Cement
Cement kiln linings have got harder to run, and it is not because the kilns got hotter. Alternative fuels changed what is in the gas, and the volatile cycle now decides the campaign.
Material systems we route here: Castables · Bricks · Ceramic Fibre
Where the lining is
Rotary kiln burning, transition and safety zones, the cooler and cooler throat, preheater cyclones, risers and the calciner, kiln hood and burner pipe, and the ducting throughout. The burning zone gets the attention, but preheater and calciner brickwork is where alternative-fuel operations most often lose material.
What takes it out
Alkali attack and structural spalling, driven by the volatile cycle. Potassium and sodium oxides penetrate alumino-silicate brick as vapour and react with the matrix to form phases that occupy more volume than what they replaced — the brick grows from the inside, closes its joints and lifts out of line. Chlorine and sulphur volatilise in the burning zone, travel with the gas and condense as salts in cooler brickwork, where their high thermal expansion drives the spalling. Note that a very low-porosity brick and an alkali-resistant brick are two different products, and buying the wrong one of that pair is a common and expensive mistake.
How we specify against it
Low open porosity to keep the vapour out, and grades formulated so the alkali reaction is not expansive — in preheaters and calciners that property decides the lining, not hot strength. But a lining cannot out-engineer an uncontrolled chlorine circuit: where campaigns are running short, the answer is usually upstream, in the bypass and the feed. A well-managed burning-zone lining is generally expected to run in the order of 8–12 months; consistently below about six months points at kiln ovality or the volatile cycle rather than at the grade on the bag.
47 product lines across 3 categories
Bricks
High Alumina Fire Brick — 30%
Bricks
High Alumina Fire Brick — 40%
Bricks
High Alumina Fire Brick — 50%
Bricks
High Alumina Fire Brick — 60%
Bricks
High Alumina Fire Brick — 70%
Bricks
High Alumina Fire Brick — 80%
Bricks
Acid Resistant Brick
Bricks
Magnesite Brick — 90%
Bricks
Magnesite Brick — 91%
Bricks
HFK Insulation Brick
Bricks
INS 110
Bricks
INS 140
Bricks
Porosint 500
Bricks
Porosint 750
Bricks
Alumina Burner Block
Bricks
Refractory Fire Tile
Castables
FIRECRETE NORMAL
Castables
FIRECRETE SUPER
Castables
FIRECRETE SPECIAL
Castables
FIRECRETE SUPER SPECIAL
Castables
WHYTHEAT A
Castables
WHYTHEAT K
Castables
WHYTHEAT C
Castables
WHYTHEAT K SUPREME
Castables
WHYTHEAT A SUPREME
Castables
WHYTHEAT C SPECIAL
Castables
COIL COAT A
Castables
ACCMON 45
Castables
ACCMON 60
Castables
ACCMON 70 LI
Castables
ACCMON 80
Castables
ACCMON 80 AL
Castables
ACCMON 90
Castables
INSULYTE 4
Castables
INSULYTE 7
Castables
INSULYTE 11
Castables
INSULYTE 11 LI
Castables
INSULYTE 13
Castables
INSULYTE 13 LI
Castables
INSULYTE 15
Castables
INSULYTE 15 LI
Castables
INSULYTE HT
Ceramic Fibre
Ceramic Fibre Blanket
Ceramic Fibre
Ceramic Fibre Module
Ceramic Fibre
Ceramic Fibre Paper
Ceramic Fibre
Ceramic Fibre Wool / Bulk Fibre
Ceramic Fibre