Uwe Schneider, Solnhofer Portlandzementwerke, Germany, and Roland Krischanitz

and Peter Fritsch, RHI AG, Austria, discuss how new refractory mixes technology
can help to improve service life in the most critical areas of the kiln.

INNOVATIVE
REFRACTORY
MIXES
TECHNOLOGY

Abstract
The cement industry is one of the most energy-intensive industries worldwide; therefore the use of
alternative fuels has a long tradition, especially in Central Europe. Portlandzementwerke Solnhofen relies
on fuel cost savings by burning alternative fuels, making an important contribution to the ecologically
and economically sensible utilisation of waste materials. Modern kiln technologies and high-grade lining
concepts enable the use of a wide range of alternative fuels. In comparison with the use of conventional
fossil fuels, refractories are subject to significantly higher stress when alternative fuels are used.
Consequently, a considerably shorter useful life of the refractory lining has to be accepted in many cases.
In cooperation with RHI AG, the plant successfully developed solutions for the most critical areas of the
kiln. The following article outlines the plant’s experience with new refractory mixes technology.
Introduction
Solnhofer Portlandzementwerke (SPZ) was founded on
13 May 1933. Known worldwide for spectacular fossil
findings, Solnhofen limestone from the Jurassic period
forms the raw material basis for the production of
premium cements. SPZ operates a modern 4-stage heat
exchanger with a capacity of roughly 1200 tpa.
The product range comprises Portland cement,
Portland composite cement, furnace cement and
binding agents. Furthermore, the medium-sized family
business operates in the areas of natural stones,
ready-mix concrete, precast concrete components and
track construction.
Alternative fuels as a challenge
The high proportion of alternative fuels poses a
considerable challenge to the production process. In
addition to coal, a mix of RDF (refuse-derived fuels
containing plastics), animal meal and flyash is currently
used. The share of refuse-derived fuels adds up to
around 60%, corresponding to the German average.
According to the German Cement Works Association
(Verein Deutscher Zementwerke, VDZ), in 2013, 62.5% of
Figure 1. View of the heat exchanger and the rotary kiln
of the Solnhofen cement plant.
Figure 2. Bullnose with severe damage after 7 months in
operation. Lining with a hydraulically bonded low-cement
high alumina gunning mix with additives of zirconium
oxide and SiC.
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\ World Cement
the energy contained in fuel was covered by alternative
fuels in German cement plants. The related introduction
of volatile components such as chlorine, sulfur and
alkalis is not unproblematic for stable operations of the
plant. Over time, these components can accumulate in
the kiln atmosphere and can severely disrupt operations
by forming coatings and by causing premature wear
of the refractory lining and corrosion of the kiln shell
and anchors. One of the procedural measures taken
to counteract this is the use of a bypass, which allows
for the reduction of chlorine content in hot meal to a
controllable level.
Nonetheless, some areas of the refractory lining are
exposed to significant chemical attack due to the high
concentration of alkali salt. Particularly critical areas in
the cooler include the bullnose and the clinker bed, as
well as the inlet chamber and the riser duct. Moreover,
the rotary kiln burner also causes significant problems
for the plant as, in the past, the monolithic lining had to
be replaced every 6 to 10 weeks.
The areas described are generally lined with
monolithics. Despite numerous tests with various
products made by different manufacturers, lifetimes of
up to only 7 months were accomplished in the critical
areas.
In some areas of the rotary kiln, Solnhofen
already relies on refractory materials produced by
RHI AG, a globally operating full-range supplier of
high-grade refractory materials for the cement industry.
ANKRAL QF, for example, is successfully used in
the highly stressed and critical sintering zone in the
area of the middle tyre. However, RHI also offers a
comprehensive product portfolio of mixes, including
the newly developed no-cement refractory castables.
After numerous successful applications of sol mixes
in the German cement industry, which uses the highest
percentage of alternative fuels worldwide, the new
mixes technology was also utilised in the critical
areas at Solnhofen. This new development consists
of chemically bonded no-cement mixes, which display
Figure 3. Bullnose lined with CARSIT SOL M10G-6 after
joint maintenance. No significant wear observable after
15 months in operation. The mix remains in the cooler
without any repair measure.
outstanding properties due to the novel type of bond. put into operation without pre-drying in February 2013.
As these mixes are solely chemically bonded and not Due to the special chemical bond and the different
hydraulically bonded, they do not have to be pre-dried pore structure in comparison with hydraulically bonded
and can consequently be heated quickly without the risk mixes, no separate pre-drying was carried out. Moreover,
of a steam explosion. The firing schedule of 36 hours, it was possible to start up the rotary kiln in 36 hours.
which is usually recommended for rotary kilns, is An intermediate inspection in September 2013 after
more than sufficient to bring sol mixes to operating 7 months of operation showed the lining still in perfect
temperature safely without prior drying. Moreover, the condition (the area usually had to be fully renewed after
absence of cement leads to an increase in hot strength 7 months). The kiln was finally shut down for major
and chemical resistance. Based on easy handling and repair in June 2014. The inspection of the bullnose again
better physical and chemical properties in comparison showed a very positive picture. After another 8 months
with hydraulically bonded mixes, the use of this in operation, no significant difference was identified
technology can increase kiln availability significantly compared with the previous kiln shutdown (Figure 3).
due to a faster startup of the kiln (no pre-drying, faster This was a good result (the service life has already
heat-up compared with cement-bonded mixes) and been at least doubled), especially considering that the
significantly longer service lives. conventional gunning method was applied. As there
was hardly any wear detected within the first 15 months,
Bullnose a forecast regarding the definitive service life is not
The high portion of alternative fuels alone is a challenge possible at present.
for the refractory material due to the increased Despite the slightly higher cost of sol-bonded mixes,
chemical stress and the properties of the fuels, which they bring considerable advantages for cement plants,
naturally fluctuate more strongly. In addition, the clinker which make the sol technology a very economical
produced shows a silica modulus between 2.9 and 3.2 solution if considered closely. The benefits result
and an alumina modulus of 2.11 to 2.18, with a lime
standard of 97 – 99. Accordingly, the melting phase Figure 4. Clinker bed with CARSIT SOL S30-6 after
content in the clinker is low, with values of 22 – 24% 15 months.
at 1450 ˚C. The clinker is therefore considered hard
burnable, which indicates higher thermal stress on the
refractory material. As the volatility of alkali salts also
heavily depends on temperature, this means not only
higher thermal stress for the refractory lining, but also
increased chemical stress.
One of the particularly critical areas is the bullnose.
Here, maximum lifetimes of 7 months were realised
with various different refractory concepts in the past.
The mixes were dried and heated according to the
manufacturers’ specifications. The drying schedule
applied for the kiln hood and the cooler took at least
88 hours, including a 24-hour setting time. The lining
is gradually heated up to 400 ˚C and this temperature
is maintained for 12 hours. The material is dried using
gas-fired auxiliary burners. After 7 months of operation, Figure 5. COMPAC SOL MB A100-15 after 7 months in
low-cement hydraulically bonded gunning mixes based operation.
on bauxite and additives of zirconium oxide and SiC
already showed severe damage (Figure 2) so that the
area had to be repaired.
In January 2013, the entire bullnose was lined
with CARSIT SOL M10G-6. This chemically bonded
mix developed by RHI AG is a no-cement sol-bonded
gunning mix on the basis of mullite, with an additive of
10% SiC. The newly developed sol gunning mixes were
applied without any problem by Möller Feuerfesttechnik.
The responsible project manager, Sascha Schultheis,
confirmed that the workability of both the sol gunning
and casting mixes was excellent. In this process,
the equipment normally used for the application of
cement-bonded dry gunning mixes is employed, with
the exception of pumping the binder, for which a
commercially available pump is required. The area was

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World Cement
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from the extended operating time (currently already
doubled), which saves not only material costs, but also
installation costs. Moreover, the use of sol-bonded
mixes does not require any pre-drying of the monolithic
lining, so shutdown times and fuel costs can be
reduced. An additional firing schedule, which prolongs
the shutdown, is not necessary either, thereby saving
time and costs.
Clinker bed
Due to the direct contact with the clinker, which is still
hot, the clinker bed is subject to high, especially hot
abrasive stress. In addition, the components, some of
which are massive, are difficult to dry and heat. Both
represent a nearly ideal application for sol mixes.
Previously, a maximum service life of 12 – 15 months
could be attained using different high-grade low-cement
castables. Severe damage was already identified after
7 months. With CARSIT SOL S30-6, an andalusite
mix with 30% SiC based on sol bonding, this can be
increased significantly.
After operating for 15 months (Figure 4), no
significant wear was identifiable. The clinker bed
lining is still in operation and has already reached the
previous lifetime. Consequently, this material also lends
itself as a substitute for prefabricated components,
which are often used in this area.
Rotary kiln burner
Despite professional installation and exemplary
pre-drying of the monolithic lining, during which
the burner lance is heated up to 450 ˚C in 72 hours,
lifetimes of only 6 to 10 weeks maximum were
achieved. Most recently, low-cement high alumina
castables based on corundum were applied. The
refractory lining is exposed to a complex combination
of different wear mechanisms in this area. The hot,
dust-loaded secondary air leads to thermal and hot
abrasive wear. Moreover, deposits of alkali salts are
formed, causing additional hot chemical attacks. As
thermal wear was assumed to be the main problem,
COMPAC SOL MB A100-15 was used in a first trial. This
is a highly refractory, high alumina no-cement mix. The
castable displays excellent refractoriness and at the
same time improved chemical resistance compared to
the low-cement castable previously used. Finally, the
unique cold crushing strength of 180 N/mm2 after firing
at 1000 ˚C was also convincing.
The burner tip was initially put into operation in
December 2013 and was not renewed until June 2014
as part of the scheduled major repair (Figure 5). A
service life of 7 months was immediately achieved.
Inlet chamber – riser duct
Although the wet gunning technique with sophisticated
pump technology was employed, a service life of only
7 months had been achieved in this area in the past.
Using a conventional gunning method (dry gunning),
only 4 – 5 months were accomplished. Due to the
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\ World Cement
high amount of alternative fuels used, high sulfur
and chlorine loads occur in the hot meal. Coating
formation can be largely controlled by means of
bypass operations and air injectors. The use of mixes
containing SiC also contributes to this. The alkali-
sulfur ratio varies between 0.79 and 1.66, so there is an
excess of alkali at times. This needs to be considered
for the refractory design. In order to counteract coating
formation and alkali bursting, CARSIT SOL M30G-6
was used. The 30% SiC sol gunning mix was applied
conventionally and achieved a service life of 7 months
in the critical areas in the zone influenced by the shock
blowers. As a result, the lifetime of the conventional
gunning mixes with a comparable raw material base
that had been used previously was improved by
2 – 3 months. In the less critical areas of the inlet
chamber, CARSIT SOL M30G-6 still shows nearly
original residual thickness.
New concepts for a further improvement of service
life in the inlet chamber are currently being developed.
Some newly developed sol products are already
available for this purpose. A considerable improvement
can be expected from the use of sol-bonded wet
gunning mixes such as CARSIT SHOT SB M10-3.
The wet gunning method, which has now also been
adapted to sol gunning mixes, enables a significantly
better compacting of the material during installation
and higher installation performance. Hence, improved
product properties and consequently better lifetimes
compared with conventional sol gunning mixes are to
be expected.
Moreover, the second generation of sol mixes is now
available – mullite-bonded sol mixes – which stand
out through a previously unattainable combination of
hot strength and resistance to alkali. This generation
has already been used very successfully on the burner.
On this basis, products for the hot areas of the heat
exchanger have also been developed.
Conclusion
With the use of alternative fuels, waste materials
can be utilised in an ecologically and economically
sensible way. Although the use of these materials
sometimes confronts the operators with challenges,
kiln technologies and refractory concepts that make it
controllable are now available. On the refractories side,
RHI, with its sol-bonded mixes, now offers products
that successfully meet increased requirements. This
has been demonstrated with service life records in the
most critical areas at Solnhofen (bullnose, clinker bed,
burner) and at many other cement plants in Germany.
The no-cement mix concept offers both superior
lifetimes and excellent workability.
RHI will continue to work on further developing
the sol technology. Special attention will be paid to
combining outstanding refractoriness, hot abrasion
and chemical resistance, in particular against alkalis.
With the second generation of sol mixes, products with
further improved properties are now available.