Cement Kiln Refractory

Acid Refractories: Any types of alumina silicate refractories (like fire bricks, alumina brick, high alumina
bricks, silimanite bricks) and silica refractories are called acid refractories. Since silica is an acidic oxide
and it is one of the main component for the bricks mentioned as above, these bricks are called acid
refractories.
Basic Refractories: Refractories having MgO or CaO (Basic Oxides) as major component are called basic
refractories. All types of magnesite brick (direct bonded, spinel bonded), mag-chrome, Chrome-
magnesite and dolomite bricks are the example for basic bricks. Spinel has a general
formula AB2O4 , where A is di positive ion like Mg+2, Fe+2, Mn+2 etc.; B is tri positive ion like Al+3,
Fe+3, Cr+3 etc. and O is oxygen
Special Refractories: Zirconia (ZrO2) based refractories and silicon carbide (SiC) based refractories are
the example of special refractories. The thermal conductivity of silicon carbide refractories are very high
and hence proper insulating layer should be used as back up lining. At high temperature silicon carbide
transform to silica in oxidizing atmosphere.
SiC + O2 = SiO2 + CO
This transformed silica (SiO2) forms a vitreous layer on the exposed surface of the refractory which acts
as a impervious layer resulting minimization of coating build up on the surface.
Zirconia on the other hand has lower thermal conductivity compared to alumina brick and is not wetted
by molten metal. Zirconia has anomalous expansion due to polymorphic transformation, hence need to
be stabilized before use as a refractory material.
Important properties of refractory are given below:
1. PHYSICAL PROPERTIES:-
 Bulk Density (BD)

 Apparent Porosity (AP)
 Cold Crushing Strength (CCS)
 Cold Modulus of rupture (MOR-Cold)
2. Thermal Properties:-
 Refractoriness Under Load (RUL)

 Pyrometric Cone Equivalent (PCE)
 Permanent Linear Change After Re-heating (PLCAR)
 Thermal Conductivity (TC)
 Spalling Resistance (SR)
 Hot Modulus of Rupture (MOR-Hot)
 Reversible Thermal Expansion (RTE)
Refractory used for different zone in kiln

Discharge zone: This is also known as cooling zone. The length of discharge zone depends on
the position of burner pipe tip. Generally, it is 0 -1 times of kiln diameter i.e. for 4 meter dia. kiln, the
length of this zone would be approx. 4 M. There will not be coating in this area. The brick used for this
area should have high abrasion resistance. High alumina brick or spinel bonded magnesia brick is
suitable for this area.
Lower Transition Zone: The area in between cooling and burning zone is called lower transition zone.
The length vary from 1 - 2 times of kiln diameter. In this zone the coating formation on brick is unstable.
Hence the brick used in this zone should have high resistance against spalling, abrasion and chemical
corrosion. Spinel bonded or hercynite bonded magnesia brick can be considered suitable for this zone.
In case of very severe kiln condition (high redox condition and high chemical corrosion) zirconia based
magnesia brick may be considered.
Burning zone: The most important area of kiln where stable coating is observed is called burning or
sintering zone. The length of this zone vary from 3 times the kiln dia up to 5 times the kiln dia. The
refractory used for this area should have high temperature resistance and high chemical corrosion
resistance. In low the alkali environment mag-chrome brick is suitable, but in high alkali environment
hercynite bonded or spinel bonded magnesia brick is suitable for this area.
Upper Transition zone: The area in between burning and calcining zone, where unstable coating is
formed, is denoted as upper transition zone. The length of this zone can be 2 - 3 times of kiln diameter.
Due to instability of coating in this zone, the bricks having high thermal shock resistance should be
used. Hecynite bonded or spinel bonded magnesia brick is suitable for this area.
Calcining zone: The area between upper transition and kiln inlet is named as calcining zone. When the
calcined raw meal enters the kiln it is usually calcined up to 92-96 %. Rest of the calcination of kiln feed
takes place in this area. The length of this zone is 7-8 times of kiln diameter. Generally no coating is
found in this area. The brick used for this area should have high spalling resistance and resistance
against alkali sulfates and chlorides. Clog shape high alumina brick having 60 & 50 % alumina is suitable
for this area. While using high alkali loading in kiln, Phosphate bonded alkali resistant bricks are also
recommended.
Effect of different properties on spalling resistance of brick :
 Grain size and percentage of coarse fraction present in the matrix of brick has critical role on
spalling resistance. Higher the percentage of coarse fraction and higher the grain size higher will
be the spalling resistance.
 Lower thermal expansion of brick will give better spalling resistance.
 Bricks having low porosity and moderate CCS will be beneficial for obtaining good spalling
resistance.
 If severity of application temperature is compatible with the refractoriness of lower alumina
containing brick, it should be beneficial to use lower alumina containing brick instead of higher
alumina brick.
 Upper limit of alumina content and CCS are also important for achieving good spalling resistance
of brick.
Mortar Lining - Advantage & Disadvantage :
Advantage: Mortar lining helps to improve the stability of construction/ laying. It will also compensates
for slight variation of dimension and warpage of bricks. During heating, mortar gets sinter and adhere
with brick surface to give monolithic (joint free) structure. In tire area and in the kiln ovality area, mortar
lining will have the advantage to digest extra mechanical stresses due to its monolithic structure. In tip
casting area brick should be laid with mortar, so that brick will not come out from the ring due to
loosening of ring during bell-mouth effect of kiln shell. Mortar lining will also reduce the possibility of
shell corrosion, since alkali salt penetration through brick joints will be minimized due to monolithic
structure. Mortar lining will also adjust the expansion of brick structure, hence all the brick work in other
area like preheater, cooler, TAD and hood should be mortar lining.
Disadvantage: Mortar on sintering have tendency to shrink, hence usage of mortar should be avoided
during laying in kiln having lower thermal expansion. Because of lower thermal expansion of alumina
brick containing 50% or lower alumina, mortar lining should be avoided in kiln, otherwise on sintering
brick ring may get loosen. Mortar lining in kiln will consume more time during laying.

Cement Kiln Refractory

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Cement Kiln Refractory

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Acid Refractories: Any types of alumina silicate refractories (like fire bricks, alumina brick, high alumina

Important properties of refractory are given below:

 Bulk Density (BD)

 Refractoriness Under Load (RUL)

Refractory used for different zone in kiln

Effect of different properties on spalling resistance of brick :

Mortar Lining - Advantage & Disadvantage :

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