Refractories For The Cement Industry
Refractories For The Cement Industry
Refractories For The Cement Industry
Contents
1
Preheater
Cyclones & connecting ducts Calciner Riser duct Smoke chamber Meal pipes 8 13 15 16 17
Kiln hood
Kiln hood 18
Conversion tools
Conversion tools 27
How to contact us
Hgans Bjuf is headquartered in Bjuv, Sweden, with subsidiaries in France, Germany, Poland, Russia, the Middle East, Malaysia and the Philippines, and agents and representatives around the world.
Hgans Bjuf AB
Box 502 SE-267 25 Bjuv Sweden Tel: +46 42 855 00 Fax: +46 42 855 66 Business hours: M-F, 08-1630 CET To find your local contact, please call or fax us at the numbers above. Up-to-date contact information can also be found at: www.cement.hoganasbjuf.com
Affiliated manufacturers
In order to provide you with comprehensive refractory solutions, Hgans Bjuf works closely with producers of complementary refractory materials and the other components necessary for refractory installations. Our global network of approved suppliers guarantees you qualified refractory installations.
1. Preheater 2. Kiln hood 3. Cooler 4. Tertiary air duct The kiln is presented in a separate brochure
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Each stage in the cement-making process places unique demands on the refractory lining. Your refractory selection is influenced by your choice of raw meal, the type(s) of fuel you burn, and your kilns design- and operating characteristics. From raw meal to ready clinker, you will find a chapter covering each primary stage in the cement
making process, with our suggestions for how to achieve long-lasting, cost-effective refractories. For each stage we present solutions for both standard and alternative-fuel installations. The process- and external shell temperatures noted are statistical approximations, and are based on an ambient temperature of + 20C.
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Preheater
2. Preheater
1
1. Cyclone Stage 1 2. Cyclone Stage 2 3. Cyclone Stage 3 4. Cyclone Stage 4 5. Cyclone Stage 5 With connecting ducts and calciner
2 3
Preheater
Plant design has evolved rapidly since the beginning of the 20th century, to meet the needs of modern cement production. The preheater system is now a major factor in efficient cement production, thanks to growing production volumes and increasing energy costs. Its design and complexity have evolved rapidly. These advances deliver both capacity and energy benefits. Todays dry process kilns, coupled to multiple-stage preheater systems, offer 20 times more capacity than similarly sized wet-process kilns. The thermal efficiency and capacity of a modern cementmaking operation is very high. But it can be even higher. On the following pages, we deal specifically with the following areas of the preheater: Cyclones (including connecting ducts) Calciner Smoke chamber and riser ducts Meal pipes
Preheater
Preheater
Build-ups
Usually caused by chemical attack, in combination with venturi effect in the cyclones complex design, build-ups can also be caused by rapid temperature drops the result of, for example, air leakage. Build-ups reduce cyclone efficiency, and their removal ultimately requires a production stop. Regardless of the method used, removal is dangerous work. In the most severe cases, explosives are used. Several mechanical alternatives exist, none of which is particularly satisfactory: Manual removal is time consuming, ineffective and unsafe. Waterblast, though effective, requires production stoppage and exposes linings to severe thermal shock. Air canons place high demands on the strength of the refractory installation. The best option, however, is a refractory that eliminates or minimizes build-ups, such as Denscast Sicto. In very severe problem areas, this solution can be advantageously combined with air canons.
Riser duct lined with 561 Denscast SIC 30
Regular test are done for measuring alkali penetration. The photo shows Bjuf SX extremly good resistance against alkali.
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Preheater
Brick or monolithic?
It is commonly believed that casting, gunning and shot-gunning are faster, and therefore less expensive than installing bricks. The simple truth is quite the opposite. Brick is simple to install and ready to use immediately unlike castables, gunnables and other monolithics. It is a finished product pressed, fired and quality-controlled before delivery. Kilo for kilo, it offers a more cost-effective solution than a monolithic with the same properties. We therefore suggest you use brick or precast wherever possible, unless a monolithic solution offers the most important refractory characteristics.
Estimated time in man hours needed for installing 1 m2 of lining. Wall thickness 215 mm (100 mm insulating & 115 mm hot face)
2.5 h 2.0 h 1.7 h 1.4 h Installation time Molding Insulating Welding 16 anchors 0.5 h Welding 5 anchors Preparation time Casting with anchors Gunning with anchors Shot gunning with anchors Bricking with anchors Bricking only
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Preheater
CYCLONE STAGE 1
Refractory lining thickness: 114 mm Process temp ~ 306 0C External shell temp ~ 97 0C
BRICK STANDARD ALTERNATIVE FUELS MORTAR MONOLITHICS ANCHORS INSULATION
H15 H15
Solcast/ Solgun
Stainless steel SIS 2368/ Ceramic Stainless steel SIS 2368/ Ceramic
None
CYCLONE STAGE 2
Refractory lining thickness: 114 mm Process temp ~ 503 0C External shell temp ~ 142 0C
BRICK STANDARD ALTERNATIVE FUELS MORTAR MONOLITHICS ANCHORS INSULATION
H15 H15
Solcast/ Solgun
Stainless steel SIS 2368/ Ceramic Stainless steel SIS 2368/ Ceramic
CYCLONE STAGE 3
Refractory lining thickness: 146 mm Process temp ~ 665 0C External shell temp ~ 132 0C
BRICK STANDARD ALTERNATIVE FUELS MORTAR MONOLITHICS ANCHORS INSULATION
H15 H15
Stainless steel SIS 2368/ Ceramic Stainless steel SIS 2368/ Ceramic
CYCLONE STAGE 4
Refractory lining thickness: 180 mm Process temp ~ 806 0C External shell temp ~ 155 0C
BRICK STANDARD ALTERNATIVE FUELS MORTAR MONOLITHICS ANCHORS INSULATION
H15 H15
Stainless steel SIS 2368/ Ceramic Stainless steel SIS 2368/ Ceramic
CYCLONE STAGE 5
Refractory lining thickness: 230 mm Process temp ~ 890 0C External shell temp ~ 134 0C
BRICK STANDARD ALTERNATIVE FUELS MORTAR MONOLITHICS ANCHORS INSULATION
H15 H15
Stainless steel SIS 2368/ Ceramic Stainless steel SIS 2368/ Ceramic
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Preheater
Calciner
Re-cycling heated air delivered from the grate cooler via the tertiary duct, the calciner dramatically improves thermal efficiency in the cyclone system. It also reduces fuel costs by optimizing the use of cheaper waste and low-grade alternative fuels. However, there are some special considerations for lining the calciner, and appropriate refractory precautions must be taken when burning waste fuels. Because of higher operating temperature, chemical attack is a more severe problem in the calciner than in the cyclones. High refractoriness and good resistance to thermal shock are also necessary, especially around the burner blocks. Correct insulation is important, but risk of chemical attack must also be considered. High operating temperature combined with the dense calciner refractories can lead to substantial heat loss if insulation is insufficient. The optimal solution must balance this against the risk of chemical attack.
Brick or monolithic?
Because of the high temperatures and chemically aggressive atmosphere of the calciner, we suggest you use only brick lining. If the decision is made to use monolithics in the roof section, remember that high temperatures require refractories with high refractoriness and hot strength. Clinker dust transported through the tertiary duct also requires that these refractories have high abrasion resistance. The Hgans Bjuf range of castables meets all these requirements.
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Preheater
114 mm Viking 330/ H15 114 mm Bjuf SX 114 mm Viking 330/ H15 114 mm Bjuf SX
Denscast 50A QF Stainless steel SIS 2368/ 65 mm Calcium silicate 1100 Ceramic Stainless steel SIS 2368/ 114 mm Porosil G2 Ceramic and CoroTexPro
114 mm Viking 330/ H15 114 mm Bjuf SX 150 mm Alsic 500 H15
Stainless steel SIS 2368/ 65 mm Calcium silicate 1100 Ceramic Stainless steel SIS 2368/ 114 mm Porosil G2 Ceramic and CoroTexPro
CALCINER CONES
Refractory lining thickness: 254 mm Process temp ~ 1,100 0C External shell temp ~ 156 0C
BRICK STANDARD MORTAR MONOLITHICS ANCHORS INSULATION
H15
ALTERNATIVE FUELS
H15
Start each cone section by setting a ring of refractory brick at the narrowest section of the cone. This provides a foundation for subsequent bricking.
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Preheater
Riser duct
The riser ducts recycle heated air from lower cyclone stages and the kiln itself, thus improving thermal efficiency and reducing fuel costs. The refractory choices, which are straightforward, are listed below. Riser ducts often have build-up problems. In the lower, hotter part of the cyclone system, chemical influences are the cause, and can affect both straight and curved duct sections. Higher up, build-ups are usually caused by a venturi effect, occurring mostly in the curved section of the duct. The closer the duct is to the hot end of the cyclone system, the greater the risk of alkali penetration and refractory spalling. Where alkalis have penetrated (which they do to a depth of 20-30 mm), the refractory can expand 10 times more than normal, causing spalling. If this process is allowed to continue, the wall can collapse. To keep alkaline vapor from condensing, reduce the amount of insulation used.
RISER DUCT
Refractory lining thickness: 230 mm Process temp ~ 1,000 - 1,100 0C External shell temp ~ 100 - 150 0C
BRICK STANDARD ALTERNATIVE FUELS MORTAR MONOLITHICS ANCHORS INSULATION
114 mm Viking 330/ H15 114 mm Bjuf SX 114 mm Viking 330/ H15 114 mm Bjuf SX
114 mm Denscast 50A QF Stainless steel SIS 2368 and CoroTexPro/Ceramic 114 mm Denscast 50A QF Stainless steel SIS 2368 and CoroTexPro/Ceramic
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Preheater
Smoke chamber
The smoke chamber is subject to all the worst exposure that cement manufacturing can cause, such as alkali attack, build-ups, anchor corrosion and high temperatures (~1300C). The refractory choice is simple: a high-density, low-cement castable such as Denscast 50 A QF, or Denscast SIC 30, to ensure long and trouble-free operation. In some locations, you can also use Denscast Sicto.
SMOKE CHAMBER
Refractory lining thickness: 254 mm Process temp ~ 1,100 0C External shell temp ~ 156 0C
BRICK STANDARD MORTAR MONOLITHICS ANCHORS INSULATION
H15
ALTERNATIVE FUELS
H15
114 mm Denscast 50 A QF Stainless steel SIS 2368/ 65 mm calcium silicate 1100 Ceramic and CoroTexPro at the shell, followed by 75 mm Porosil 23 140 mm Denscast SIC 30 A-bricks and stainless 114 mm Porosil G2 or Denscast Sicto steel SIS 2368 /Ceramic and CoroTexPro
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Preheater
Meal pipes
The meal pipes that connect different cyclone stages usually have small diameters. They may be lined with either brick or castable. Bjuf SX brick and Solcast castable are the natural refractory alternatives. Because meal pipes usually come in short sections, their refractory lining can be pre-installed, to enable quick installation.
MEAL PIPES
Refractory lining thickness: mm Process temp ~ 0C External shell temp ~ 0C
BRICK STANDARD ALTERNATIVE FUELS MORTAR MONOLITHICS ANCHORS INSULATION
H15 H15
Solcast
(one ring only) Denscast 50 A QF Stainless steel 2368 (one ring only)
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Kiln hood
3. Kiln hood
Kiln hood
Low thermal conductivity and abrasion resistance are important for refractories at the kiln hood and burner lead-in. Waste fuels can make chemical resistance necessary too. An arched brick construction is the best refractory solution. We suggest the high-alumina Victor 60 RK brick. If hood design makes brick installation difficult, a good alternative is Denscast 50 A QF castable (or, when waste fuels are a problem, Denscast SIC 30 castable or Firebolt precast). Anchorex anchoring simplifies anchoring as well as subsequent wrecking.
KILN HOOD
Refractory lining thickness: 250 - 350 mm
MORTAR
PRECAST MONOLITHICS
ANCHORS
INSULATION
Firebolt
Stainless steel SIS 2368/ Ceramic Stainless steel SIS 2368/ Ceramic
18
Grate cooler
Clinker enters the cooler at a temperature of around 1,200C, rapidly spreading its heat into the grate and surrounding refractories. High refractoriness, high abrasion resistance and resistance to thermal shock are necessary, especially at the clinker downfall and bull nose. The cooler walls directly above the grate are also subject to extreme wear. The partition wall, designed to limit the inflow of cool air to the kiln system, must withstand the abrasive effect of clinker dust entering the tertiary air duct as well as the temperature fluctuations resulting from its exposed position.
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Grate cooler
The cooler is effectively divided into two zones the hot zone and the cold zone. In the first, from the clinker downfall to the bypass duct and partition wall, the goal is to rapidly liberate heat and route it back to the preheater via the tertiary duct. In the second, when clinker temperature has dropped below 800C, it is most important to achieve a uniform temperature decline throughout the clinker body. For dramatically extended refractory life and the fastest possible installation at the clinker downfall, bull nose, front sidewalls and roof, use Firebolt refractory precasts, which can be quickly bolted into place and just as quickly removed. For brick or monolithic alternatives, refractories should offer high refractoriness, abrasion-resistance and cold crushing strength. Bypass duct wear linings should be lined with Bjuf SX bricks and Denscast 50A QF castable in order to withstand the abrasive, alkaline effects of the tertiary airstream.
To maximize heat recovery, line the grate cooler and bypass duct with proper insulation materials. To achieve exceptionally long life in the partition wall separating the two zones, use Denscast 50 A QF refractory precast. Abrasion is the worst problem in the second section. The optimal refractory alternative is a brick such as Viking 330 or Bjuf SX, complemented by Denscast 50 A QF castable.
20
GRATE COOLER
- "HOT" zONE
ALTERNATIVE FUELS
Denscast 80 QF Stainless steel SIS 2368/ Ceramic Firebolt, Sicto, Denscast SIC 30 Stainless steel SIS 2368/ Denscast 80 Ceramic Firebolt Denscast 50 A
Calcium silicate 1100 at the shell, followed by Porosil 23 Porosil 23/ Porosil G
BULL NOSE
Refractory lining thickness: 300 - 400 mm Process temp ~ 1,000 - 1,200 0C
BRICK STANDARD MORTAR PRECAST MONOLITHICS ANCHORS INSULATION
Victor 60 RK
ALTERNATIVE FUELS
Victor 60 RK
Firebolt, Sicto, Denscast 80 QF Firebolt Denscast 50 A Firebolt, Sicto, Denscast SIC 30 Firebolt Denscast 50 A
Stainless steel SIS 2368/ Ceramic Stainless steel SIS 2368/ Ceramic
Calcium silicate 1100 at the shell, followed by Porosil 23 Porosil 23/ Porosil G
GRATE COOLER
- "COLD" zONE Refractory lining thickness: 200 - 250 mm Process temp < 800 0C
BRICK MORTAR PRECAST MONOLITHICS ANCHORS INSULATION
H15 H15
COOLER ROOF
Refractory lining thickness: 200 - 250 mm Process temp < 800 0C
BRICK STANDARD ALTERNATIVE FUELS MORTAR PRECAST MONOLITHICS ANCHORS INSULATION
Denscast 50 A QF Stainless steel SIS 2368 Denscast 50 A QF/ Stainless steel SIS 2368/ Denscast SIC 30 Ceramic
21
Denscast 50 A QF Stainless steel SIS 2368/ Ceramic Denscast 50 A QF Stainless steel SIS 2368/ Ceramic
22
Protect anchors against alkali attack Test conditions 48 hours 950 0C atmosphere K 2C03 + 10 % graphite Unprotected 15-18 % weight loss Coro Tex Pro-Coated 0-2 % weight loss Test piece of anchors can be seen to the left.
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Fire Bolt
Hgans Bjuf AB has registered the name FIRE BOLT as trade mark for our Prefab Areas such as: Preheater Riser Cooler (Clinker down fall area) (Bull nose) Kilnhood
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Conversion tools
Conversion tools
MEASUREMENTS
Metric to Imperial
Multiply cm meter (m) meter (m) liter kg metric ton m/sec
0
By 0.393 3.281 1.094 0.2642 2.205 1.102 1.94 1.8 0.06242 142.23 14.223 6.9347
To obtain inch feet yard us gallon pound (lb) short ton knots
0
C + 17.78
Imperial to Metric
Multiply inch feet yard us gallon pound (lb) short ton knots
0
By 2.540 0.304 0.914 3.785 0.454 0.907 0.515 0.556 16.02 7.03 x 10 -3 7.03 x 10 -3 0.144
F - 32
C + 17.78
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Our offices
HEAD OFFICE: Hgans Bjuf AB | Box 502 | SE-267 25 Bjuv | Sweden Phone: +46 42 855 00 | Fax: +46 42 855 66
www.cement.hoganasbjuf.com