Monolithic

concept
solutions for

Cement
Industry
Monolithic Refractories in Cement Industry

Introduction of modern heat exchangers, calciner &

tertiary air ducts, rotary systems for the sintering zone,
discharge sections with the kiln hood and burner
lances, and clinker cooler have allowed Calderys to
implement innovative, state-of-the-art monolithic
products and de-sign solutions, which have proven to
be superior to brick linings in the Cement Industry.
Progress has been made through the development of in-
novative solutions such as LCC (low cement castables)
and ULCC (ultra low cement castables) that are alkaline
resistant and specially dedicated to cement production
conditions. The combination of recent product design with
modern installation techniques, such as Spraycast
(shotcrete) and low porosity gunning allows Calderys to
be a pioneer in refractory technology and solutions.

These solutions, developed in partnership with our customers, extend the reliability and the
availability of the installations. Calderys own team of experienced engineers can provide

total monolithic refractory lining solutions,

including custom-designed anchoring systems, selection of correct materials, professional

supervision and installation/project management.
A modern cement unit includes a cyclone pre-heater, a calciner with tertiary air duct, a
rotary system and a clinker cooler.

Calderys relies on decades of ex-

perience in the complete monolithic
refractory lining of static areas but
also provides solutions for the dy-
namic parts such as the inlet cone
and the nose ring of the kiln or
rotary cooler.

Our engineering solutions are well-known and trusted both by plant operators and design-
ers, many of whom cooperate closely with Calderys for their day-to-day refractory needs.

Calderys is well-known and respected for its high quality products and services. Our pre-
sence in local markets is essential in helping our customers to meet ever-increasing
produc-tion demands. Decades of experience in refractory technology and development,
coupled with modern production facilities, means that Calderys can truly be regarded as a
high quality, reliable supplier.
 Stresses in cement units
Higher temperatures

Better chemical resistance:

New products need to be not only resistant to high temperatures but also chemically inert to alkali and
sulphur and have a maximum infiltration resistance. The cement industry has undergone a change in
the use of fuel from oil and natural gas to low-grade coal and combustion of waste materials including
rubber tyres, plastics, solvents, coke, wood, used oil etc.
Selecting the most suitable monolithic material requires experience and knowledge of existing produc-
tion conditions to avoid further reaction or chemical infiltration.

Alkali resistant Alkali non resistant Bursting effect

Calderys monolithic products selection will have a strong impact on reducing the build up effect in the
different parts of cement unit.
Alternative fuels and the Low Cement castables pore size:

Depending on the composition of the alternative fuels, compounds containing alkalis, chlorine
and sulphur, etc are introduced into the kiln system. Salt compounds are also used in coal-
fired cement kilns.

The use of alternative fuels results in increased salt concentration in the structure of the
refractory lining, depending on the temperature level. Materials with the lowest pore size and
permeability have to be considered to avoid excessive infiltration of chemicals. Compared to
bricks, properly de-signed monolithic materials will develop these densification properties
resulting in very small pores.

Low Cement Castable: GIBRAM after firing at 800C

Standard bricks

Installation technique:
The introduction of gas suspension pre-heaters andcal-
ciners, with their complex geometry, has further encour-
aged the installation of monolithic refractories in place of
brick linings. In these new installations, sections of the
cyclones, pipe lines, inlet chamber, kiln hood and the
cooler were installed with the LCC castables.
Monolithic solution simplify thermal control of the
lining, result in increased efficiency, faster delivery
times and ultimately a reduction in the total cost of
installation. The most economical option is achieved
by applying a combination of dry or wet gunning
products together with conventional castables, self-
flowing castables and LC castables.
 Solutions for the Monolithic
Installations Concepts
Dense gunning & Spraycast solution

Due to the fast development of the thermal industries and high increase of
the demand coming from our customers, Calderys was the first to came to
the market with the new range of products like: Spraycast and Low Porosity
Gunning Mixes. Those products are Low Cement containing materials,
combining high chemical and mechanical resistance with cost effective
installation.

In most situations, by using a wet gunning option, it is possible to achieve in-

stallation rates which are 3-10 times faster compared to traditional products,
whilst still achieving a service life which is similar to, or above that of regular
castables. An additional advantage is a limited amount of rebounds, no dust
during installation, no moulds required and most importantly, these products
can be applied as wet gunning material, castable as well as pumping material.

Global rates of up to 2.5 T/h (including

preparation, gunning, cleaning...) can be
achieved by dry dense gunning (Low
Poros-ity Gunning Mixes = LPGM) or up to
10T/H by wet gunning Spraycast
(shotcrete), compared to a maximum 1T/h
for standard gunning. Products installed
using standard gunning techniques also
achieve good performan-ces and can be
installed 2-3 times faste than traditional
brick linings.

MID. CYCLONES
AH 404 | AH 410 | SPRAYCAST F 50 R

LOWER CYCLONES KERLITE | PLICAST LW-Mix |

BASACAST ISO
AH 405 | AH 410 | AH 411 |
AH 413 | SPRAYCAST F 50 R AS INSULATION

MEAL PIPE TERTIARY AIR DUCT ELBOW

SPRAYCAST F 50 R
AH 404 | SPRAYCAST F 50 R AH 411 | SPRAYCAST F 50 R
(cast)

FIRING-HOOD
| AH 410 | AH 420 | SPRAYCAST F 50 R
AH 405 |
SPRAYCAST BX 85
PRECALCINER NOSE-RING
SPRAYCAST F 50 R
AH 405 | AH 410 | SH 411 | AH 13 | |
SPRAYCAST BX
SPRAYCAST F 50 R | SPRAYCAST F 40 S30 85
INLET CHAMBER
AH 411 | SPRAYCAST F 40 S30 | COOLER TOP
SPRAYCAST F 50 R AH 411 | SPRAYCAST F 50 R

CHUTE-WALL
FEED TILE
AH 410 | SH 420 | SPRAYCAST F 50 R |
SPRAYCAST F 40 S30 (cast) | SPRAYCAST BX 85
SPRAYCAST F 50 R

BULL-NOSE
AH 411 | SPRAYCAST F 50 R |
SPRAYCAST BX 85
CONUS COOLER-MID BOTTOM COOLER BOTTOM END
AH 411 SR | SPRAYCAST F 50 R AH 405 | SPRAYCAST F 50 R AH 404 | SPRAYCAST F 50
Solutions for the
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 expe-
rienced in the area. The wall installation may have several
layers of castables with an appropriate anchoring system.
The following installation methods can be applied:

Casting with: PLICAST, PHLOCAST, BASACAST,

INTRACAST, ULTRACAST, GIBRAM

Standard gunning with: PLIGUN, KERGUN, BASAGUN

Dense gunning with: SPRAYCAST or
LPGM (AH/SH/HC products)

UPPER CYCLONES/
GAS DUCTS

Standard PLICAST 18 C/G

and severe KERGUN C 20 SR
conditions

MID CYCLONES/
GAS DUCTS/MEAL PIPES LOWER CYCLONES/ GAS
DUCTS/MEAL PIPES
All PLIGUN Strong-Mix
conditions PLICAST Strong-Mix Standard PLIGUN FL 40
KERGUN C 28 HR SR conditions PLICAST FL 40
PHLOCAST M 28 HR SR PHLOCAST M 28 HR SR
KERGUN C 28 HR SR

INSULATING Severe BASACAST LC 35-407

MATERIALS conditions PLICAST LZ 106
PHLOCAST SiC 30 SR
BASACAST ISO
BASAGUN 40-407
PLICAST LW-Mix 124 C/G
SPRAYCAST & LPGM
PLICAST LW-Mix 106 C/G (AH products)
Solutions for the
Preheater Tower
Calciner - Combustion Chamber - Riser Duct

The installation of a calciner in the cyclone heat

exchanger enables preheating and calcination of the
cement dust 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 re-fractory material is exposed to severe
thermal and chemical conditions.
Here, alkali-resistant products are required:

COMBUSTION
CHAMBER
RISER DUCT
CALCINER

Standard PLICAST FL 40
conditions PHLOCAST M 28 HR SR
PLIGUN FL 40
KERGUN C 28 HR SR
Severe PLICAST ML 55 S5
conditions BASACAST LC 35-407
PLIGUN MM 55 S5
BASAGUN 40-407
PLISTIX Zircon
PLIBRICO Redd Ram
SPRAYCAST & LPGM
(AH products)

INSULATING
MATERIALS
Standard BASACAST ISO 13-135 0-5
and severe PLICAST LW-Mix 124 C/G
conditions PLICAST LW-Mix 106 C/G
Solutions for the
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
PLICAST FL 40
Standard
conditions PHLOCAST M 28 HR SR
PLIGUN FL 40
KERGUN C 28 HR SR
Severe PLICAST LZ 106
conditions INTRACAST 440 SR
BASACAST LC 35-407
PHLOCAST SiC 30 SR
MONROX SiC 60 SR
PLISTIX Zircon
PLISTIX ZM 30 S15 INSULATING
PLIGUN MM 55 S5 MATERIALS
BASAGUN 40-407 0-6
BASAGUN 40-205 Standard BASACAST ISO

SPRAYCAST & LPGM

and severe PLICAST LW-Mix 124 C/G
(AH products) conditions PLICAST LW-Mix 106 C/G
Solutions for the
Kiln Hood & Cooler
Burner Lance - Nose Ring

Areas such as nose ring, burner lances, kiln

hoods and cooler ducts, lined with
monolithic material, operateunder 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 life-
time. 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

BURNER PIPE exposed to alkalis corrosion and abrasion by
the clinker. They also experience vibration and
Standard PLICAST ML 55 S5 exposure to high temperature.
and severe BASACAST LC 60-717 F Calderys solutions concerning the choice of
material, dimensioning, anchoring and
conditions GIBRAM SR
instal-lation technique guaranty long lasting
MONROX AX SR opera-tion time.
PLIFLOW A 50 Z/S
PLIBRICO Superal-X AB
PLIBRICO 90 AB

NOSE RING

Standard PLICAST LX 68
and severe GIBRAM SR
conditions BASACAST MC 55-305 F 0-6
BASACAST LC 60-717 F
Solutions for the
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, a 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.

KILL HOOD

Standard PLICAST LX 58
conditions PHLOCAST M 28 HR SR
PLIGUN MM 55 S5
KERGUN C 28 HR SR
BASAGUN 60-500
Severe BASACAST LC 60-717 F
conditions PLICAST LZ 106
PLICAST ML 55 S5
KERGUN C 28 HR SR
PLIGUN MM 55 S5
PLIGUN GX A 60 S7 TAD ELBOW
SPRAYCAST & LPGM
(AH products) Severe PLIGUN MM 55 S5
conditions GIBRAM SR
SPRAYCAST & LPGM
TERTIARY (AH products)
AIR DUCT

All KERGUN C 28 HR SR INSULATING

conditions BASAGUN 55-503 MATERIALS
PLIGUN FL 40
PLIGUN MM 55 S5 Standard BASACAST ISO
SPRAYCAST & LPGM
and severe PLICAST LW-Mix 124 C/G
(AH products) conditions PLICAST LW-Mix 106 C/G
Solutions for the
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 com-
plete 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
alkalis released by the clinker cooling process.

COOLER WALL/ROOF

Standard PLICAST FL 40 IMPACT ZONE

conditions PHLOCAST M 28 HR SR
KERGUN C 28 HR SR Standard ULTRACAST 387 SR
BASAGUN 60-500 and severe PLICAST LX 58 W2
PLIGUN FL 40 conditions GIBRAM SR

Severe BASACAST MC 55-305 F

conditions BASACAST LC 60-717 F INSULATING
ULTRACAST SiC 30 SR MATERIALS
PLICAST LX A-51 S 5
PLIGUN GX A-60 S 7 Standard BASACAST ISO
SPRAYCAST & LPGM
and severe PLICAST LW-Mix 124 C/G
(AH products) conditions PLICAST LW-Mix 106 C/G
Solutions for the
Kiln Hood & Cooler
Grate Cooler

BULL NOSE

Standard PLICAST LX A-51 S 5

& severe BASACAST MC 55-305 F
conditions GIBRAM SR
BASACAST 50-501
PLIGUN GX A-60 S 7 COOLER COLD ZONE
SPRAYCAST &
LPGM (AH products) Standard KERGUN C 20 HR SR
& severe PLICAST 18 C/G
conditions
COOLER MID. ZONE

Standard PLICAST FL 40 INSULATING

& severe PHLOCAST M 28 HR SR MATERIALS
conditions KERGUN C 28 HR SR
BASACAST ISO
PLIGUN FL 40
PLICAST LW-Mix 124 C/G
SPRAYCAST & LPGM
(AH products) PLICAST LW-Mix 106 C/G
Solutions for the
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
PLANETARY COOLER -
Standard GIBRAM SR
REST
& severe BASACAST LC 60-717 F
conditions BASACAST MC 55-305 F Standard PHLOCAST M 28 HR SR
MONROX B SR & severe PLIGUN MM 55 S5
SPRAYCAST & LPGM conditions SPRAYCAST & LPGM
(AH products) (AH products)
 Products characteristics by type of installation

Working Chemical Analysis (%)

Raw Material Density CCS 110 C
Type Temperature
Product name (base) (g/cm )
3
(Mpa)
(C) Al2O3 SiC ZrO2

Castable

BASACAST LC 35-407 LCC chamotte 1350 44 na na 2.3 95

BASACAST LC 60-717 F LCC bauxite 1600 76 na na 2.8 50

BASACAST MC 55-305 F LCC chamotte 1550 31 35 na 2.4 120

INTRACAST 440 SR LCC andalusite 1650 50 10 10 2.85 120

GIBRAM SR LCC bauxite 1600 82 na na 2.95 125

PHLOCAST M 28 HR SR LCC chamotte 1550 46 na na 2.25 100

PHLOCAST SiC 30 SR MC SIC 1500 33 na 2.35 95

PLICAST FL 40 LCC chamotte 1450 40 na na 2.26 70

PLICAST LX 58 LCC andalusite 1650 57 na na 2.5 95

PLICAST LX A-51 S 5 LCC andalusite 1600 51 5.0 na 2.42 90

PLICAST LZ 106 ULCC zircon 1600 29 na 43 3.2 50

PLICAST ML 55 S5 LCC High Alumina 1550 55 5.0 na 2.48 95

PLICAST Strong-Mix ULCC Chamote 1320 40 na na 2.0 65

ULTRACAST 387 SR ULCC Tabluar Alumina 1750 92 na na 3.2 120

ULTRACAST SiC 30 SR ULCC SIC 1500 34 31 na 2.46 60

Self-flow

PLIFLOW A 50 Z/S LCC zircon 1650 60 10 10 2.79 90

MONROX AX SR LCC andalusite 1650 52 10 9 2.78 110

MONROX B SR LCC bauxite 1600 85 na na 2.85 60

MONROX SiC 30 SR LCC SIC 1500 33 35 na 2.42 80

MONROX SiC 60 SR LCC SIC 1500 25.5 59.5 na 2.55 85

 Working Chemical Analysis (%)
Raw Material Density CCS 110 C
Type Temperature
Product name (base) (g/cm )
3
(Mpa)
(C) Al2O 3 SiC ZrO2

Standard Gunning

PLICAST 18 C/G MC chamotte 1300 34 na na 1.87 30

PLIGUN FL 40 LCC chamotte 1450 42 na na 2.08 30

PLIGUN GX A-60 S 7 LCC andalusite 1550 51 7 na 2.17 28

PLIGUN MM 55 S5 MC High Alumina 1500 57 5 na 2.35 90

PLIGUN Strong Mix C/G R chamotte 1320 37 na na 1.95 60

BASAGUN 20-305 R chamotte 1200 35 17 na 2.2 40

BASAGUN 40-205 MC SIC 1400 26 52 na 2.3 55

BASAGUN 40-407 0-6 MC chamotte 1400 43 na na 2.1 45

BASAGUN 55-503 MC chamotte 1550 55 na na 2.3 70

BASAGUN 60-500 MC High Alumina 1600 57 na na 2.25 70

KERGUN C 20 SR MC chamotte 1350 38 na na 2.05 40

KERGUN SiC 30 HR SR MC chamotte 1400 35 34 na 2.25 80

KERGUN C 28 HR SR MC chamotte 1500 53 na na 2.17 90

PLISTIX Zircon MC zircon 1350 37 na 30 2.8 40

PLISTIX ZM 30 S15 MC zircon 1350 31 14 26 2.8 40

Dense Gunning & Shotcrete

AH 404 SR LCC chamotte 1500 48 na na 2.25 60

AH 410 SR LCC andalusite 1650 58 na 10 2.7 98

AH 411 SR LCC andalusite 1650 51 10 10 6.7 70

AH 413 SR LCC chamotte 1500 43 10 na 2.2 70

SH 420 SR LCC SIC 1500 31 na 2.35 63

SPRAYCAST F 50 R LCC chamotte 1550 51 na na 2.4 45

SPRAYCAST BX 85 ULCC bauxite 1700 84 na na 2.9 50

SPRAYCAST F 40 S30 LCC chamotte 1600 44 30 na 2.45 60

Ramming

PLIBRICO 90 AB ceramic Corundum 1750 90 na na 2.77 15

PLIBRICO Redd Ram ceramic High Alumina 1650 69 na na 2.5 44

PLIBRICO Superal-X AB ceramic bauxite 1650 73 na na 2.42 13

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