1094

THERMAL
500

INDUSTRY
1500

Monolithic Concept Solutions

CEMENT PLANTS

1094

500

1500

Innovative Refractory Solutions for

the Cement industries

Calderys has been working for decades with successful activity in the cement industry worldwide, and we are considered as a reference supplier.
We offer a full range of solutions based on monolithic refractories that result in an efficient lining life. Progress have been made through the research and development of innovative products families such as the LCC (Low Cement Castables) and their alkali resistant versus which are specially dedicated to cement production conditions. The combination of recent product design with modern installation techniques such as Spraycast (shotcrete) and LPGM (Low Porosity Dense Gunning Mixes) allows Calderys to be a pioneer in refractory technology and solutions. Supervising team

Calderys own team of experienced engineers can provide:

TOTAL monolithic refractory lining solutions, MIXED lining solutions combining bricks and monolithics.

We can offer TURN KEYS projects including:

Refractory solution design and engineering Job site preparation Time and delivery schedules Planning of ressources Refractory & material supplies Management of manpower Supervision and installation First drying

Design specialists

Monolithic concept solutions for Thermal Industry - Cement Plants

Stresses in the Cement industry

The different units of cement plant:

Heat exchanger Precalciner Inlet chamber Firing hood Nosering Burner lance and cooler.

suffer from:
High abrasion Severe corrosion by alkalies, sulphur and chloride.

Abrasion

The lining is progressively worn off in the lower part of the tower by hot meal, and in the lower static units by clinker. Low cement castables,

thanks to their original and very dense structure compared to conventional castables, present very high mechanical resistance and up to exceptional

abrasion resistance associated with thermal shock properties.

Conventional castable matrix

Low Cement matrix

Ultra Low Cement matrix

Monolithic concept solutions for Thermal Industry - Cement Plants

Corrosion

More and more cement producers try to lower the cost of energy and move from traditional coal to petcoke and alternative fuels.

Reduction of the fuel cost

COSTS

Coal & Petcoke Lignite Wood Time Bottom Ash Natural Gas Secondary Fuel Secondary Raw Materials Animal Meal
Development of costs

Costs /t klinker

PROFITS

By sulfur
Petcoke introduces sulfur. Alternative fuels such as plastics, tyres, animal meals, wood, RDS (Residu Domestic Solid waste), solvents, used oils contain alkalies, sulphur and chlorine. The use of alternative fuels results in increased salt concentration in the structure of refractory lining. Materials with the lowest pore size and permeability must be preferred to avoid excessive infiltration, condensation of salts with bursting destruction.

By alkalies
The worst is the corrosion by alkalies. Alkalies K2O and Na2O are in volatile form as sulfates and chlorides. When they penetrate the refractories, alkalies react with the matrix and aggregates to form with alumina and silica new phases with growth-expansion and very low melting point leading to severe build up and destruction of the lining. LC and ULCC present the lowest permeability and when they are enriched with additives such as silicium carbide (SiC) and zircon ZrO2, they are protected from corrosion by alkalies. Calderys offers a full range of these products to face the most severe conditions. Build up formation is drastically reduced and lifetime is extended.

Bursting destruction

Poor alkali resistant castable

Good alkali resistant castable

Monolithic concept solutions for Thermal Industry - Cement Plants

Solutions for

Dense gunning LPGM and Spraycast solutions

Due to the request of cement industry for short stoppage and fast installations, Calderys was the first to come to the market with the new gunning technologies Spraycast or

LPGM, LC products with high abrasion and alkaly resistance. These techniques render possible installation times 3 to 10 times quicker compared to bricks or casting

behind formworks. Installation rates up to 2.5/3T per hour can be achieved (including preparation, gunning and cleaning).

Mid Cyclones
CALDE GUN LA 60 Z CALDE GUN LF 50 CALDE SPRAYCAST F 50 R

Tertiary Air Duct

CALDE GUN LF 50 CALDE SPRAYCAST F 50 R

Elbow
CALDE GUN LA 50 SZ CALDE SPRAYCAST F 50 R

Insulation
CALDE GUN LW

Lower Cyclone
CALDE GUN LA 50 SZ CALDE GUN LA 60 Z CALDE GUN LB 84 CALDE GUN LF 45 S CALDE SPRAYCAST F 50 R

Firing-Hood
CALDE GUN LA 60 Z CALDE GUN LB 84 CALDE GUN LS 30 CALDE SPRAYCAST BX 85 CALDE SPRAYCAST F 50 R

Cooler Top
CALDE GUN LA 50 SZ CALDE SPRAYCAST F 50 R

Precalciner
CALDE GUN LA 50 SZ CALDE GUN LA 60 Z CALDE GUN LB 84 CALDE GUN LF 45 S CALDE SPRAYCAST SIC 30 R

Nose-Ring
CALDE GUN LA 50 SZ CALDE SPRAYCAST BX 85

Inlet Chamber
CALDE GUN LA 50 SZ CALDE SPRAYCAST F 50 R CALDE SPRAYCAST SIC 30 R

Feed Tile
CALDE GUN LA 50 SZ CALDE SPRAYCAST F 50 R CALDE SPRAYCAST SIC 30 R (cast)

Conus
CALDE GUN LF 45 S CALDE SPRAYCAST F 50 R

Chute-Wall
CALDE GUN LA 60 Z CALDE GUN LS 30 CALDE SPRAYCAST BX 85

Bull-Nose
CALDE GUN LA 50 SZ CALDE SPRAYCAST BX 85 CALDE SPRAYCAST F 50 R
Monolithic concept solutions for Thermal Industry - Cement Plants

Cooler-Mid Bottom
CALDE GUN LB 84 CALDE SPRAYCAST F 50 R

Cooler Bottom End

CALDE GUN LF 50 CALDE SPRAYCAST F 50 R

Solutions for

Preheater Tower Cyclones - Gas Ducts - Meal Pipes

Meal enters through the uppermost hot air duct and is preheated within the various levels of the cyclones by hot combustion gas coming from the rotary kiln. In these cyclones, temperatures vary from 300C (upper part) to 930C (lower part).

The choice of the appropriate monolithic lining material is made according to thermal and chemical conditions experienced in the area.
CASTING WITH STANDARD GUNNING WITH DENSE GUNNING WITH

The wall installation may have two layers of castables with an appropriate anchoring system. The following installation methods can be applied:
CALDE CAST CALDE GUN CALDE SPRAYCAST or LPGM

Upper Cyclones/Gas Ducts

Standard & severe conditions CALDE CAST F 32 C/G CALDE GUN C 20

Insulating Materials
CALDE CAST LW MIX 124 C/G CALDE CAST XL 106 C/G

Mid Cyclones/Gas Ducts/ Meal Pipes

All conditions CALDE CAST F 32 CALDE CAST M 28 HR CALDE FLOW AZ CALDE GUN C 28 HR

Lower Cyclones/Gas Ducts/ Meal Pipes

Standard conditions CALDE CAST LF 40 CALDE CAST M 28 HR CALDE GUN C 28 HR CALDE GUN F 40 A Severe conditions CALDE CAST LR 45 CALDE CAST LZ 106 CALDE FLOW AZ CALDE SPRAYCAST & Low porosity dense gunning mixes in the CALDE GUN range

Monolithic concept solutions for Thermal Industry - Cement Plants

Solutions for

Preheater Tower Calciner - Combustion Chamber - Riser Duct

The installation of a calciner in the cyclone heat exchanger enables preheating and calcination of the raw meal using for burning different kind of combustion materials,

therefore resulting in a reduction of the entire combustion process. In these areas, due to a high temperature process of about 1100 - 1250C, as well as chlorine-alkali

circulation, the refractory material is exposed to severe thermal and chemical conditions. Here, alkaliresistant products are required.

Insulating Materials
Standard & severe conditions CALDE CAST LW MIX 124 C/G CALDE CAST XL 106 C/G

Combustion Chamber Riser Duct / Calciner

Standard conditions CALDE CAST LF 40 CALDE CAST M 28 HR CALDE GUN C 28 HR CALDE GUN F 40 A Severe conditions CALDE CAST LR 45 CALDE CAST ML 55 S5 CALDE GUN MM 55 S5 CALDE SPRAYCAST & Low porosity dense gunning mixes in the CALDE GUN range CALDE STIX ZIRCON

Monolithic concept solutions for Thermal Industry - Cement Plants

Solutions for

Preheater Tower Inlet Chamber - Kiln Inlet

Due to the fast development in the cement industry, furnace builders have to consider new construction concepts with much more sophisticated design. The best and the most flexible solution is to apply monolithic refractories.

The most intricated part is the inlet arch with the skewback transition to the intake chute. The mix runner profile is cut into the back wall to allow precise guiding of the raw meal. Due to the complex

shape of the casing and to the angular arrangements around the shock blower nozzle, this type of lining can only be carried out with a monolithic refractory product in: cast, gunning and spraycasting version.

Inlet Chamber/Feed Tile/ Kiln Inlet

Standard conditions CALDE CAST LF 40 CALDE CAST M 28 HR CALDE GUN C 28 HR CALDE GUN F 40 A Severe conditions CALDE CAST LA 50 SZ CALDE CAST LR 45 CALDE CAST LZ 106 CALDE GUN MM 55 S5 CALDE SPRAYCAST & Low porosity dense gunning mixes in the CALDE GUN range

Insulating Materials
Standard & severe conditions CALDE CAST LW MIX 124 C/G CALDE CAST XL 106 C/G

Monolithic concept solutions for Thermal Industry - Cement Plants

Solutions for

Kiln Hood & Cooler Burner Lance - Nose Ring

Areas such as nose ring, burner lances, kiln hoods and cooler ducts, lined with monolithic materials, operate under the most severe conditions. The use of multi-fuel burners is becoming more common practice in cement plants, a pattern that is likely to increase in the near future due to the large amount of alternative and residual fuels available.

Unfortunately, these emerging problems influence coating formation, clinker quality and refractory lifetime. The combustion problems in a cement kiln are very complex and affected by a lot of factors. The burner lance tips, for example, are always exposed to alkalis corrosion and abrasion by the clinker.

They also experience vibration and exposure to high temperature. Calderys solutions concerning the choice of material, dimensioning, anchoring and installation technique guaranty long lasting operation time.

Burner Pipe
Standard & severe conditions CALDE CAST GIBRAM CALDE CAST MF 35 S35 CALDE CAST ML 55 S5 CALDE FLOW AX CALDE PLAST C 90 AB CALDE PLAST SUPERAL X AB

Nose Ring
Standard & severe conditions CALDE CAST GIBRAM CALDE CAST LX 68 CALDE FLOW AX
Monolithic concept solutions for Thermal Industry - Cement Plants

Solutions for

Kiln Hood & Cooler Kiln Hood - Tertiary Air Duct

The proper selection of the refractory material for the kiln hood is of the highest importance. Due to the big temperature differences and to avoid erosion caused by the coming clinker, high abrasion, thermal shock and

chemical resistant materials should be applied. Calderys long-term experience allows providing you with the solutions combining: the right selection of the materials - depending on the chemical problems, the actual speed of the kiln

and the temperature level; detailed design, anchoring system and installation techniques to guarantee future long service life.

Kiln Hood
Standard conditions CALDE CAST LX 58 CALDE CAST M 28 HR CALDE GUN C 28 HR CALDE GUN MM 55 S5 Severe conditions CALDE CAST LA 50 SZ CALDE CAST LZ 106 CALDE CAST ML 55 S5 CALDE GUN MM 55 S5 CALDE SPRAYCAST & Low porosity dense gunning mixes in the CALDE GUN range

Tertiary Air Duct

All conditions CALDE GUN C 28 HR CALDE GUN F 40 A CALDE GUN MM 55 S5 CALDE SPRAYCAST & Low porosity dense gunning mixes in the CALDE GUN range

Tad Elbow
All conditions CALDE CAST GIBRAM CALDE GUN MM 55 S5 CALDE SPRAYCAST & Low porosity dense gunning mixes in the CALDE GUN range

Insulating Materials
Standard & severe conditions CALDE CAST LW MIX 124 C/G CALDE CAST XL 106 C/G
Monolithic concept solutions for Thermal Industry - Cement Plants

10

Solutions for

Kiln Hood & Cooler Grate Cooler - Hot Zone

The function of the clinker cooler is to cool clinker from 1300C down to near 100C and to complete its 3 CaO SiO2 transformations to the

main component of Portland cement. In this area, the refractory material is exposed to high temperature changes, difficult mechanical conditions in the

sidewalls (high wear), and severe chemical attack due to the presence of alkalies released by the clinker cooling process.

Cooler Wall & Roof

Standard conditions CALDE CAST LF 40 CALDE CAST M 28 HR CALDE GUN C 28 HR CALDE GUN F 40 A Severe conditions CALDE CAST LA 51 S CALDE CAST MF 35 S35 CALDE CAST UF 35 S30 CALDE SPRAYCAST & Low porosity dense gunning mixes in the CALDE GUN range

Impact Zone
Standard & severe conditions CALDE CAST GIBRAM CALDE CAST LT 95 CALDE GUN LS 30

Insulating Materials
Standard & severe conditions CALDE CAST LW MIX 124 C/G CALDE CAST XL 106 C/G

Monolithic concept solutions for Thermal Industry - Cement Plants

11

Solutions for

Kiln Hood & Cooler Grate Cooler

Bull Nose
Standard & severe conditions CALDE CAST GIBRAM CALDE CAST LA 51 S CALDE CAST MF 35 S35 CALDE SPRAYCAST & Low porosity dense gunning mixes in the CALDE GUN range

Cooler Medium Zone

Standard & severe conditions CALDE CAST LF 40 CALDE CAST M 28 HR CALDE GUN C 28 HR CALDE GUN F 40 A CALDE SPRAYCAST & Low porosity dense gunning mixes in the CALDE GUN range

Cooler Cold Zone

Standard & severe conditions CALDE CAST F 32 C/G CALDE GUN C 20

Insulating Materials
CALDE CAST LW MIX 124 C/G CALDE CAST XL 106 C/G

12

Monolithic concept solutions for Thermal Industry - Cement Plants

Solutions for

Kiln Hood & Cooler Planetary Cooler

For the monolithic lining of grate, rotary and planetary coolers, Calderys offers advanced materials like:

CAST, GUN or SPRAYCAST, which are the most suitable for this application.

Planetary Cooler - Inlet

Standard & severe conditions CALDE CAST GIBRAM CALDE CAST MF 35 S35 CALDE FLOW LB 85

Planetary Cooler - Rest

Standard & severe conditions CALDE CAST M 28 HR CALDE GUN MM 55 S5

Monolithic concept solutions for Thermal Industry - Cement Plants

13

Technical Data

Product name

Main component

Binding system

Max. recomm. temp.(C)

Max. grain size

Chemical analysis (wt %) Al2O3 SiO2 Fe2O3 SiC

Material required (t/m3)

Water required for mixing on site (litres/100kg)

Permanent linear change (%)

CCS (N/mm2)

CALDE CAST F 32 C/G CALDE CAST F 42 CALDE CAST GIBRAM CALDE CAST LA 50 SZ CALDE CAST LA 51 S CALDE CAST LF 40 CALDE CAST LR 45 CALDE CAST LT 95 CALDE CAST LW MIX 124 C/G CALDE CAST LX 58 CALDE CAST LZ 106 CALDE CAST M 28 HR CALDE CAST MF 35 S35 CALDE CAST ML 55 S5 CALDE CAST UF 35 S30 CALDE CAST XL 106 C/G CALDE FLOW AX CALDE FLOW LB 85

Chamotte Chamotte Bauxite Andalusite Andalusite Chamotte Chamotte Tabular Alumina Insulating Chamotte Vermiculite Andalusite Zircon Chamotte Silicon Carbide Chamotte High Alumina Raw Materials Silicon Carbide Vermiculite Andalusite Bauxite

Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic

1280 1320 1600 1650 1600 1450 1350 1750 1140 1650 1600 1550 1550 1550 1500 1060 1650 1600

6 6 5 5 6 6 6 7 4 6 6 5 6 10 3 3 5 5

33 41 82.5 50 51 40 44 93 24 57 29 45.5 31 55 34.2 22 52 84.5

54 38 12.4 9.4 (ZrO2) 40 54 48 5 42 38 24 47.8 28 35 31.7 41 25.7 9.5

2.3 5 1.5 0.6 1 1.2 0.2 0.1 9.5 1.1 0.2 1.3 0.6 0.9 1 9 9.3 (ZrO2) 1

9.7 5 43 (ZrO2) 35 5 31 9.5 -

1.85 (cast) 2 2.9 2.85 2.47 2.26 2.3 3.1 1.24 (gun) 2.5 3.25 2.2 2.4 2.51 2.5 0.73 (gun) 2.8 2.8

14 to 16 (cast) 12 to 14 5 to 6 4.5 to 5.5 6 to 6.4 6.4 to 7.2 6.5 to 7.5 4 to 5.5 added at the nozzle 5.6 to 6 5 to 5.6 6 to 7.5 6 to 7 5.2 to 5.6 4 to 5 added at the nozzle 5.5 to 6.5 6 to 7

-0.1 (cast) (800C) -0.15 (800C) -0.2 (800C) -0.2 (800C) -0.05 (800C) -0.1 (800C) -0.2 (800C) -0.2 (800C) -0.4 (gun) (800C) -0.04 (800C) -0.1 (800C) -0.3 (800C) -0.15 (800C) -0.2 (800C) -0.2 (1200C) -0.7 (800C) -0.2 (800C) -0.2 (800C)

25 (cast) (800C) 45 (800C) 140 (800C) 140 (1200C) 100 (800C) 80 (800C) 100 (800C) 130 (800C) 3 (gun) (800C) 100 (800C) 50 (800C) 80 (800C) 150 (800C) 130 (800C) 140 (1200C) 1.2 (gun) (800C) 130 (800C) 70 (800C)

14

Monolithic concept solutions for Thermal Industry - Cement Plants

Technical Data

Product name

Main component

Binding system

Max. recomm. temp.(C)

Max. grain size

Chemical analysis (wt %) Al2O3 SiO2 Fe2O3 SiC

Material required (t/m3)

Water required for mixing on site (litres/100kg)

Permanent linear change (%)

CCS (N/mm2)

CALDE GUN C 20 CALDE GUN C 28 HR CALDE GUN F 40 A CALDE GUN LA 50 SZ CALDE GUN LA 60 Z CALDE GUN LB 84 CALDE GUN LF 45 S CALDE GUN LF 50 CALDE GUN LS 30 CALDE GUN MM 55 S5 CALDE PLAST C 90 AB CALDE PLAST SUPERAL X AB CALDE SPRAYCAST BX 85 CALDE SPRAYCAST F 50 R CALDE SPRAYCAST F 50 S7 CALDE SPRAYCAST SIC 30 R CALDE STIX ZIRCON

Chamotte Chamotte Chamotte Andalusite Andalusite Bauxite Chamotte Chamotte Silicon Carbide High Alumina Raw Materials Corundum Bauxite Bauxite Chamotte Chamotte Silicon Carbide Chamotte Zircon

Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Ceramic Ceramic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic

1350 1500 1450 1650 1650 1650 1500 1500 1500 1500 1750 1650 1700 1550 1550 1600 1350

5 5 6 5 5 7 5 5 3 6 6 6 6 6 6 6 6

38.5 51 42 52 58 83 43.3 48 36 57 90 73 84 50.5 48 44 37

47.5 38.8 53.5 25 9.4 (ZrO2) 10.5 42 46 28.2 30 8 22 11 45 41 21 26

4.8 1.1 0.8 9.6 (ZrO2) 0.5 1.5 1.1 1.3 0.9 0.8 0.7 1.35 0.8 0.7 0.8 0.4 1.1

9.8 9.6 31.3 5 7 30 30 (ZrO2)

2.3 2.35 2.28 2.65 2.75 2.65* 2.25* 2.2* 2.3* 2.6 2.95 2.62 3.05 (spray) 2.55 (spray) 2.42 (spray) 2.57 (spray) 3.1

added at the nozzle added at the nozzle added at the nozzle added at the nozzle added at the nozzle added at the nozzle added at the nozzle added at the nozzle added at the nozzle added at the nozzle 5.6 to 6.4 6.2 to 6.8 6.4 to 7.2 6.4 to 6.8 added at the nozzle

-0.1 (800C) -0.3 (800C) -0.15 (800C) -0.1 (800C) 0 (1200C) -0.3 (1200C) -0.4 (800C) -0.35 (800C) -0.3 (1200C) -0.3 (800C) -1.25 (800C) -1.3 (800C) -0.15 (spray) (800C) 0 (800C) -0.25 (spray) (800C) -0.3 (spray) (800C) -0.3 (800C)

25 (800C) 60 (800C) 30 (800C) 70 (800C) 100 (1200C) 90 (1200C) 70 (800C) 71 (800C) 81 (1200C) 80 (800C) 44 (800C) 35 (800C) 70 (spray) (800C) 70 (spray) (800C) 70 (spray) (800C) 80 (spray) (800C) 48 (800C)

* Rebound excluded

NOTES: CALDERYS does not warrant the accuracy, fitness for purpose or update of any information disclosed herein. The recipient shall refer to instructions and advice provided under any technical documentation. This document and the information contained herein are the exclusive property of CALDERYS. Reproduction, alteration, copy, release, publication or distribution, in whole or in part, is not allowed. References, trademarks and specifications of the products may change according to the geographical area to be supplied. Please check the availability of the products with the sales area manager.
Monolithic concept solutions for Thermal Industry - Cement Plants

15

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- Inside: nLongrine (9908) - 01-2009 - Copyright: G. Defaix, Calderys, Lafarge, GF Automotive

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