THERMAL INDUSTRY
Monolithic Concept Solutions
CEMENT PLANTS
Innovative Refractory Solutions for
the Cement industries
Calderys has been working for decades with successful activity in the cement industry worldwide, worldwide, and we are considered as a reference supplier. We oer a ull range o solutions based
Calderys’ own team of
on monolithic reractories that result in
experienced engineers can
an ecient lining lie.
provide:
Progress have been made through
•
the research and development o
TOTTAL monolithic reractory lining TO solutions,
innovative products amilies such
•
as the LCC (Low Cement Castables)
MIXED lining solutions combining bricks and monolithics.
and their alkali resistant versus which are specially dedicated to cement
We can offer TURN KEYS projects
production conditions.
including:
The combination o recent product
•
design with modern installation
engineering
techniques such as Spraycast (shotcrete) and LPGM (Low Porosity Calderys to be a pioneer in reractory Supervising team
•
•
Dense Gunning Mixes) allows technology and solutions.
Reractory solution design and
•
Job site preparation Time and delivery schedules Planning o ressources
•
Reractory & material supplies
•
Management o manpower
•
Supervision and installation
•
First drying
Design specialists
2
Monolithic concept solutions or Thermal Thermal Industry - Cement Plants
Stresses in the Cement industry
The different units of cement plant: •
•
Heat exchanger Precalciner
•
Inlet chamber
•
Firing hood
•
Nosering
•
suffer from: •
•
High abrasion Severe corrosion by alkalies, sulphur and chloride.
Burner lance and cooler.
Abrasion
The lining is progressively worn o
thanks to their original and very dense
abrasion resistance associated with
in the lower part o the tower by hot
structure compared to conventional
thermal shock properties.
meal, and in the lower static units
castables, present very high mechanical
by clinker. Low cement castables,
resistance and up to exceptional
Conventional castable matrix
Low Cement matrix
Monolithic concept solutions or Thermal Industry - Cement Plants
Ultra Low Cement matrix
3
Corrosion
More and more cement producers try to lower the
Reduction of the fuel cost
cost of energy and move from traditional coal to petcoke
COSTS
and alternative fuels. r e k n i l k t / s t s o C
Coal & Petcoke Lignite Wood Bottom Ash
Time
Natural Gas Secondary Fuel Secondary Raw Materials Animal Meal
PROFITS
Development of costs
By sulfur
By alkalies
Petcoke introduces sulur. Alternative
The worst is the corrosion by alkalies.
LC and ULCC present the lowest
uels such as plastics, tyres, animal
Alkalies K2O and Na2O are in volatile
permeability and when they are
meals, wood, RDS (Residu Domestic
orm as sulates and chlorides. When
enriched with additives such as
Solid waste), solvents, used oils…
they penetrate the reractories, alkalies
silicium carbide (SiC) and zircon ZrO2,
contain alkalies, sulphur and chlorine.
react with the matrix and aggregates
they are protected rom corrosion by
The use o alternative uels results
to orm with alumina and silica new
alkalies. Calderys oers a ull range o
in increased salt concentration in
phases with growth-expansion and
these products to ace the most severe
the structure o reractory lining.
very low melting point leading to
conditions.
Materials with the lowest pore size
severe build up and destruction o the
Build up ormation is drastically
and permeability must be b e preerred
lining.
reduced and lietime is extended.
Poor alkali resistant castable
Good alkali resistant castable
to avoid excessive inltration, condensation o salts with bursting destruction.
Bursting destruction
4
Monolithic concept solutions or Thermal Thermal Industry - Cement Plants
Solutions or
Dense gunning LPGM and Spraycast solutions
Due to the request o cement
LPGM, LC products with high abrasion
behind ormworks. Installation rates
industry or short stoppage and ast
and alkaly resistance.
up to 2.5/3T per hour can be achieved
installations, Calderys was the rst
These techniques render possible
(including preparation, gunning and
to come to the market with the new
installation times 3 to 10 times
cleaning).
gunning technologies Spraycast or
quicker compared to bricks or casting
Mid Cyclones CALDE™ GUN LA 60 Z CALDE™ GUN LF 50 CALDE™ SPRAYCAST F 50 R
Tertiary Air Duct
Elbow
CALDE™ GUN LF 50 CALDE™ SPRAYCAST F 50 R
CALDE™ GUN LA 50 SZ CALDE™ SPRAYCAST F 50 R
Lower Cyclone
Firing-Hood
CALDE™ GUN LA 50 SZ CALDE™ GUN LA 60 Z CALDE™ GUN LB 84 CALDE™ GUN LF 45 S CALDE™ SPRAYCAST F 50 R
CALDE™ GUN LA 60 Z CALDE™ GUN LB 84 CALDE™ GUN LS 30 CALDE™ SPRAY SPR AYCAST CAST BX 85 CALDE™ SPRAYCAST F 50 R
Precalciner
Nose-Ring
CALDE™ GUN LA 50 SZ CALDE™ GUN LA 60 Z CALDE™ GUN LB 84 CALDE™ GUN LF 45 S CALDE™ SPRAYCAST SIC 30 R
CALDE™ GUN LA 50 SZ CALDE™ SPRAYCAST BX 85
Insulation CALDE ™GUN LW
Cooler Top CALDE™ GUN LA 50 SZ CALDE™ SPRAYCAST F 50 R
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
Chute-Wall
CALDE™ GUN LF 45 S CALDE™ SPRAYCAST F 50 R
CALDE™ GUN LA 60 Z CALDE™ GUN LS 30 CALDE™ SPRAYCAST BX 85
Bull-Nose
Cooler-Mid Bottom
Cooler Bottom End
CALDE™ GUN LA 50 SZ CALDE™ SPRAYCAST BX 85 CALDE™ SPRAYCAST F 50 R
CALDE™ GUN LB 84 CALDE™ SPRAYCAST F 50 R
CALDE™ GUN LF 50 CALDE™ SPRAYCAST F 50 R
Monolithic concept solutions or Thermal Industry - Cement Plants
5
Solutions or
Preheater Tower Cyclones - Gas Ducts - Meal Pipes
Meal enters through the uppermost
The choice o the appropriate
The wall installation may have two
hot air duct and is preheated within
monolithic lining material is made
layers o castables with an appropriate
the various levels o the cyclones by
according to thermal and chemical
anchoring system. The ollowing
hot combustion gas coming rom
conditions experienced in the area.
installation methods can be applied:
the rotary kiln. In these cyclones,
CASTING WITH
CALDE™ CAST
temperatures vary rom 300°C
STAN ST ANDA DARD RD GU GUNN NNIN ING G WI WITH TH
CALD CA LDE™ E™ GU GUN N
(upper part) to 930°C (lower part).
DENSE GUNNING WITH
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™ C ALDE™ GUN range
6
Monolithic concept solutions or Thermal Thermal Industry - Cement Plants
Solutions or
Preheater Tower Calciner - Combustion Chamber - Riser Duct
The installation o a calciner in the
thereore resulting in a reduction o
circulation, the reractory material
cyclone heat exchanger enables
the entire combustion process.
is exposed to severe thermal and
preheating and calcination o the
In these areas, due to a high
chemical conditions. Here, alkali-
raw meal using or burning dierent
temperature process o about 1100
resistant products are required.
kind o combustion materials,
- 1250°C, as well as chlorine-alkali
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™ C ALDE™ GUN range CALDE™ STIX ZIRCON
Monolithic concept solutions or Thermal Industry - Cement Plants
7
Solutions or
Preheater Tower Inlet Chamber - Kiln Inlet
Due to the ast development in the
The most intricated part is the inlet
shape o the casing and to the angular
cement industry, urnace builders have
arch with the skewback transition to
arrangements around the shock
to consider new construction concepts
the intake chute.
blower nozzle, this type o lining can
with much more sophisticated design.
The mix runner prole is cut into the
only be carried out with a monolithic
The best and the most fexible solution
back wall to allow precise guiding o
reractory product in: cast, gunning and
is to apply monolithic reractories.
the raw meal. Due to the complex
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
8
Monolithic concept solutions or Thermal Thermal Industry - Cement Plants
Solutions or
Kiln Hood & Cooler Burner Lance - Nose Ring
Areas such as nose ring, burner lances,
Unortunately, these emerging
They also experience vibration and
kiln hoods and cooler ducts, lined with
problems infuence coating ormation,
exposure to high temperature.
monolithic materials, operate under
clinker quality and reractory lietime.
Calderys solutions concerning the
the most severe conditions. The use o
The combustion problems in a cement
choice o material, dimensioning,
multi-uel burners is becoming more
kiln are very complex and aected by a
anchoring and installation technique
common practice in cement plants, a
lot o actors.
guaranty long lasting operation time.
pattern that is likely to increase in the
The burner lance tips, or example, are
near uture due to the large amount o
always exposed to alkalis corrosion and
alternative and residual uels available.
abrasion by the clinker.
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 or Thermal Industry - Cement Plants
9
Solutions or
Kiln Hood & Cooler Kiln Hood - Terti Tertiary ary Air Duct D uct
The proper selection o the reractory
chemical resistant materials should be
and the temperature level; detailed
material or the kiln hood is o the
applied. Calderys long-term experience
design, anchoring system and
highest importance. Due to the big
allows providing you with the solutions
installation techniques to guarantee
temperature dierences and to avoid
combining: the right selection o the
uture long service lie.
erosion caused by the coming clinker,
materials - depending on the chemical
high abrasion, thermal shock and
problems, the actual speed o the kiln
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
10
Insulating Materials Standard & severe conditions
CALDE™ CAST LW MIX 124 C/G CALDE™ CAST XL 106 C/G Monolithic concept solutions or Thermal Thermal Industry - Cement Plants
Solutions or
Kiln Hood & Cooler Grate Cooler - Hot Zone
The unction o the clinker cooler is to
main component o Portland cement.
sidewalls (high wear), and severe
cool clinker rom 1300°C down to near
In this area, the reractory material is
chemical attack due to the presence o
100°C and to complete its
exposed to high temperature changes,
alkalies released by the clinker cooling
3 CaO SiO2 transormations to the
dicult mechanical conditions in the
process.
Cooler Wall Wall & Roof Standard conditions
CALDE™ CAST LF 40 CALDE™ CAST M 28 HR CALDE™ GUN C 28 HR CALDE™ GUN F 40 A
Impact Zone Standard & severe conditions
CALDE™ CAST GIBRAM CALDE™ CAST LT 95 CALDE™ GUN LS 30
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
Insulating Materials Standard & severe conditions
CALDE™ CAST LW MIX 124 C/G CALDE™ CAST XL 106 C/G
Monolithic concept solutions or Thermal Industry - Cement Plants
11
Solutions or
Kiln Hood & Cooler Grate Cooler
Cooler Medium Zone 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
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™ C ALDE™ 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 or Thermal Thermal Industry - Cement Plants
Solutions or
Kiln Hood & Cooler Planetary Cooler
For the monolithic lining o grate,
CAST, GUN or SPRAYCAST, which are
rotary and planetary coolers, Calderys
the most suitable or this application.
oers advanced materials like:
Planetary Cooler - Inlet Standard & severe conditions
CALDE™ CAST GIBRAM CALDE™ CAST MF 35 S35 CALDE™ FLOW LB 85
Monolithic concept solutions or Thermal Industry - Cement Plants
Planetary Cooler - Rest Standard & severe conditions
CALDE™ CAST M 28 HR CALDE™ GUN MM 55 S5
13
Technical Data
Binding system
Max. recomm. temp.(°C)
Max. grain size
Material required
Permanent linear change
SiC
(t/m3)
Water required for mixing on site
Al2O3
SiO2
Fe2O3
CALDE™ CAST F 32 C/G
Chamotte
Hydraulic
1280
6
33
54
2.3
-
1.85 (cast)
14 to 16 (cast)
-0.1 (cast) (800°C)
25 (cast) (800°C)
CALDE™ CAST F 42
Chamotte
Hydraulic
1320
6
41
38
5
-
2
12 to 14
-0.15 (800°C)
45 (800°C)
CALDE™ CAST GIBRAM
Bauxite
Hydraulic
1600
5
82.5
12.4
1.5
-
2.9
5 to 6
-0.2 (800°C)
140 (800°C)
CALDE™ CAST LA 50 SZ
Andalusite
Hydraulic
1650
5
50
9.4 (ZrO2)
0.6
9.7
2.85
4.5 to 5.5
-0.2 (800°C)
140 (1200°C)
CALDE™ CAST LA 51 S
Andalusite
Hydraulic
1600
6
51
40
1
5
2.47
6 to 6.4
-0.05 (800°C)
100 (800°C)
CALDE™ CAST LF 40
Chamotte
Hydraulic
1450
6
40
54
1.2
-
2.26
6.4 to 7.2
-0.1 (800°C)
80 (800°C)
CALDE™ CAST LR 45
Chamotte
Hydraulic
1350
6
44
48
0.2
-
2.3
6.5 to 7.5
-0.2 (800°C)
100 (800°C)
CALDE™ CAST LT 95
Tabular Alumina
Hydraulic
1750
7
93
5
0.1
-
3.1
4 to 5.5
-0.2 (800°C)
130 (800°C)
CALDE™ CAST LW MIX 124 C/G
Insulating Chamotte Vermiculite
Hydraulic
1140
4
24
42
9.5
-
1.24 (gun)
added at the nozzle
-0.4 (gun) (800°C)
3 (gun) (800°C)
CALDE™ CAST LX 58
Andalusite
Hydraulic
1650
6
57
38
1.1
-
2.5
5.6 to 6
-0.04 (800°C)
100 (800°C)
CALDE™ CAST LZ 106
Zircon
Hydraulic
1600
6
29
24
0.2
43 (ZrO2)
3.25
5 to 5.6
-0.1 (800°C)
50 (800°C)
Chamotte
Hydraulic
1550
5
45.5
47.8
1.3
-
2.2
6 to 7.5
-0.3 (800°C)
80 (800°C)
CALDE™ CAST MF 35 S35
Silicon Carbide Chamotte
Hydraulic
1550
6
31
28
0.6
35
2.4
6 to 7
-0.15 (800°C)
150 (800°C)
CALDE™ CAST ML 55 S5
High Alumina Raw Materials
Hydraulic
1550
10
55
35
0.9
5
2.51
5.2 to 5.6
-0.2 (800°C)
130 (800°C)
CALDE™ CAST UF 35 S30
Silicon Carbide
Hydraulic
1500
3
34.2
31.7
1
31
2.5
4 to 5
-0.2 (1200°C)
140 (1200°C)
CALDE™ CAST XL 106 C/G
Vermiculite
Hydraulic
1060
3
22
41
9
-
0.73 (gun)
added at the nozzle
-0.7 (800°C)
1.2 (gun) (800°C)
CALDE™ FLOW AX
Andalusite
Hydraulic
1650
5
52
25.7
9.3 (ZrO2)
9.5
2.8
5.5 to 6.5
-0.2 (800°C)
130 (800°C)
Bauxite
Hydraulic
1600
5
84.5
9.5
1
-
2.8
6 to 7
-0.2 (800°C)
70 (800°C)
CALDE™ CAST M 28 HR
CALDE™ FLOW LB 85
14
Chemical analysis (wt %)
Main component
Product name
(litres/100kg)
(%)
CCS
(N/mm2)
Monolithic concept solutions or Thermal Industry - Cement Plants
Technical Data
Water required for mixing on site
Permanent linear change
2.3
added at the nozzle
-0.1 (800°C)
25 (800°C)
-
2.35
added at the nozzle
-0.3 (800°C)
60 (800°C)
0.8
-
2.28
added at the nozzle
-0.15 (800°C)
30 (800°C)
25
9.6 (ZrO2)
9.8
2.65
added at the nozzle
-0.1 (800°C)
70 (800°C)
58
9.4 (ZrO2)
0.5
-
2.75
added at the nozzle
0 (1200°C)
100 (1200°C)
7
83
10.5
1.5
-
2.65*
added at the nozzle
-0.3 (1200°C)
90 (1200°C)
1500
5
43.3
42
1.1
9.6
2.25*
added at the nozzle
-0.4 (800°C)
70 (800°C)
Hydraulic
1500
5
48
46
1.3
-
2.2*
added at the nozzle
-0.35 (800°C)
71 (800°C)
Silicon Carbide
Hydraulic
1500
3
36
28.2
0.9
31.3
2.3*
added at the nozzle
-0.3 (1200°C)
81 (1200°C)
CALDE™ GUN MM 55 S5
High Alumina Raw Materials
Hydraulic
1500
6
57
30
0.8
5
2.6
added at the nozzle
-0.3 (800°C)
80 (800°C)
CALDE™ PLAST C 90 AB
Corundum
Ceramic
1750
6
90
8
0.7
-
2.95
-
-1.25 (800°C)
44 (800°C)
CALDE™ PLAST SUPERAL X AB
Bauxite
Ceramic
1650
6
73
22
1.35
-
2.62
-
-1.3 (800°C)
35 (800°C)
CALDE™ SPRAYCAST BX 85
Bauxite
Hydraulic
1700
6
84
11
0.8
-
3.05 (spray)
5.6 to 6.4
-0.15 (spray) (800°C)
70 (spray) (800°C)
CALDE™ SPRAYCAST F 50 R
Chamotte
Hydraulic
1550
6
50.5
45
0.7
-
2.55 (spray)
6.2 to 6.8
0 (800°C)
70 (spray) (800°C)
CALDE™ SPRAYCAST F 50 S7
Chamotte
Hydraulic
1550
6
48
41
0.8
7
2.42 (spray)
6.4 to 7.2
-0.25 (spray) (800°C)
70 (spray) (800°C)
CALDE™ SPRAYCAST SIC 30 R
Silicon Carbide Chamotte
Hydraulic
1600
6
44
21
0.4
30
2.57 (spray)
6.4 to 6.8
-0.3 (spray) (800°C)
80 (spray) (800°C)
Zircon
Hydraulic
1350
6
37
26
1.1
30 (ZrO2)
3.1
added at the nozzle
-0.3 (800°C)
48 (800°C)
Chemical analysis (wt %)
Main component
Binding system
Max. recomm. temp.(°C)
Max. grain size
Al2O3
SiO2
Fe2O3
SiC
(t/m )
CALDE™ GUN C 20
Chamotte
Hydraulic
1350
5
38.5
47.5
4.8
-
CALDE™ GUN C 28 HR
Chamotte
Hydraulic
1500
5
51
38.8
1.1
CALDE™ GUN F 40 A
Chamotte
Hydraulic
1450
6
42
53.5
CALDE™ GUN LA 50 SZ
Andalusite
Hydraulic
1650
5
52
CALDE™ GUN LA 60 Z
Andalusite
Hydraulic
1650
5
CALDE™ GUN LB 84
Bauxite
Hydraulic
1650
CALDE™ GUN LF 45 S
Chamotte
Hydraulic
CALDE™ GUN LF 50
Chamotte
CALDE™ GUN LS 30
Product name
CALDE™ STIX ZIRCON
Material required 3
(litres/100kg)
(%)
CCS
(N/mm2)
* Rebound excluded
NOTES: CALDERYS CALDERYS does not warrant the accuracy, tness or purpose or update o any inormation disclosed herein. The recipient shall reer to instructions and advice provided under any technical documentation. This document and the inormation contained herein are the exclusive property o CALDERYS. Reproduction, alteration, copy, release, publication or distribution, in whole or in part, is not allowed. Reerences, trademarks and specications o the products may change according to the geographical area to be supplied. Please check the availability o the products with the sales area manager. Monolithic concept solutions or Thermal Thermal Industry - Cement Plants
15
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[email protected] uk Calderys UK Ltd Ph.: +44 (0)113 26 36 268
[email protected] ukrAine Calderys Ukraine LLC Ph.: +38 (0)62 387 10 01
[email protected] VenezuelA Calderys Refractarios Venezolanos S.A. Ph.: +58 (0)286 994 1211
[email protected] VietnAm Calderys Taïwan Co. Ltd Ph.: +84 (0)4 6251 0806
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: r e v o C L 2 6 2 F A N 0 3 0 1 3 0 2 0 7 y a n r e p E : S C R s y r e d l a C
