Cement Industry

CEMENT KILN PREHEATER

RISER DUCT( Calsil + Brick/Castable)
Stages I- III
Roof : FIRECRETE Special/ Accmongun BF
Rest: AC 40
Stages IV-VI
Roof : WHYTHEAT C Spl/ Accmongun BF
Rest: AC 40 ; Why C Spl; Accmon 45, Accmon CRC
CYCLONE (Calsil + bricks/castables)
CALCINER Roof : AC 40, Flowmon 45.
AC 40D / Accmon 45/ Accmon
Side Wall & Cone : AC 40 ; Accmongun
CRC/ Accmon CAR
BF, Firecrete Spl. / Why C Spl
MEAL CHUTE / FEED PIPES
Stages I- III – Whytheat C SPL
Stages IV-VI – Accmon CRC/ WHYTHEAT C
SPL
 CEMENT ROTARY KILN
TIP CASTING
LOWER TRANSITION ZONE RISER DUCT
BURNER PIPE
AC 70 S / MAG AL SPINEL ACCMON CRC
ACCMON CRC
TERTIARY AIR DUCT
AC CAR / Accmon
CAR

Burner Pipe
Accmon CRC

BURNING ZONE UPPER TRANSITION Z ONE CALCINING ZONE

AC 70S/ AC 70S / MAG AL SPINEL REFRATHERM
 CEMENT KILN COOLER
COOLER COLD ZONE PREDUSTER
ROOF & SIDE WALL: AC 40 ; ACCMON 45 ROOF: AC 40 / AC CAR

BOTTOM : ACCMON 45 ;ACCMON GUN 60 WALL : ACcmon 45/ Accmon

CAR
CONE : Accmon 45

COOLER HOT ZONE

I-Accmon CAR / Accmon 45/AC 40D
Bull Nose – Accmon CRC ( BN) & Cer.
PREDUSTER OUTLET Anchor
Whtheat C SPECIAL Roof : Ac 40 D / Ac CAR
Throat – AC 40 D / Accmon CAR
New Innovative Monolithic
Solution for Critical Areas
 Goals Ahead of the Indian
Cement Makers

• Energy Conservation
• Usage of Alternate Fuels
• Avoid Shutdowns
• Increase Production by Modification /
Up - Gradation / De - Bottlenecking
 Result of Increased Kiln
Capacity

• Operation Has Become Complex

• Increased Air Velocity and Temperature
• Secondary and Tertiary Air is Dustier
• Alkali Build Up
 Impact On Refractory?

Increased Demand for Lesser

Shut Down Due to Refractory
Failure
 Developmental Process

• Areas With Below Par Performance

• Analyse the Cause
• Improve Relevant Properties
 Minor Constituents
Problems
• Self - Enrichment of Volatiles in the
Kiln System
• Potassium Compounds are Major
Concern
 The Results

• Alkali Enriched Raw Meal Adherence

on the Refractory Surface
• Vulnerable Temperature Range Is
800 – 900 0C
 Monolithics for Other Areas

• Better Abrasion Resistance

Therefore,
– Kiln Inlet
– Kiln Outlet
– Grate Cooler Take off Duct
Wear Resistant Parameters
REDUCING INCREASING

PROPERTIES
CRYSTALLITE SIZE
DENSITY

HARDNESS
FRACTURE TOUGHNESS
Thermal Shock Resistance
REDUCING INCREASING
PROPERTIES
Thermal Expansion
MOR
Elastic Modulus
Fracture Toughness
Thermal Conductivity
 ACCMON CAR
A Low Cement Castable for Take Off
Duct, Duct Bends etc.
Characteristics of ACCMON CAR
– Good Strength
– Excellent Abrasion Resistance (< 1 cc)
– Ease of Application
– Minor Property Variation With Increased
Water
 ACCMON CRC

• LOW CEMENT CASTABLE – BEST

THERMAL SPALLING RESISTANT
• VOLUME STABLE
• GOOD ABRASION RESISTANT
• BEST ANTI COATING PROPERTY
• ALKALI RESISTANT.
 APPLICATION AREAS

• ACCMON CRC ( TC ) – TIP CASTING

• ACCMON ( BP ) - BURNER PIPE
• ACCMON ( BN ) – BULL NOSE,
COOLER SIDE WALLS
• ACCMON CRC – RISER DUCT, SMOKE
CHAMBER, KILN INLET WHERE
ALKALI COATING IS PROMINENT.
 ANTI COATING PHENOMIMA
OF CRC
• REACTS WITH ALKALIES PRESNT IN THE
RAW MEAL / FUEL
• MELTS AT TEMP OF 800 DEG. C
• GLASS FORMATION ON THE SURFACE
• MAKE THE LINING IMPERVIOUS
• DOES NOT ALLOW STRONG COATING /
BUILD UPS.
• EASILY DISLODGEABLE
• NO DAMAGE TO THE REFRACTORY.
Refractories for Energy
Conservation in Cement
Industries.
 Introduction
Indian Cement Industry is under
consistent pressure to be cost
effective.

• Energy consumption has been

targeted to be below 700 KCal
• Power consumption has been
targeted to be below 70 KWH
In 1990 itself , we identified this need
and in technical collaboration
introduced

“REFRATHERM ACE” .
The locations identified are,
• Calcination zone of Cement Kiln.
•
•
Refractory to address above Concerns..

• Calcination zone of Kiln- Refratherm

ACE bricks. These bricks are used by
nearly 60 % of the Indian Cement Kilns
in last 14 years.
• The performance of Refratherm bricks
is not affected by fuel, RPM, raw mix &
out put.
•
 Product capabilities to address
concerns at these zones.
• Lighter weight-lower lining weight, lower thermal
conductivity-less heat transfer through kiln shell.
• Chemically bonded- better alkali resistance, finely
porous structure-better thermal shock resistance.
• Sufficiently high crushing strength to withstand
mechanical abrasion.
• Reduction in shell temperature 50-90 deg C
achieved. This has effect of 8-9 K Cal/kg of clinker
produced in smaller kilns.
• This saving increases to 12 to 18 K Cal/kg of
clinker burned for dry process kilns.
Thus we recommend to use,

Refratherm ACE Bricks for the

Calcination zone of Cement Kilns,
We can work out Refractory requirement
for the different region Kiln wise to
optimal maximum Refractory
performance.
APPLICATION OF

REFRACTORIES
Selection of Refractories

ACE Calderys ltd

 Why Refractory lining is required ?

To protect the Furnace/ Kiln Shell from the

influence of flame/heat
To protect the kiln shell from raw material/ end product
impact
Reduction of heat losses from the furnace by insulation
Protect the shell from reaction by the material handled
inside the kiln
Efficient transfer of thermal energy from hot gases to the
reactants
 Selection Criteria of REFRACTORIES
To protect the Shell from the High Service Temp,
influence of heat/temp (Melting point)
To protect the kiln shell from High CCS, B.D, MOR,
impact or abrasion (Abrasion resistance)
To Protect the material handled Non reactive, Inert,
(Corrosion resistance)
Reduction of heat losses Thermal Conductivity

Efficient transfer of thermal Emissivity

energy
Note: Reversible thermal expansion, PLC
 IMPORTANT PROPERTIES OF REFRACTORIES

Ambient Condition High Temperature

•Specific Gravity •R U L
•Bulk Density •PCE
•Porosity •HMOR
•Cold Crushing Strength •Thermal Conductivity
•Abrasion •Spalling
•PLC
INSTALLATION OF THE REFRACTORY
CASTABLES

• Installation is very important and Performance

of Refractories depend greatly upon the quality
of Installation.

• Performance can be improved by almost 30% to

40% by proper Installation.
 SEQUENCE

• Correct batching and mixing of materials

• Anchoring and Welding
• Coating of Anchors
• Form Work
• Expansion and Construction Joints
• Placement & Compaction
• Wet Curing
• Heat Maturing
• To get the maximum performance each of above points is
equally important.
 ANCHORING

A) Types as per suitability

B) Spacing
C) Coating
D) Welding
E) Checking of Welding
 ANCHORING
B) COVER & SPACING
•Cover- between Anchor & Hot face and it should
be 30mm to 50mm.
Y

•Spacing depends upon thickness of castable/

Thickness of Anchor:
Y Y
 EXPANSION JOINTS
•Size of expansion joints is computed as followed-
Thermal expansion=Coeff of TE +PLC
•If it is negative ,no expansion joints are required.
•If it is positive , expansion joints are required
 CONSTRUCTION JOINTS
•Aluminous castables usually shrink during
post installation drying or when cooled
after heating,to protect lining from
damage,separation joints are left (~2- 3
mm/ sqr mtr )
 MIXING AND PLACING
•Use of pan mixer is must for mixing.
•Use of recommended water is very
important as even 1% excess water can
reduce the strength by 30%.
Mix the castable for 3-5 minutes to get
the correct workability
Place it within 15- 20 minutes after
mixing ACE Refractories
 CURING OF CASTABLES

•Castable Refractories develop 90% of the

strength within 24 hours of application.During
this period, heat of hydration will be high. ,To
control this, water curing is needed to maintain
the surface moisture level.
•Curing is done by keeping water saturated cloth
or gunny bags over exposed castable surface.
•Low cement castables can be cured by covering
it with polyethylene film.
INITIAL HEAT- UP FOR CASTABLES

For CONVENTIONAL CASTABLES

• Up to 110*C- @ 20-25*C/Hr
•Soaking at 110*C for 12-24 Hrs depending upon
thickness
•From 110*C-550*C @30-40*C/Hr
•Soaking at 550* C for 12-24 Hrs
•From 550*c to working temp @ 50*c/Hr
 INITIAL HEAT- UP RATE OF CASTABLES

Heat Up Schedule for ACE Castables

1200

1000
Temp Deg C

800

600

400

200

0
10

11

12

13

14

15

16

17

18

19

20
1

Time in Hrs
THANK YOU