Modern refractory layout of a new clinker burning unit

26th International REFRA-Training

Göttingen, June 3rd , 2015
Harald Merker (ME Mining)
Senior Manager Project Department
Refratechnik Cement GmbH
Agenda

Refractory layout of a cement plant

Anchoring

REFRA „AR-Lining Concept“

Final refractory engineering (overview)

approx. 60 drawings
for a project of this size
Detailed drawing, riser duct stage 4-3 (FLS)
Part list to detailed drawing
 Stage 1

Stage 2
Complete layout of a
clinker burning unit
Stage 3

Stage 4

Stage 5

Stage 6

TA-duct Calciner
Kiln Hood
Inlet chamber

Cooler Kiln
Temperature profile, FLS 5-stage ILC

source: FLS brochure

“Dry process kiln systems”
 preheater

stage I
gas duct II-I
310°C

stage II
bend II KHD 5-stage, 3.500tpd
gas duct III-II
500°C PYROTOP bend Gas temperatures
880°C
bend III PYROTOP compact

665°C stage III PYROCLON round

gas duct IV-III
bend IV

stage IV PYROCLON connection,

angular
790°C 950°C
connection to
gas duct V-IV tertiary air duct 1.200°C
inlet duct to 1.050°C
stage V 950°C tertiary air duct kiln hood dust chamber
dust chamber
880°C

bend 90° / stage V

grate cooler

rising duct 1.200°C

above inlet chamber
inlet chamber kiln burner
(sketch without raw meal ducts) Source:
1.200°C 1.000°C 500°C 250°C
Refractory layout, upper stage cyclones 1 to 3 (example)

Working lining:
KRONEX® 20
REFRACLAY 25 (MCG, JC)
REFRALITE® 40 (G), for cyclone 1

Insulating lining:
REFRALITE® 32 (G)
REFRALITE® 30 (G)
REFRALITE® 20 (G)
Calcium Silicate
Refractory layout, middle stage cyclones 4 and 5 (example)

Working lining:
KRONEX® 20
REFRACLAY 25 (MCG, JC)

Insulating lining:
REFRALITE® 32 (G)
REFRALITE® 30 (G)
REFRALITE® 20 (G)
Calcium Silicate
Refractory layout, bottom stage cyclone 6 (example)

Working lining:
KRONEX® 20
REFRACLAY 25 (MCG, JC)

Insulating lining:
REFRALITE® 40 (G) behind castable
REFRALITE® 32 (G) behind bricks
REFRALITE® 30 (G) behind bricks
REFRALITE® 20 (G) behind bricks
Calcium Silicate
Goose neck and Working lining:
falling duct
KRONEX® 20 Refractory layout,
REFRACLAY 25 (MCG, JC) calciner (example)
REFRACLAY 40 LCC/LCG

REFRALITE® 40 (G)
Insulating lining:

Calcium Silicate
Burnout- and
burner section
Working lining:
REFRACLAY 40 ZAR
REFRAMULLITE 63 MCG AR
REFRAMULLITE 60 LCG ZAR
KRONAL® 50 AR
Mixcrete
“lift off” of calciner head

The lift off is caused by

growing of refractories due
approx. 80mm to alkalis
Shell destruction

caused by growing of
Position of supporting flange inside refractories due to alkalis

Welding points of gussets

Shell destruction (cyclone roof)

caused by growing of
refractories due to alkalis
Shell destruction

caused by growing of
refractories due to alkalis
How to prevent this worst case scenario?

1. Selection of a suitable refractory material

2. Installation of well designed expansion joints
3. Preventive maintenance of expansion joints
4. Change refractories at the right time
insulating layer working layer

The Friction Compensator

A Refratechnik design
24
Refractory layout, inlet chamber (example)

Working lining:
REFRACLAY 40 ZAR
REFRAMULLITE 63 MCG AR
REFRAMULLITE 60 LCG ZAR
REFRA SIC 50 AR
Mixcrete

Insulating lining:
REFRALITE® 40 (G)
Calcium Silicate
Refractory layout, TA-duct (example)

Working lining:
KRONEX® 30
KRONEX® 50
REFRABAUXITE 75 LCC
REFRACLAY 40 LCC

Insulating lining:
Perlite Insulating Brick (PIB)
Calcium Silicate
TAD – layout of insulating and working lining

Working lining CaSi board

Tongue and groove shape

Refractory layout, kiln hood (example)

Working lining:
KRONAL® 60 AR
KRONEX® 60
REFRABAUXIT 75 LCC
REFRAMULLITE 63 MCG AR (JC)
REFRAMULLITE 60 LCG ZAR
Mixcrete

Insulating lining:
REFRALITE® 30 (G)
REFRALITE® 40 (G)
Calciumsilicate
Refractory layout, cooler (example)

Walls:
REFRABAUXITE 75 LCC
Bull nose: Walls:
RLE 30G, RLE 40G
KRONEX® 87 REFRACLAY 25 MCC
Anchor 1.4835, 10mm Walls, roof:
RLE 40 RLE 20G
KRONEX® 20
Anchor 1.4301, 8mm
RLE 20G

Walls, roof:
Horse shoe, wear bench: Wear bench:
KRONEX® 60 Layout depending
REFRABAUXITE 85 EDAR REFRABAUXITE 75 LCC
RLE 30 on crusher type
Mixcrete REFRABAUXITE 85 EDAR
Anchor 1.4835, 10mm (roller, hammer)
RLE 40G, PIB 45 RLE 30G
Anchor 1.4835, 10mm Anchor 1.4835, 10mm
 Cyclone Refractory layout of a cement plant

Calciner

Inlet chamber &

Riser duct Kiln hood and Cooler
Kiln

LO 13/58
 Typical application areas for castables and bricks

cylindrical/
round areas

Arches

Roofs

Straight walls

Inlet chamber

LO 14/58
 Cyclone

Refractory layout of a cement plant

Detailed views cyclone

LO 15/58
 Cyclone, refractory layout

bricks

bricks

castable

castable

LO 16/58
 Cyclone roof
FLS style, upper stage

High quality design

with tongue and
groove bricks and
castable in corners

LO 17/58
 Cyclone roof corner, upper stage

Special tongue and

groove bricks;
changeover roof to wall

LO 18/58
 Cyclone roof – Gas duct, top stage

Tongue and groove bricks

and castable

Castable: REFRACLAY 25 Brick type: KRONEX® 20

REFRACLAY 25 MCG, JC
REFRALITE® 40 G

LO 19/58
 Old style roof construction, hanger brick

LO 20/58
 New style roof construction, hanger brick tongue and groove

LO 22/58
 New style roof construction, hanger brick tongue and groove

LO 21/58
 Tongue and groove brick
(cyclones and TA-duct)

LO 23/58
Application of
insulating castable
behind bricks

straight and round walls in:

calciner
cyclones
cooler
 Cyclone roof, monolithic
Insulating Castables
REFRALITE® 20 G
REFRALITE® 30 G
REFRALITE® 40 G

JC-Castable
MCG-Castable
Standard castable (vibrating/gunning)
LO 24/58
 Cyclone installation,
REFRACLAY 25 bricks and castable
(lower Stage)

KRONEX® 20

LO 26/58
 REFRATHERM® 800/250 SP

Gas duct

REFRACLAY 25 MCG

LO 27/58
 Refractory layout of a cement plant
Calciner Detailed views calciner

LO 30/58
 Calciner, refractory layout bricks
bricks
castable
castable insulation

LO31/58
 REFRACLAY 40 JC AR
Calciner,
refractory layout

KRONAL® 50 AR

LO 36/58
 Calciner, change-over
castable to bricks
KRONAL® 50 AR

REFRACLAY 40 JC AR

LO 37/58
 Refractory layout of a cement plant
Detailed views inlet chamber and riser duct

Inlet chamber &

Riser duct

LO 38/58
 castable

insulation
Inlet chamber (AR-lining)

LO 40/58
 Refra-SIC 50 AR Inlet chamber, vibrating
castable

LO 43/58
 Inlet chamber
(Jetcast-Installation)

REFRACLAY 40 JC AR

LO 44/58
 Refractory layout of a cement plant
Detailed view kiln

Kiln

LO 45/58
 Typical refractory layout
Rotary Kiln

KRONEX® 50/60

REFRACLAY 40 ZAR
PERILEX®CF REFRAMAG®AF
TOPMAG®AF
TOPMAG®AF
LO 45/58
 Refractory layout of a cement plant
Detailed views kiln hood and cooler

Kiln hood and Cooler

LO 47/58
 insulation
bricks
castable

Kiln hood, front wall

LO 49/58
 Kiln hood, roof construction

insulation

tongue and groove bricks

LO 51/58
 Kiln hood ,
entrance TAD

LO 50/58
 Bullnose design, standard and
tapered tongue and groove
bricks

Roof shapes
(standard)

Bullnose shapes (tapered)

LO 52/58
 KRONEX® 87 Cooler-Inlet chamber
Bull Nose, roof

REFRA-Blockline
RBL SIC 50 AR

LO 55/58
 Agenda

Refractory layouts (examples) in a cement plant

Anchoring

REFRA „AR-Lining Concept“

Anc 1/6
Anchoring
General Questions
 Resistance of different steel alloys

reducing oxidizing
alkalis embrittlement temperature
atmosphere atmosphere

1.4301 * ( *) ** * * *
1.4835
(253 MA) * ( *) ** *** * *
1.4845 * ( *) * ** -- *
1.4876 *** *** *** --- *
2.4856
(INCONEL®) ***(*) *** *** -- *
**** very good ** moderate -- almost no resistance
*** good * limited --- no resistance
Anc 4/6
 Price levels of different steel anchor qualities
x 14.5
factor

Price factor

x 2.5
x 2.0
x 1.5
1.0

steel quality
Material number: 1.4301 1.4835 1.4845 1.4876 2.4856
Also known as: 304 253 MA 310 (S,H) 800 Inconel®
 preheater

stage I
gas duct II-I

Anchor material selection

bend II
stage II
gas duct III-II 1.4301
PYROTOP bend

bend III PYROTOP compact

1.4835
stage III PYROCLON round
2.4856
gas duct IV-III
bend IV

stage IV PYROCLON connection,

1.4876
angular

connection to
gas duct V-IV tertiary air duct
inlet duct to
stage V tertiary air duct kiln hood dust chamber
dust chamber

bend 90° / stage V

grate cooler

rising duct
above inlet chamber
inlet chamber
kiln burner

Source:
Correct welding of anchors
 Agenda

Refractory layouts (examples) in a cement plant

Anchoring

REFRA „AR-Lining Concept“

ARL 1/11
 REFRA AR-Lining, 3 in 1 concept

ARL 2/11
 Conventional Layout AR-Lining „the main principle“

Corrosion area

AR-Lining Concept

Kiln gas Kiln gas

ARL 3/11
Anchor damage
Cold face

Insulation
Sigma-phase
embrittlement

corrosion Working layer

Hot face
 REFRA AR-lining system and wall/roof structure
(detailed layout)

roof structure wall structure

ARL 5/11
 AR-Lining
step 1 and 2

ARL 6/11
 AR-Lining step 3

ARL 7/11
 AR-Lining step 4

ARL 8/11
 AR-Lining, steps 5 and 6

ARL 9/11
 AR-Lining, step 7

ARL 10/11
 AR-Lining, completed

ARL 11/11
 Product group 3:
Refractory mounting in general Insulation

Product group 4:
Metallic elements

Product group 5:
Expansion material
Product group 1:
Refractory bricks

Product group 2:
End 1/4
Refractory castable
 A „flight“ through a clinker
burning unit

End 2/4
 Summary

• Refractory layout of a cement plant

Result: design and material always a customized solution

• Anchoring

Result: always a compromise

• REFRA „AR-Lining Concept“

Result: Innovative protection against corrosion; it's worth it

End 3/4