Refractory Solutions for Critical Areas in Cement Kilns
Refractarios Especiales, S.A. P.I. Poyo de Reva – C/ Poniente, 6 – 1A bajo
46190 Ribarroja del Turia (Valencia), Spain [email protected]
Content:
I. Introduction
III. Applications
IV. Advantages & Savings V. Experience
1940: Foundation of Refractarios Especiales, S.A. - Refracta Company:
1997: New generation of qualities obtained
1993: Focus on cement industry R&D on special qualities
2006: Company moves to a new plant
2005: Refracta stops making traditional refractories, to produce only special qualities
• Superior raw material, special manufacturing process • Ta > 1600 ºC
• Low Porosity 12-14 %
• Excellent Chemical Attack Resistance • Extremely Abrasion resistant
• High Crushing strength
•Thermal Shock resistance 1. Bricks: R-2000
II. Products:
2. Castable: PF-97-H
• Ultra Low Cement Castable
II. Products:
• Superior performance, does not crack • Ta > 1600 ºC
• High Degree of Chemical Attack Resistance • Extremely Abrasion resistant
Advantages:
II. Products:
• Very long service life (2-3x more) • Alkali, chemical attack protection • Spalling protection
• Shell corrosion protection: less thickness loss and maintainence • Nose ring protection (longer service life of mechanical parts) • Solution for Rings, build ups and snowman
Alkali attack with a
standard alumina
brick
Result of:
chemical reaction between brick and alkalis
Consequences:
• formation of cracks within the brick and destruction lower lifetime
• kiln shell corrosion: infiltration of the alkalis penetrates to the kiln shell
reacting with H2O to corrosive acids
II. Products:
• Uneven (spalled) Surface leading to ring formation
Alkali attack with
magnesia spinel
bricks
Result:
infiltration of alkalis through the brick.
Consequences:
• cristalisation of salts (up to 30 % more volume!) Cracks on refractory
• kiln shell corrosion: infiltration of the alka-lis goes to the kiln shell and reacts with H2O to create corrosive acids
Alkali attack with
R2000
Result:
No infiltration of alkalis, no cracks No chemical reaction
Consequences:
- much longer lifetime
- better protection of the kiln shell against corrosion
- quick transport of material through the kiln (better process control)
UTZ up to kiln inlet
Advantages: No Rings, No Buildups, No Spalling, Long Service Life
no rings or build ups
II. Products:
• No Coating
• R2000 forms a glassy layer reducing porosity and protecting from infiltration
Advantages: •No Rings •No Buildups •No Spalling •Long Service Life
II. Products:
Alkali attack with PF-97-H
Tests realized under reducing conditions at CSIRO labs, Australia. Result after 96 h.
Result:
No infiltration of alkalis No chemical reaction
Consequences:
- longer lifetime
- minimized sticky substance formation
II. Products: Castable performance:
Holcim Lorca Bullnose - 1 yr result. No cracks PF97H on bottom, competitor on top
II. Products:
III. Applications
• Tertiary air duct /
Damper area
• Nose ring
• Outlet zone, retaining ring
• UTZ up to kiln inlet
• Grate and planetary cooler
• Inlet chamber
• Tertiary air duct/damper
area
R2000
PF97H
• Nose ring
• Riser / Calciner
• Cyclone roofs
• Inlet chamber / Cone
• Cooler / Bullnose
III A. Cement Kiln - Grate Cooler:
4. Other Areas: R-2000 and/or PF97-H 1. Outlet Zone : R-2000 and/or PF-97-H
2. UTZ up to kiln inlet: R-2000
1a. Nosering in PF-97H/R-2000:
Extremely good resistance against axial thrust from the other refractories caused by thermal expansion and gravity thrust of bricks
1b. Nosering in PF-97-H / R2000
1b. Nosering in PF-97-H / R2000
1b. Nosering in PF-97-H / R2000
1b. Nosering in PF-97-H / R2000
1c. Typical Outlet Profiles
1c. Typical Outlet Profiles
1c. Typical Outlet Profiles
1c. Typical Outlet Profiles
1d. Outlet Zone Samples in PF-97-H / R-2000
1d. Nosering / Outlet Zone - FLS type
kiln with grate cooler: R-2000 from 30-35 m - inlet
kiln with satelite cooler: R-2000 from 45-50 m - inlet
OZ LTZ BZ UTZ SZ CZ
0 30-35 m / 98´-115´
0 45-50 m
R2000 areas with chemical attack and kiln shell corrosion
2. UTZ up to kiln inlet
2. UTZ up to kiln inlet
2. UTZ up to kiln inlet
Holcim Orizabal 4 years and 3 months later
K1 11/02/2003
Ring 1 Ring 2
2 Rings in area 40-50 m 4.6m dia, 4800tpd, nsp, 3.3 rpm.
K1 08/05/2003
Ring 2
Holcim Mason City Install
Holcim Mason City 1 yr results and extension
Holcim Mason City 1 yr results and extension, no height loss
Holcim Mason City 2 yr results and extension, no height loss
Holcim Mason City 2 yr results and extension, no height loss
3. Grate cooler
Lining with R2000 in combination with castable PF97H:
• no cut bricks. Fill in with castables • anchored bricks to wall
• no build ups or snowmen • longer lifetime
IIIB. Cement kiln with planetary coolers:
3. Satellites:
1. Outlets/discharge ports: 2. Cooling zone:
5. UTZ up to kiln inlet: 4. Elbows: R-2000 R-2000 and PF-97-H R-2000 R-2000 R-2000 and PF-97-H
Planetary Coolers
Planetary Coolers
4. Other Areas
4. Other Areas
4. Other areas: Riser / Duct
• Real Infiltration resistance, chemical attack protection • Very high abrasion and impact resistance
• Encapsulation installation: insulation and anchor protection • Long service life in excellent conditions