DCVL / India

P-02-0098.
Refractory Lining
Oct,2011
page 1 of 26

DALMIA CEMENT VENTURES LTD

P-02-0098.

Technical Specification
Refractory and Insulating Linings
 DCVL / India
P-02-0098.
Refractory Lining
Oct,2011
page 2 of 26

DALMIA CEMENT VENTURES LTD

P-02-0098.

Technical Specification
Refractory and Insulating Linings

Contents:

1. General

2. General information on the plant

2.1 Location and climatic conditions
2.2 Operating conditions
2.3 Operating temperatures

3. Material specification of the different components

3.1 Preheater: PR LN Z 7350/6 Pc
3.2 PYRORAPID rotary kiln: diam. 4.4 x 60m long
3.3 Kiln hood with 1xTertiary air withdrawal: Diam. 4.4m
3.4 Burner carrier tube: Pyro jet HPJ/350
3.5 Tertiary air duct: 2.70/3.10 x 98 m long, with slide gate
3.6 Dust settling chamber: Diam. 6.30/6.73m, with inlet duct
and dust return chute
3.7 Pyro floor cooler: PFC 746AH
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4. Qualities of the anchors

4.1 Preheater
4.2 Rotary kiln
4.3 Kiln hood with tertiary air withdrawal
4.4 Burner carrier tube
4.5 Tertiary air duct with slide gate
4.6 Dust settling chamber with inlet duct
and dust return chute
4.7 Pyro floor cooler

5. Qualities of the refractory and insulating lining

5.1 Working lining / bricks
5.2 Working lining / castable
5.3 Insulation

6. Information for the refractory suppliers

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1. General
This technical specification is the basis for procurement and/or supply of the refractory
and insulating linings. It contains the required technical data and information.
Details on the build-up of the walls and the allocation of qualities within the different plant
sections have been given in the relevant separate material specifications (item 3 below
refers).
The suggestions for lining given by us under item 3) below are exclusively based on
qualities that have stood the test in the cement industry. The quality data have been taken
from the catalogs of well-known refractory producers and given as average values.
Obviously, there are alternatives to our suggestions. However, it would go beyond the
scope of this document to comment on all opportunities.
The chemical and physical properties we have specified, in particular, abrasion and alkali
resistance as well as thermal shock resistance shall be duly observed.
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2. General information on the plant

2.1 Location and climatic conditions

Location: BELGAUM, India
Altitude above sea level: 607 mtr M.S.L
Ambient temperature: Max. 46o C, Min. 16o C.
Relative humidity: Max.85 % and Min. 25 %

2.2 Operating conditions

Capazity: 4500 t/d

Fuel for rotary kiln: Coal,
Secundary fuel: Coal,
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2.3 Operating temperatures

Anticipated operating temperatures upon „normal operation“ of the plant:

gas temperatures
component
normal operation
inlet chamber 1150 - 1250°C
connection to tertiary air duct 950 - 1100°C
rising duct above inlet chamber 1100 - 1200°C
PYROCLON rising duct
PYROTOP with bend, 880 - 950°C
PYROCLON falling duct,
bend 90° / stage VI
cyclone stage VI 880 - 900°C
cyclone stage V 770 - 810°C
preheater

cyclone stage IV 650 - 700°C

cyclone stage III 530 - 580°C
cyclone stage II 400 - 440°C
double separator stage I 260 - 300°C
raw meal duct:
temperatures

stage VI-inlet chamber 840 – 880°C

material

stage V-PYROCLON 750 – 790°C

stage IV-V 630 – 680°C
stage III-IV 510 – 560°C
stage II-III 380 – 420°C
stage I-II 240 – 280°C

kiln hood
1000 – 1200°C
(without radiation heat from the kiln)

Pyro floor cooler:

inlet zone 1000 - 1200°C
rekuperative zone 600 – 800°C
middle zone 300 – 600°C
outlet zone 250 – 300°C

inlet duct and dust chamber 1000 – 1200°C

tertiary air duct 950 – 1100°C
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3. Material specification of the different components

The lining consists of working and insulating layers. The working lining essentially consists
of standard shapes and shaped bricks as well as suitable castables. The insulating layers
may be of block type, insulating bricks or insulating compounds.
Where refractory castable is used to avoid too many or too complicated shaped bricks, the
chemical and physical properties of that material shall at least correspond to those of the
relevant brick quality.

BA 412-1505 en :Preloading of cyclone ceilings

412-241 UD
214-011-100059-SH1
214-011-100057-SH1
214-011-100058-SH1
:Prestressing of cyclone ceilings
: Arrangement of hangers for
double separators (stage I)
: Arrangement of hangers for Cyclone
combi ceiling (stage II, III, IV, V,VI)
: Hangers for ceilings-PYROTOP
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3.1 Preheater: PR LN Z 7350/6 Pc

Important information:

• For balancing the thermal expansions between the cyclone stages, the ceilings
of the cyclone stages are operating according to the principle of a membrane.
When reaching operating temperature, the cyclone ceilings return into their
horizontal position. In this way, the thermal expansions between the cyclone
stages can be balanced without additional compensators.
After the installation of the bricklining and the insulating lining, this basic
operating mode must be ensured.
During the assembly, the cyclone ceilings are lifted, e.g. preloaded, see BA 412-
1505 with drawing ZD 412-241 D/E. Then, the refractory and insulating lining is
installed.
The working sequence, i.e. first preloading, then installing, must be observed.

• The ceilings can be installed in a combination of stone and castables or in

castables only.
In the case of a combination of stone and castable, make sure that the
suspension irons are radially arranged. Examples for the arrangement and type
of the suspension irons are enclosed.
A parallel arrangement of the suspension irons is not possible in view of
preloading.

• The maximum plate temperature of all components in the area of the preheater
must not exceed 140 degrees centigrade.
Preconditions are an intact refractory lining and „normal operation“ of the plant.
Information on the operating temperatures of the different components have
been given under item 2.2) above.
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The following qualities are recommended. Quality data see chapter 5.:
wall system:
working 1st 2nd
component total
lining insulation insulation
main part type thickn. type thickn. type thickn. thickn.
bricks castable mm mm mm mm
2xStage I
roof - FC1 160 - - - - 160
spiral, straight - FC1 65 IP1 25 - - 90
spiral, inclined - FC1 65 IP1 25 - - 90
walls, round - FC1 65 IP1 25 - - 90
cone - FC1 65 IP1 25 - - 90
star for stage I - FC1 80 - - - - 80
2xGas duct II-I
adapter element - FC1 65 IP1 25 - - 90
bend - FC1 115 - - - - 115
walls, round FB1 - 115 - - - - 115
cone - FC1 115 - - - - 115
2xStage II / top section
roof - FC1 150 IP1 80 - - 230
spiral, straight FB1 - 115 IP1 100 - - 215
spiral, inclined - FC1 115 IP1 100 - - 215
walls, round FB1 - 115 IP1 100 - - 215
2xStage II / bottom section
cone FB1 - 115 IP1 100 - - 215
cone tip - FC1 115 IP1 100 - - 215
2xBend III-II
roof - FC1 150 IP1 80 - - 230
walls, straight - FC1 115 IP1 100 - - 215
walls, round FB1 - 115 IP1 100 - - 215
2xGas duct III-II
walls, round FB1 - 115 IP1 100 - - 215
cone - FC1 115 IP1 100 - - 215
2xStage III / top section
roof - FC1 150 IP1 80 - - 230
spiral, straight FB1 - 115 IP1 100 - - 215
spiral, inclined - FC1 115 IP1 100 - - 215
walls, round FB1 - 115 IP1 100 - - 215
2xStage III / bottom section
cone FB1 - 115 IP1 100 - - 215
cone tip - FC1 115 IP1 100 - - 215
2xBend IV-III
roof - FC1 150 IP1 80 - - 230
walls, straight - FC1 115 IP1 100 - - 215
walls, round FB1 - 115 IP1 100 - - 215
2xGas duct IV-III
walls, round FB1 - 115 IP1 100 - - 215
cone - FC1 115 IP1 100 - - 215
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working 1st 2nd

component total
lining insulation insulation
main part type thickn. type thickn. type thickn. thickn.
bricks castable mm mm mm mm
2xStage IV / top section
roof - FC1 150 IP1 80 - - 230
spiral, straight FB1 - 115 IP1 100 - - 215
spiral, inclined - FC1 115 IP1 100 - - 215
walls, round FB1 - 115 IP1 100 - - 215
2xStage IV / bottom section
cone FB1 - 115 IP1 100 - - 215
cone tip - FC1 115 IP1 100 - - 215
2xBend V-IV
roof - FC1 150 IP1 80 - - 230
walls, straight - FC1 115 IP1 100 - - 215
walls, round FB1 - 115 IP1 100 - - 215
2XGas duct V-IV
walls, round FB1 - 115 IP1 100 - - 215
cone - FC1 115 IP1 100 - - 215
2xStage V / top section
roof - FC2 150 IP2 80 - - 230
spiral, straight FB2 - 115 IP2 40 IP1 60 215
spiral, inclined - FC2 115 IP2 40 IP1 60 215
walls, round FB2 - 115 IP2 40 IP1 60 215
2xStage V / bottom section
cone FB2 - 115 IP2 40 IP1 60 215
cone tip - FC2 115 IP2 40 IP1 60 215
2xBend VI-V
roof - FC2 150 IP1 80 - - 230
walls, straight - FC2 115 IP1 100 - - 215
walls, round FB2 - 115 IP1 100 - - 215
2xGas duct VI-V
walls, round FB2 - 115 IP1 100 - - 215
cone - FC2 115 IP1 100 - - 215
2xStage VI / top section
roof - FC2 150 IP2 80 - - 230
spiral, straight FB2 - 115 IP2 40 IP1 60 215
spiral, inclined - FC2 115 IP2 40 IP1 60 215
walls, round FB2 - 115 IP2 40 IP1 60 215
2xStage VI / bottom section
cone FB2 - 115 IP2 40 IP1 60 215
cone tip - FC2 115 IP2 40 IP1 60 215
bottom - FC2 115 IP2 40 IP1 60 215
2x bend 90°/stage VI

roof - FC2 150 IP2 80 - - 230

walls, straight - FC2 115 IP2 40 IP1 60 215
walls, round FB2 - 115 IP2 40 IP1 60 215
Bottom - FC2 115 IP2 40 IP1 60 215
PYROCLON falling duct, round
walls, round FB2 - 115 IP2 40 IP1 75 230
PYROTOP compact
roof - FC2 150 IP2 80 - - 230
spiral, straight FB2 - 115 IP2 40 IP1 75 230
spiral, inclined - FC2 115 IP2 40 IP1 75 230
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main cylinder FB2 - 115 IP2 40 IP1 75 230

adapter element - FC2 115 IP2 40 IP1 75 230
connection cylinder FB2 - 115 IP2 40 IP1 75 230
Bend for PYROTOP compact
roof - FC2 150 IP2 80 - - 230
walls, straight - FC2 115 IP2 40 Ip1 75 230
walls, round FB2 - 115 IP2 40 IP1 75 230
PYROCLON rising duct, round
walls, round FB2 - 115 IP2 40 IP1 75 230
PYROCLON rising duct, angular
walls, straight - FC4 115 IB1 65 IP2 50 230
Inlet chamber
walls, compl. - FC4 150 IB1 65 IP2 40 255
bottom - FC4 150 IB1 65 IP2 90 305
channel in bottom - FC4 150 IB1 30 IP2 25 205
2xRaw meal duct
I-II, only inlet chute with angular part - FC3 100 IP1 25 - - 125
2xRaw meal duct
II-III, III-IV,IV-V - FC3 100 IP1 25 - - 125
2xRaw meal duct
V-PYROCLON, VI-inlet cham. - FC3 100 IP2 25 - - 125
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3.2 Rotary kiln: Diameter 4.4 x 60 m long

Important note:

A guide value for the maximum shell temperature of the rotary kiln is 350°C.

The steel normally used for the kiln tube no longer features a defined stability at
temperatures above 350°C. However, as long as the kiln continues to revolve
temperatures up to 400°C do not yet mean an immediate risk.

Temperatures above 400°C mean a direct danger for the stability of the kiln tube.

Therefore, the specified kiln temperatures must definitely be maintained. This

aspect shall be duly considered when selecting the refractory lining.

The following qualities are recommended. Quality data see chapter 5.:
Split up of zones:

working lining L/D thickness length

zone
type mm mm

1. inlet zone / only cone HC1 - 200 5000

2. security zone HB2 2 200 8800

basic bricks

3. upper transition zone BB1 3 200 13200

4. sintering zone BB2 4 200 17600

5. lower transition zone BB1 3 200 13200

6. outlet zone HB3 or BB1 - 250 2200

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3.3 Kiln hood with 1xTertiary air withdrawal: Diam. 4.4m

Important information:

• The maximum plate temperature of the kiln hood must not be more than 200°C.
Preconditions are an intact refractory lining and „normal operation“ of the plant.
Operating temperatures of the different components have been given under 2.2)
above.

• It should be emphasized at this juncture that for reasons of strength the rear
wall of the kiln hood has to be of concave shape, i.e. slightly vaulted towards
the plate shell. The brickwork shall then be bricked up stepwise towards the
cooler shaft in order not to create larger surfaces near the cooler connection
that will encourage the formation of dust deposits.

The following qualities are recommended. Quality data see chapter 5.:
wall system:
working 1st 2nd
component total
lining insulation insulation
main part type thickn. type thickn. type thickn. thickn. surface
2
bricks castable mm mm mm mm approx. m
head wall at kiln end
walls, straight - HC3 230 IB1 65 IP2 60 355 XX
arch section
arch roof HB3 - 230 IB1 65 IP2 60 355 XX
side walls
walls, straight HB3 - 230 IB1 65 IP2 60 355 XX
rear wall with door
walls, straight HB3 - 230 IB1 65 IP2 60 355 XX
connection to inlet duct
for dust chamber
roof - HC3 150 IB1 65 IP2 40 255 X
walls, straight / bottom HB3 - 115 IB1 65 IP2 60 240 XX
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3.4 Burner carrier tube

The refractory encasing consists of the wear layer made up of suitable castable and a
corresponding anchoring system.

The following qualities are recommended. Quality data see chapter 5.:
Encasing:
working lining thickness length
zone
type mm mm

burner tip HC4 100 approx. 1000

burner lance HC3 80 approx. 7250

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3.5 Tertiary air duct: Diam. 2.710/3.100 x 98m long with slide gate:

Important information:

• The maximum plate temperature of the tertiary air duct must not be more than
140°C.
Preconditions are an intact refractory lining and „normal operation“ of the plant.
Operating temperatures of the different components have been given under 2.2)
above.

The following qualities are recommended. Quality data see chapter 5.:
wall system:
working 1st 2nd
component total
lining insulation insulation
main part type thickn. type thickn. type thickn. thickn.
bricks castable mm mm mm mm
tertiary air duct
walls, round FB2 - 100 IP2 40 IP1 60 200
connection to dust chamber
adapter element - FC3 100 IP2 40 IP1 60 200
connection to preheater
walls, round FB2 - 100 IP2 40 IP1 60 200

working
component volume
lining
main part type thickn.
3
bricks castable mm approx. m
slide gate
walls, straight - HC4 210 1.7
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3.6 Dust settling chamber: Diam. 6.30/6.73m with inlet duct and dust return chute:

Important information:

• The maximum plate temperature of dust settling chamber, inflow channel and
dust return system must not exceed 140°C.
Preconditions are an intact refractory lining and „normal operation“ of the plant.
The operating temperatures of the different components have been given under
2.2) above.
Roof arrangement acc-214-011-100060-SH1

The following qualities are recommended. Quality data see chapter 5.:
wall system:
working 1st 2nd
component total
lining insulation insulation
main part type thickn. type thickn. type thickn. thickn.
bricks castable mm mm mm mm
dust chamber
roof - FC4 150 IP2 80 - - 230
walls, straight - FC4 115 IP2 40 IP1 60 215
walls, round FB3 - 115 IP2 40 IP1 60 215
cone FB3 - 115 IP2 40 IP1 60 215
cone tip - FC4 115 IP2 40 IP1 60 215
inlet duct
roof - FC4 150 IP2 80 - - 230
walls, straight FB3 - 115 IP2 40 IP1 60 215
bottom FB3 - 115 IP2 40 IP1 60 215
dust return chute
walls, round - HC2 80 - - - - 80
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3.7 Pyro floor cooler: PFC 746 AH

Important information:

• The maximum plate temperature of the Pyro floor cooler must not exceed 140°C.
Preconditions are an intact refractory lining and „normal operation“ of the plant.
The operating temperatures of the different components have been given under
2.2) above.

The following qualities are recommended. Quality data see chapter 5.:
wall system:
working 1st 2nd
component total
lining insulation insulation
main part type thickn. type thickn. type thickn. thickn.
bricks castable mm mm mm mm
inlet zone
head wall HB3 - 175 IP2 50 IP1 65 290
side walls HB3 - 175 IP2 50 IP1 65 290
horse shoe I - HC3 300 IB2 500 - - 800
horse shoe II - HC3 300 IB2 500 - - 800
bull nose HB3 -x 175 IP2 50 IP1 65 290
recuperative zone
roof HB3 - 180 IM1 75 - - 255
side walls HB3 - 175 IP2 50 IP1 65 290
recuperative wall/side walls - HC3 150 IC2 50 - - 200
below beam - HC3 180 IC2 50 - - 230
middle zone
roof FB2 - 180 IM1 75 - - 255
side walls, upper part FB2 - 175 IP2 75 - - 250
□side walls, lower part (clinker bed) - HC3 175 IP2 75 - - 250
waste air take off
roof, inclined - FC2 150 IP2 80 - - 230
side wall, inclined - FC2 115 IP2 60 - - 175
side wall, upper part FB2 - 175 IP2 75 - - 250
□side wall, lower part (clinker bed) - HC3 175 IP2 75 - - 250
partitions walls 1 and 2 - FC2 115 IP2 60 - - 175
outlet zone
roof FB2 - 180 IM1 75 - - 255
side walls, upper part FB2 - 175 IP2 75 - - 250
behind armouring - - - IC2 220 - - 220
end wall FB1 - 115 IP2 60 - - 175

*Height of side walls, lower part: 1000mm

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4. Qualities of the anchors

Important information:

Arrangement, distance and type of the anchors to be determined by the refractory

supplier.

4.1 Preheater: Following materials are recommanded

component straight walls with brick lining parts of castable lining

material no. 1)AISI 2) DIN material no. 1)AISI 2) DIN

2xstage I - - - 1.4301 304 X5 CrNi 18 10

2xgas duct II-I - - - 1.4301 304 X5 CrNi 18 10

2xstage II 1.4301 304 X5 CrNi 18 10 1.4301 304 X5 CrNi 18 10

2xgas duct III-II with bend 1.4301 304 X5 CrNi 18 10 1.4301 304 X5 CrNi 18 10

2xstage III 1.4301 304 X5 CrNi 18 10 1.4301 304 X5 CrNi 18 10

2xgas duct IV-III with bend 1.4301 304 X5 CrNi 18 10 1.4301 304 X5 CrNi 18 10

2xstage IV 1.4301 304 X5 CrNi 18 10 1.4301 304 X5 CrNi 18 10

gas duct V-IV with bend 1.4301 304 X5 CrNi 18 10 1.4301 304 X5 CrNi 18 10

2xstage V 1.4301 304 X5 CrNi 18 10 1.4301 304 X5 CrNi 18 10

2xgas duct V-VI with bend 1.4301 304 X5 CrNi 18 10 1.4301 304 X5 CrNi 18 10

2xstage VI 1.4301 304 X5 CrNi 18 10 1.4301 304 X5 CrNi 18 10

bend 90°/stage VI 1.4841 314 X15 CrNiSi 25 20 1.4845 310S X12 CrNi 25 21

PYROCLON falling duct, - - -

1.4845 310S X12 CrNi 25 21
round
PYROTOP with bend 1.4841 314 X15 CrNiSi 25 20 1.4845 310S X12 CrNi 25 21

PYROCLON rising duct, - - -

1.4845 310S X12 CrNi 25 21
round
PYROCLON rising duct, - - -
1.4845 310S X12 CrNi 25 21
angular
inlet chamber - - - 1.4845 310S X12 CrNi 25 21

raw meal ducts: - - -

1.4301 304 X5 CrNi 18 10
I-II, II-III, III-IV,IV-V
raw meal ducts: - - -
V-PYROCLON 1.4845 310S X12 CrNi 25 21
VI-inlet chamber

1) AISI American Iron and Steel Institute

2) DIN Deutsches Institut für Normung
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4.2 Rotary Kiln: Following materials are recommended

component parts of castable lining

material no. 1)AISI 2) DIN

inlet zone, cone 1.4845 310S X12 CrNi 25 21

1) AISI American Iron and Steel Institute

2) DIN Deutsches Institut für Normung

4.3 Kiln Hood: Following materials are recommended

component straight walls with brick lining parts of castable lining

material no. 1)AISI 2) DIN material no. 1)AISI 2) DIN

head wall at kiln end - - - 1.4845 310S X12 CrNi 25 21

arch section - - - 1.4845 310S X12 CrNi 25 21

side walls 1.4837 - GX 40 CrNiSi25-12 1.4845 310S X12 CrNi 25 21

rear wall 1.4837 - GX 40 CrNiSi25-12 1.4845 310S X12 CrNi 25 21

connection to inlet duct for 1.4837 - GX 40 CrNiSi25-12 1.4845 310S X12 CrNi 25 21
dust chamber

1) AISI American Iron and Steel Institute

2) DIN Deutsches Institut für Normung

4.4 Burner: Following materials are recommended

component parts of castable lining

material no. 1)AISI 2) DIN

complete burner lance 1.4845 310S X12 CrNi 25 21

1) AISI American Iron and Steel Institute

2) DIN Deutsches Institut für Normung
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4.5 Tertiary Air Duct: Following materials are recommended

component parts of castable lining

material no. 1)AISI 2) DIN

complete tertiary air duct 1.4845 310S X12 CrNi 25 21

1) AISI American Iron and Steel Institute

2) DIN Deutsches Institut für Normung

4.6 Dust Chamber / Inlet Duct / Dust Return Chute:

Following materials are recommended

component straight walls with brick lining parts of castable lining

material no. 1)AISI 2) DIN material no. 1)AISI 2) DIN

dust chamber 1.4841 314 X15 CrNiSi 25 20 1.4845 310S X12 CrNi 25 21

inlet duct 1.4841 314 X15 CrNiSi 25 20 1.4845 310S X12 CrNi 25 21

duct return chute - - - 1.4845 310S X12 CrNi 25 21

1) AISI American Iron and Steel Institute

2) DIN Deutsches Institut für Normung

4.7 Pyro Floor Cooler:

Following materials are recommended

component straight walls with brick lining parts of castable lining

material no. 1)AISI 2) DIN material no. 1)AISI 2) DIN

inlet zone 1.4837 - GX 40 CrNiSi25-12 1.4845 310S X12 CrNi 25 21

recuperative zone 1.4837 - GX 40 CrNiSi25-12 1.4845 310S X12 CrNi 25 21

middle zone 1.4837 - GX 40 CrNiSi25-12 1.4845 310S X12 CrNi 25 21

waste air take off 1.4837 - GX 40 CrNiSi25-12 1.4845 310S X12 CrNi 25 21

outlet zone 1.4837 - GX 40 CrNiSi25-12 1.4845 310S X12 CrNi 25 21

1) AISI American Iron and Steel Institute

2) DIN Deutsches Institut für Normung
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5. Qualities of the refractory and insulating lining

Explanation of the code: raw material basis type category

F = fireclay B = brick 1
H = high alumina C = castable 2
B = basic P = plate 3
I = insulating M= mat 4

for example: FB1 → fireclay / brick / 1

HB1 → high alumina / brick / 1
FC2 → fireclay / castable / 2
HC2 → high alumina / castable / 2
BB1 → basic / brick / 1
IP1 → insulating / plate / 1
IM1 → insulating / mate / 1
IC1 → insulating / castable / 1

5.1 working lining / bricks:

The following qualities are recommanded:

FB1 FB2 FB3

brick brick brick
fireclay with
raw material basis fireclay fireclay
silicon carbite
material abrasion abrasion very high abrasion
characteristics resistent resistent resistent
characteristic ≥ 40% Al2O3
30-35% Al2O3 40-45% Al2O3
component ≥ 25% SiC
3 3 3
bulk density ~ 2.2 kg/dm ~ 2.3 kg/dm ~ 2.5 kg/dm
2 2 2
cold chrushing strength ≥ 40 N/mm ≥ 40 N/mm ≥ 50 N/mm
refractoriness under load,
> 1200 °C > 1300 °C > 1500 °C
ta-value
apparent porosity ≤ 18 % ≤ 18 % ≤ 18 %
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HB1 HB2 HB3

brick brick brick
raw material basis high alumina high alumina high alumina
material abrasion and
alkali resistent alkali resistent
characteristics alkali resistent
characteristic
50-55% Al2O3 60-65% Al2O3 ~ 85% Al2O3
component
3 3 3
bulk density ~ 2.4 kg/dm ~ 2.6 kg/dm ~ 2.8 kg/dm
2 2 2
cold chrushing strength ≥ 50 N/mm ≥ 55 N/mm ≥ 80 N/mm
refractoriness under load,
> 1400 °C > 1450 °C > 1450 °C
ta-value
apparent porosity ≤ 18 % ≤ 18 % ≤ 20 %

BB1 BB2
basic brick basic brick
raw material basis magnesia spinel magnesia spinel
material resistent to resistent to
characteristics thermal shocks thermal shocks
characteristic
85-89% MgO 89-93% MgO
component
3 3
bulk density ~ 2.9 kg/dm ~ 2.9 kg/dm
2 2
cold chrushing strength ≥ 50 N/mm ≥ 50 N/mm
refractoriness under load,
> 1700 °C > 1700 °C
ta-value
apparent porosity ≤ 18 % ≤ 18 %
remarks chrome ore free chrome ore free
 DCVL / India
P-02-0098.
Refractory Lining
Oct,2011
page 23 of 26

5.2 working lining / castable:

The following qualities are recommanded:

FC1 FC2 FC3 FC4

castable castable castable castable
fireclay with
raw material basis fireclay fireclay fireclay
silicon carbite
material abrasion abrasion abrasion very high abrasion
characteristics resistent resistent resistent resistent
characteristic ≥ 20% Al2O3
~30% Al2O3 ~40% Al2O3 ~45% Al2O3
component ≥ 30% SiC
3 3 3 3
material required ~ 2.1 kg/dm ~ 2.1 kg/dm ~ 2.2 kg/dm ~ 2.5 kg/dm
cold chrushing 2 2 2 2
≥ 30 N/mm ≥ 30 N/mm ≥ 30 N/mm ≥ 95 N/mm
strength, 1000°C
max. temperature
of application ~ 1100 °C ~ 1200 °C ~ 1400 °C > 1450 °C

HC1 HC2 HC3 HC4

castable castable castable castable
raw material basis high alumina high alumina high alumina high alumina
material abrasion abrasion and abrasion and extremely
characteristics resistent alkali resistent alkali resistent abrasion resistent
characteristic
~55% Al2O3 ~75% Al2O3 ~85% Al2O3 ~95% Al2O3
component
3 3 3 3
material required ~ 2.3 kg/dm ~ 2.6 kg/dm ~ 2.8 kg/dm ~ 2.8 kg/dm
cold chrushing 2 2 2 2
≥ 50 N/mm ≥ 70 N/mm ≥ 80 N/mm ≥ 80 N/mm
strength, 1000°C
max. temperature
of application ~ 1400 °C ~ 1500 °C ~ 1600 °C > 1800 °C
 DCVL / India
P-02-0098.
Refractory Lining
Oct,2011
page 24 of 26

5.3 insulating layers:

The following qualities are recommanded:

IP1 IP2 IM1

insulating plate insulating plate insulating mate
raw material basis calcium silicat calcium silicat basalt fibres
3 3 3
bulk density ~ 0.25 kg/dm ~ 0.25 kg/dm ~ 0.12 kg/dm
classification
800°C 1000°C 750°C
temperature
400°C ~ 0.09 W/mK ~ 0.10 W/mK ~ 0.12 W/mK
thermal
600°C ~ 0.12 W/mK ~ 0.14 W/mK
conductivity
800°C ~ 0.17 W/mK

IB1 IB2
fire light brick fire light brick
light weight light weight
raw material basis
fireclay fireclay
characteristic
~38% Al2O3 ~35% Al2O3
component
3 3
bulk density ~ 0.5 kg/dm ~ 0.8 kg/dm
2 2
cold chrushing strength ≥ 1.5 N/mm ≥ 1.5 N/mm
classification
1260°C 1350°C
temperature
400°C ~ 0.16 W/mK ~ 0.36 W/mK
thermal
conductivity 800°C ~ 0.20 W/mK ~ 0.41 W/mK
1000°C ~ 0.25 W/mK ~ 0.47 W/mK
 DCVL / India
P-02-0098.
Refractory Lining
Oct,2011
page 25 of 26

IC1 IC2
insulating insulating
castable castable
raw material basis light weight light weight
fireclay fireclay
characteristic
~30% Al2O3 ~40% Al2O3
component
3 3
material required ~ 1.0 kg/dm ~ 2.1 kg/dm
cold chrushing 2 2
≥ 2.0 N/mm ≥ 30 N/mm
strength, 1000°C
max. temperature of
~ 1200 °C ~ 1200 °C
application
300°C ~ 0.25 W/mK ~ 0.40 W/mK
thermal
700°C ~ 0.25 W/mK ~ 0.40 W/mK
conductivity
1000°C ~ 0.30 W/mK ~ 0.50 W/mK
 DCVL / India
P-02-0098.
Refractory Lining
Oct,2011
page 26 of 26

6. Information for the refractory suppliers:

The suppliers of the refractory materials will assume warranties with respect to the
physical properties of the materials to be used, their chemical composition and
dimensional stability as well as durability and service life of the lining.
The production of the refractory and insulating lining shall be in compliance with the latest
state of technology and is the sole responsibility of the supplier.
A general statement regarding bricklining is that the complete brickwork shall be properly
and exactly processed with mortar at a maximum joint thickness of 2 - 3mm.
Changing of the wall construction and/or the qualities of the refractory and insulating lining
are only allowed after previous consultation with KHD.
Apart from all refractory and insulating materials all auxiliary materials, such as e.g.
mortar, adhesive, bitumen, locking plates and fitting bricks for the rotary kiln, special
mixing water, joint cardboard, expansion joint materials, retaining elements incl. special
welding electrodes, brackets – if any, etc. required for all plant sections shall be part of the
delivery scope of the refractory suppliers.

The following notes shall be duly observed:

• Retaining elements of heat-resistant steel of appropriate quality shall be used
• it has to be ensured that a sufficient number of retaining elements (hangers,
anchors, etc.) will be available for the refractory and insulating linings
• suitable means for protecting the retaining elements (e.g. bitumen, anti-corrosion
paint, acid-resisting cement, etc.) shall also be part of the delivery scope of the lining
suppliers
• because of the significant expansion of the refractory and insulating linings, the
required expansion joints shall be exactly calculated for expansion in height and
width with due regard to the specific properties of the material used
• all expansion joints shall be filled with suitable material that has been matched to the
particular temperature profile and that will remain flexible
• in general a sufficient reserve of refractory and insulating material is to provide