whether the surfaces
are flat or curved. The solution may also be used to
increase cross-sectional areas, where possible, in
bottle-neck areas.

Precast Kiln Hood

8 9
 HASLE precast elements
– unsurpassed quality
n HASLE’s precast elements are manufac-
tured under highly controlled conditions
Nothing is left to chance. The freshness of the
castable, the addition of water, vibration, curing
and subsequent firing to more than 1,000°C are
carefully controlled for every single production run.
To control the process, samples of each batch are
taken after curing. The samples are dried in a dry-
10
ing cabinet, after which their bending and compres-
sive strength are tested. A batch is only allowed to
continue in the manufacturing process if it complies
with our high quality requirements. Each element
is inspected both at the time of formwork removal
and after firing to ensure that only perfect elements
are delivered to our customers.
11
 Choosing the right castable
n Choosing the right castable
A castable that works well and has a long service
life in one area can be unsatisfactory in another.
Therefore, it is crucial to know which properties you
are looking for.
In the following, we briefly explain the most impor-
tant technical data for all HASLE castables. The
actual values are to be found on our data sheets.
Compressive and bending strength:
MPa (CCS and MOR)
These strengths must be high in order to resist the
Alkali-test with K2CO3
at 1100°C CEN/TS15418 physical contact to which the castable is exposed
and to ensure the lining’s long service life. HASLE’s
castables are more uniform and stronger than simi-
lar castables from other manufacturers.
Abrasion resistance: Cm³
This property is important in areas with great wear,
typically caused by airborne particles. The lower
Determination of cold modulus the value the higher the abrasion resistance, and all
of rupture. EN1402-6 HASLE low-cement castables are highly resistant
to abrasion.
Al2O3 content
Together with the castable’s other ingredients, the
Al2O3 content indicates the castable’s structure.
By contrast with conventional castables whose
price and refractoriness increase concurrent with
the content of Al2O3, HASLE’s low-cement casta-
bles are renowned for having a more flexible chem-
Determination of resistance ical structure where the most important properties
to thermal shock. EN993-11 are not solely related to the content of Al2O3. In
HASLE low-cement castables, the castable’s bind-
ing system is crucial, regardless of the details of
the chemical structure.
The relatively low Al2O3 content gives the castable
low bulk density, compared to similar high-quality
castables. In addition, the reduced Al2O3 content
Determination of cold also improves its chemical resistance and insulation.
crushing strength. EN1402-6
12
Bulk density: Kg/m³
This property is important in calculating the amount
of castable to be used for casting in a specific area.
Low bulk density is good because it means that
less (weight) is required to cover the desired area.
The bulk density of HASLE castables is low com-
pared to many other castables. This means that
HASLE castables often cost less, after adjusting
for their lower bulk density, as a smaller volume is
required for casting the same area.
Thermal conductivity: W/mK
This property is important as it indicates whether a
castable has insulating capacity. Low thermal con-
ductivity ensures that the heat remains in the area
cast, thereby contributing to the process desired.
By contrast, a castable with high thermal conduc-
tivity can transport lots of heat, which is useful for
steam-generating facilities. HASLE provides casta-
bles with both high and low thermal conductivity,
thereby covering all areas of utilisation.
Alkali resistance is indicated on a scale
of 0 to 10
This property is very important if the fuels – such
as wood chips, bark, straw and waste – emit alka-
line gasses. Alkaline gases substantially reduce the
castable’s service life. The figure 0 indicates that a
castable has maximum resistance against alkaline
attack.
HASLE Research and Development
HASLE has its own R&D facilities where specific
slag testing can be carried out using a customer’s
own fuel. This means we will gladly assist with test-
ing to optimise the refractory lining in your system
and thus achieve longer service life, fewer repairs
and less maintenance. We are constantly focused
on optimization and development of castables to
meet the challenges of new technologies and alter-
native fuels.
13
 Refractory commodities
n To supplement our own manufactured
products, HASLE offers a wide range of
ceramic fibres, insulating bricks and fire-
place bricks
Ceramic fibres
Ceramic fibre products are used wherever a high
insulating capacity is required. If mechanical wear
is not present, ceramic fibres can be used as the
only refractory material which is in contact with the
process.
HASLE sells only synthetic bio-soluble fibres. The
fibre is water soluble and therefore less harmful to
human health than traditional ceramic fibres.
14
Insulating bricks
Insulating bricks are distinguished from other bricks
by their high porosity and, thus, lower compressive
strength. The advantage of insulating bricks is that
they can be used for both primary lining and insu-
lation backing. They have good insulating capacity,
good thermal resistance and provide a lightweight
refractory structure.
Fireplace bricks
Used for building wood-burning stoves, small
stoves and ceilings, etc. The bricks are made of
chamotte and fire clay.
15
Store bags in dry conditions,
sheltered against rain, wind
and direct sunshine.
Add water according to
prescriptions on bag.
Use clean tap water only.
Vibrate thoroughly until
castable flows together.
Please note: PU- and EF-
versions need less vibration.
Follow HASLEs instructions for
drying out and firing.
Use clean pan mixer.
Mix for 4 minutes with water.
Add more water if too dry and
mix for 4 minutes.
Allow curing for a minimum
of 24 hours. Protect surface
from drying out.
www.hasle-refractories.com
info@hasle-refractories.com
Mix dry material for 3 minutes.
The material should be installed
immediately after mixing.
Please note: PU- versions are
for pumpcasting.
Ideal casting temperature
is 15-25˚C / 59-77˚ Fahrenheit.
Under very cold or warm we-
ather, hardening of the castable
can be significantly prolonged
or accele­rated respectively.
HASLE 01-2015
 Daniel Hansted-Martin,
HASLE Refractories, explains
how Lafarge Canada’s
Exshaw Cement Plant
has reduced abrasion and
chemical challenges and
tripled the lifetime of the
refractory lining in the
facility’s Riser Duct using a
precast Modular Lining.

S
et in pristine surroundings at the foot
of the Canadian Rocky Mountains,
Lafarge’s modernised cement plant
showcases environmental and economic
efficiency. Built in 1906, as ‘the Western
Canadian Cement & Coal Company’, the
Lafarge Exshaw Cement Plant is Canada’s
biggest cement factory with a capacity of
2.4 million tpy. Over the years, the plant has had
six lines in operation, however, today only line
K#5 and K#6 are being operated. Each has a
production capacity of 2200 tpd and 4200 tpd,
respectively. Lafarge Exshaw operates on 100%
natural gas and is working towards using low
carbon alternative fuels in the future. Its updated
facilities operate the latest cement production
technology. As a member of LafargeHolcim, the
plant is continually seeking solutions to operate
more efficiently and sustainably.
Solving short lining lifetime in the
Riser Duct
Responding to Western Canada’s significant
cement demands, Lafarge Exshaw seeks to
increase capacity and minimise stoppages.
However, in 2017, the plant faced abrasion and
chemical challenges in its refractory lining in
Riser Duct K#6. The lifetime of the company’s
 A LIFETIME
ACHIEVEMENT
existing refractory lining was no more than six
to 12 months. Needing a long-life, sustainable
alternative, Plant Manager, Kate Strachan,
contacted HASLE Refractories with a
recommendation from another cement plant
within the LafargeHolcim Group, which was
already using HASLE’s precast Modular Lining.
“We needed to achieve a significantly longer
lifetime”, said Kate. “When the Modular Lining
was already showing excellent performance
at another plant within the group, we didn’t
hesitate to install it here at our Canadian plant.”
Upon receiving the technical drawings
from Lafarge Exshaw, HASLE’s team of
engineers designed a tailor-made solution
for line K#6, based on the standard precast
element design. Detailed drawings of all
138 m2 of the riser duct were made, and once
they were approved by Lafarge Exshaw, the
installation was scheduled for mid-March to
mid-April 2018. To ensure that the optimal
installation technique is used, a team of
HASLE supervisors always participates on
site whenever the precast Modular Lining is
installed – in this case, they had the pleasure
of cooperating with the Canadian installation
company, Alliance, who undertook the
installation at Lafarge Exshaw.
A worthwhile recommendation
By September of 2020, the precast Modular Lining
installation had been in operation for more than two
and a half years. The Lafarge Exshaw Cement Plant
has achieved an excellent lining lifetime in its riser
duct, with no re-linings or repairs needed to keep it
running. This has lowered its use of natural resources
per produced unit and resulted in an overall more
stable production. When Lafarge Exshaw implements
the use of low carbon alternative fuels in the future, the
precast Modular Lining will remain a beneficial lining
choice for the riser duct, as its low, open porosity and
smooth impact surface makes it highly resistant to
alkali attack and build-up – even in extremely hostile
environments.
“Currently, the precast Modular Lining has achieved
a lifetime of +30 months”, said Plant Manager,
Kate Strachan, and adds, “We estimate it will have an
additional lifetime of up to 24 months, so we are very
satisfied with it. It certainly proved to be a worthwhile
recommendation.”
Although HASLE’s pre-cast Modular Lining has
been installed at more than 100 plants worldwide, this
instance was the first in which the company supplied
the lining to a Canadian company; the future might
Earlier refractory lining in K#6 riser duct with a
lifetime of only 6 – 12 months.
Steel rails are welded onto the casing and
HASLE’s console lining is installed with mortar
between the elements. It is now ready for
installation of the precast Modular Lining
elements.
hold more precast Modular Lining installations for
the North American country, whose cement industry
in the year of the installation generated around
CA$10.5 billion in revenue. 
The design
The HASLE precast Modular Lining was designed
almost 20 years ago. The goal was to create a hot
face refractory lining for the critical areas of high
temperature industries, which was durable and
resistant to abrasion, chemical attack and coating,
resulting in a significantly longer lifetime than the
existing alternatives on the market. Since its creation,
it has stood the test of time and can last twice or
even three times as long as a traditional cast lining,
and sometimes even longer.
Whereas traditional in-situ cast solutions typically
have an open porosity of 18 – 20% or more,
HASLE’s precast Modular Lining was designed
to have a low open porosity of only 8 – 10%. This
quality is achieved through a combination of selecting
raw materials with an optimal corn distribution curve
and adding only a very small amount of water (as
little as 4.5%) when mixing the castable. The result
is a refractory lining which has a longer lifetime,
is abrasion- and alkali-resistant, and even when
installed in plants operating on 100% RDFs, build-up
is almost eliminated.
With the precast Modular Lining, it is also possible
to achieve a lining thickness as low as 185 mm. This
is often less than the thickness of a traditional cast
lining, and presents two options; the plant can either
decide to go for a reduction in heat loss by applying
more back-up lining, or it can decide to increase the
cross sectional volume, which will give additional
space in the given area. In many cases, an increased
production capacity has been achieved by removing
a process bottle neck though the installation of the
precast Modular Lining, thus increasing the volume
of the given area.
In order to secure the highest quality of the
Modular Lining elements, all elements are cast
and pre-fired under strictly controlled conditions in
HASLE’s plant in Denmark. Casting the elements
at the plant using specialised equipment such
as vibration tables, special moulds and dry-out
ovens and employing skilled workers secures a
strong focus on each step of the casting process
and ensures a consistent optimal quality. The
process includes dry mixing for 60 seconds, adding
water, wet mixing for 4 – 5 minutes., casting it into
the moulds and covering the elements in plastic
immediately after. The elements are then left to
cure for 24 hours and are subsequently pre-fired
for five days up to a peak temperature of 500ºC.
All these steps are carefully monitored in order
to secure the highest possible consistent quality
of all pre-cast elements. However, even in this
carefully monitored production environment, small
deviations in quality can occur, and therefore each
World Cement Reprinted from April 2021
element is both visually inspected and subjected to
a strict quality control procedure prior to leaving the
production facility.
Installation
Installing the precast Modular Lining is both fast
and easy. Due to a smart element design combining
steel anchors with a tongue-and-groove system,
the installation of the pre-cast Modular Lining often
takes about 50% less time than the installation of a
traditional in-situ cast solution. Once preparations
are completed, the time required for a typical lining is
80 min/m2, depending on the condition of the area to
be lined i.e. number of air blasters, inspection holes,
manholes etc. After the welding of the rails and steel
plates holding the elements, the console elements
are easily installed. Upon these, the square modular
elements (250 x 250 mm) with a tongue and grove
system are installed. The precast elements weigh only
about 15 – 16 kg each, so no special lifting equipment
is required.
All elements are pre-fired at HASLE’s
production facility in Denmark, so no dry out of
the lining is required, which allows for a faster
restart of production. To ensure the successful
Precast elements are installed on the steel
rails, on top of the console elements, with
vermiculite back-up insulation between the
rails. Ceramic fibres are installed between every
four elements (every 1 m) to allow thermal
expansion. Now, the system is only missing the
pouring of the insulating castable behind the
pre-cast lining.
After 1.5 years of operation, HASLE’s logo
embedded on the elements is still visible.
Reprinted from April 2021 World Cement
completion of each individual installation
project, HASLE Refractories always supplies
approximately 5% more elements than needed, and
if a surplus of elements remains after completed
installation, these can be stored and kept for many
years as there is no limited shelf life. Compared to the
limited shelf life of castables, this is another valuable
advantage.
Applications
Now, the precast Modular Lining at Lafarge Exshaw
has been in operation for +36 months, and the
cement plant is looking into the possibilities of the use
of the precast Modular Lining in other areas of their
production.
Depending on the lifetime achieved from traditional
castable or brick linings, there are many other
areas in which the precast Modular Lining could be
applied. HASLE’s Modular Lining has shown good
performance when installed in a variety of applications
throughout the world, i.e. feed pipes, coolers, cooler
bull noses, smoke chambers, cyclone roofs as well as
cyclone bull noses. All areas are lined with the same
type of elements and can also be adapted for curved
and cylindrical structures.
As long as there is a steel casing the rails can be
welded to, the precast Modular Lining can be applied,
and has even been installed in a number of boilers and
incineration plants.
A sustainability perspective
Driven by climate policies and a desire to run a
sustainable production, more and more cement plants
are implementing sustainability goals. To reach these
goals, efficiency improvements are necessary and
using HASLE’s precast Modular Lining could be a
step towards running a more sustainable operation.
Not only does it require less material per installation
to create a HASLE precast Modular Lining compared
to an in-situ castable solution, but the Modular Lining
also has the potential to last longer. Consequently,
plants can lower their use of natural resources per
produced unit, as using the Modular Lining reduces
the number of re-linings and repairs needed.
Contrary to a stocked monolithic castable, which can
become unfit for use over time, HASLE’s precast
Modular Lining has an unlimited shelf-life, thus
reducing material waste.
The lining offers tangible efficiency improvements that
companies in high temperature industries can make
on their journey to becoming more sustainable.
About the author
Daniel Hansted-Martin is Regional Sales
Manager at HASLE Refractories. Daniel holds a
Bachelor’s Degree in International Management and
services the European and North American cement
markets. He has extensive theoretical and practical
experience from on-site installations, and an in-depth
understanding of refractory challenges and solutions.
Asian Cement Plant achieves 36-months lifetime in Inlet Chamber and Riser Duct
with HASLE D59A.

An 8.000 TPD cement plant in Asia, operating on

coal and up to 25% alternative fuel, has achieved an
outstanding life of three years in their Inlet
Chamber and Riser Duct using HASLE D59A.

Previously, the cement plant was experiencing

severe coating in their Inlet Chamber and Riser
Duct. We suggested lining the Inlet Chamber and
Riser Duct with HASLE’s D59A castable which is
highly resistant to coating, thermal shock and
abrasion. To achieve the best possible performance
of our castable lining, a team of experienced HASLE
engineers provided on-site supervision during
installation.

After installing HASLE D59A, the cement plant

experienced a significant drop in the number of
unscheduled shutdowns to remove coating. Over
time, they also had a big economic saving because
less material was needed for lining in Inlet Chamber
and Riser Duct.

If you would like to improve your cement plant's

run factor, call us today +45 5695 1800 or e-mail us
at info@hasle-refractories.com to find out how we
can help. HASLE D59A after 36 months
Cement plant achieves 3,5 years lining lifetime in Calciner with HASLE D59A

A 10,000 TPD Asian cement plant, operating on

100% coal, was having trouble with short lining
lifetime in their Calciner. Using a castable from a
different supplier, they never achieved a lifetime of
more than 2 years. The downtime, manhours and
materials needed for relining was becoming costly.
Needing a longer lasting alternative, the cement
plant decided to install HASLE D59A in their Calciner.
HASLE D59A has high mechanical strength, good
shock resistance and excellent abrasion resistance.
It is known to extend lining lifetime significantly. As
always, a team of skilled HASLE engineers
supervised the installation to achieve the best
possible performance of our castable lining after
installation.
After lining the Calciner with HASLE D59A, the
cement plant has close to doubled the lining life in
their Calciner and achieved twice as much run time
before re-lining is needed. Over time, this becomes
a significant financial gain for the cement plant, as
downtime, manhours and materials needed for re-
lining has been halved.
Contact us to learn how we can help improve your
high temperature process. Calciner after 29 months. Final lifetime 3,5 years!
 +5 YEARS IN DUST SETTLING
CHAMBER WITH HASLE D59A

+5 years lifetime achieved in conical portion of Dust Settling Chamber

A 10000 TPD cement plant in Northern India

operating on 100% pet coke was experiencing
premature failure of the lining in the conical portion
of their dust settling chambers due to high abrasion
and material sticking in cone causing red spots.
They routinely had to repair the conical portion
from the outside, by placing around 15-20 stone
boxes in a campaign life of one year.xxxxxxxxxxxxxx

We suggested trying HASLE D59A castable lining,

which is highly abrasion- and coating resistant. In
July 2016, HASLE D59A was applied at the conical
portion of the dust settling chamber. In 2021, the
lining reached an exceptional +5 years lifetime and
is still in operation. In 2017, the plant decided to
install HASLE D59A in the conical portion of the
second dust settling chamber. This lining now has a
+4 years lifetime and is also still running.

Using HASLE D59A is both cost-effective and

environmentally friendly. With HASLE D59A you
avoid unscheduled breakdowns to clean off coating
and the longer lining lifetime lowers the overall use
of natural resources per produced unit.

To learn how we can help you achieve a longer

lifetime on your castable lining installation call our
headquarter at +45 56951800 or send us an e-mail
at info@hasle-refractories.com. D52A in Dust Settling Chamber at inspection after 4 years
36-months lifetime in Inlet Walls of Cooler with HASLE D52A
An 8.000 tpd cement plant in Asia, running on coal
and 20-25% alternative fuel, installed HASLE’s D52A
in the Side Walls of the Cooler Inlet. The lining
achieved a 36-month lifetime. This far exceeds the
performance of generic castables in this critical
area, which usually have a lifetime of 12-24
months.
This Asian cement plant has used HASLE D52A for a
long time. The lifetime of this recent installation is
not unusual, as HASLE D52A is known to extend the
lining lifetime significantly. It is a very dense low
xxxx
HASLE D52A after 24 months
cement castable, which has high mechanical
strength and excellent abrasion resistance.
After installing HASLE D52A, the cement plant is
cutting costs as less material is needed for re-lining
the Cooler Inlet Side Walls over time. They are also
improving the plant’s run factor, as fewer
shutdowns for repairs or re-lining are necessary.
If you would like to know more about how we can
help improve your cement plant’s run factor,
contact us at info@hasle-refractories.com.
HASLE D52A after 24 months
Asian Cement Plant achieves three years lifetime in Kiln Hood using HASLE D52A

A 10,000 TPD cement plant in Asia, operating on With HASLE D52A they have doubled the lining life
coal and up to 25% alternative fuel, has once again in their kiln hood and achieved twice as much run
achieved an exceptional lifetime of three years in time before re-lining is needed, which becomes a
their Kiln Hood by using HASLE’s castable D52A. great financial saving for the cement plant.

Prior to installing HASLE D52A for the first time, the To achieve the best possible performance of our
cement plant had been using a castable from castable lining after installation, a team of skilled
another high-end supplier, but never achieved a HASLE engineers always supervise the installation.
lifetime of more than 1-1.5 years.
Needing a longer lasting alternative, the cement Would you like to improve your cement plant's run
plant began using HASLE D52A about a decade ago. factor, contact us at info@hasle-refractories.com.

On-site supervision during installation Kiln Hood after 30 months


Excellent Performance of HASLE D52A Castable in Cooler Bull Nose!
A 6000 TPD cement plant in South India, using
imported coal with up to 20% pet coke as fuel, was
facing refractory challenge in its Cooler Bull Nose
area. Using a low cement castable from a different
supplier, refractory life in this area was always less
than 12 months. The plant had to shut down and
replace the castable lining once a year, which was
costly and caused loss of valuable production time.
In 2015, HASLE supplied the well-known D52A
castable to the cement plant for the first time. The
lining of D52A performed much better than the
previous lining, much to the customer’s satisfaction.
COOLER BULL NOSE LIFETIME
DOUBLED WITH HASLE D52A
The latest installation of HASLE D52A took place in
2018, and in September 2020, it was still found to
be in good shape. No cracks or other signs of major
abrasion and chemical attack were observed.
In order to achieve the best possible performance
of our castable lining, a team of experienced HASLE
engineers always do on-site supervision.
If you would like to improve your cement plant's
run factor and eliminate costly, unplanned stops
due to refractory problems, contact us today at
info@hasle-refractories.com to learn more.
Both images show HASLE D52A on Cooler Bull Nose after 24 months
36-months lifetime reached in Tertiary Air Duct and Damper Gate using HASLE D59A
An 8.000 tpd Asian cement plant, running on coal
and 20-25% alternative fuel, installed HASLE’s D59A
in Tertiary Air Duct and Damper Gate in 2017.
The lining achieved a 36-month lifetime. This far
exceeds the performance of generic castables,
which usually have a lifetime of 12-24 months.
This Asian cement plant has used HASLE D59A for a
long time. The lifetime of this recent installation is
not unusual, as HASLE D59A has a high mechanical
strength, good shock resistance and excellent
abrasion resistance. It is a very dense low cement
HASLE D59A after 12 months
castable, which combines the best refractory
properties from several natural high-alumina raw
materials, including andalusite and mullitized
bauxitic clay.
After installing HASLE D59A, the cement plant is
saving money as less material is needed for re-
lining the Tertiary Air Duct and Damper Gate. They
are also improving the plant’s run factor, as fewer
shutdowns for repairs or re-lining are necessary.
Contact us today to learn how we can help
improve your cement plant's run factor.
HASLE D59A after 3 years

Indian cement plant reaches 1 year lifetime in burner pipe with HASLE D52A
In 2014, a cement plant in South India, using
imported coal with up to 20% pet coke as fuel,
upgraded their production capacity from 4500 TPD
to 6000 TPD. Prior to 2014, they had been using a
low cement castable from a well-known
competitor, but after upgrading their production
capacity, they were unable to achieve 6 months of
lining life in the burner pipe area.
The cement plant decided to install HASLE D52A in
their burner pipe, which significantly improved the
lining lifetime in the burner pipe. The first year it
reached an 8 months lifetime. In the last campaign,
1 YEAR LIFETIME IN BURNER
PIPE WITH HASLE D52A
the lining in the burner pipe achieved life of 12
months and is still running without any issue.
In late 2020, the cement plant replaced the burner
pipe with a spare burner, which has already been
casted using HASLE D52A. In order to achieve the
best possible performance of our castable lining, a
team of experienced HASLE engineers always do
on-site supervision.
Would you like to improve your cement plant's run
factor and eliminate costly, unplanned stops,
contact us today at info@hasle-refractories.com.
Both images show Burner Pipe with HASLE D52A after 1 year
 XXXX
GERMAN CEMENT PLANT
Modular Lining during installation
REDUCES USE OF MATERIALS
WITH HASLE MODULAR LINING

Would you like to lower the use of natural resources per produced unit?

Among our customers is a cement plant in Germany,

which runs on 60-70% refuse-derived fuel (RDF). Using
RDFs, the lining in the critical areas of their production is
subjected to significant alkali attack. In recent years, they
have had to replace their lining regularly. Therefore, they
were looking for a more durable refractory lining with a
significantly longer lifetime.

In 2018, the cement plant installed a 6m2 trial of

HASLE’s precast Modular Lining. After two years, they
saw no wear on the lining of the cooler roof. In fact, the
Modular Lining still looked brand new, so they decided
to install additional m2.

Using HASLE’s precast Modular Lining is a long-lasting

solution. It requires fewer shut-downs, and it also lowers
the quantities of raw materials needed for keeping the
lining operational. With HASLE’s precast Modular Lining
you achieve a better run factor, while lower the use of
natural resources per produced unit at the same time.

Contact us today at info@hasle-refractories.com or call

(+45) 5695 1800 if you would like to explore how we
can help you towards a more sustainable cement
production. Modular Lining after 2 years

Australian cement plant achieves 5-year lifetime in Cyclone Bull Nose with HASLE
Precast Modular Lining.
One of our valuable customers, a cement plant in Australia
which runs on both coal and waste (10%), has achieved an
outstanding lifetime of 5 years for the lining in their Vertical
Bull Nose in the lowest stage Cyclone.
The Australian cement plant had a problem with short life in
the Cyclone Bull Nose, dealing with cracking and abrasion of
the gunning material installed. We suggested switching to
HASLE’s precast Modular Lining, and our team of skilled
engineers designed a new element for the corner section
with a 60° angle. It was cast at our state-of-the-art plant in
Denmark, using our unique castable HASLE D59A.
HASLE’s precast Modular Lining during installation
5-YEAR LINING LIFETIME
REACHED IN CYCLONE BULL NOSE
HASLE's supervisors provided technical support and
supervision during the installation in the Vertical Bull Nose
for both strings of the lowest stage cyclone.
Recently, the Modular Lining achieved an excellent lifetime
of 5 years! It is still in good shape, expected to last an
additional one or two campaigns.
Using HASLE’s precast Modular Lining is a long-lasting
solution. If you are having problems with the lining in high
temperature areas of your cement plant, contact us today
at info@hasle-refractories.com or call (+45) 5695 1800.
HASLE’s precast Modular Lining after 2 years
 MODULAR LINING IN CYCLONE ROOF
REACHES +3.5 YEARS

Cement plant reaches +3.5 years lifetime in cyclone roof with precast Modular Lining

In early 2016, a cement plant in France installed 11 m2
of HASLE’s precast Modular Lining in their cyclone roof.
It was cast at our state-of-the-art plant in Denmark,
using our unique castable HASLE D59A. After 3.5 years, it
is still in operation and in excellent condition.
The lifetime of HASLE’s Modular Lining is typically 2-3
times longer than that of an in-situ casted lining. With
HASLE’s Modular Lining, you’ll get no coating, and
compared to other refractory solutions, our precast
lining even has the possibility of leaving more room in
the burn chamber or providing better insulation. Both
factors contribute to lowering the CO2-emission through
optimal use of the energy.
Using HASLE’s precast Modular Lining is a long-lasting
solution. If you are having problems with the lining in
high temperature areas of your cement plant, contact us
today at info@hasle-refractories.com or call (+45) 5695
1800.

Precast Modular Lining at instllation Precast Modular Lining after 2 years Precast Modular Lining after 3,5 years