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Transactions of the INDIAN CERAMIC SOCIETY   Vol. 53  1994
Newer Refractory Materials for Cement Rotary Kiln
S. C. SHARMA AND SHRI GOPAL
Pages : 116-122
DOI : 10.1080/0371750X.1994.10804654
Abstract
As the modification in the clinkerization technology has been a continuous process over the years, the trend of refractory application in Cement Rotary Kiln {CRK) system has also undergone a considerable change. The fireclay/alumino-silicate bricks, high alumina bricks of different grades and conventional castables have been replaced by aluminous bricks with specific characteristics, e.g. coating repellent type, high strength insulating bricks, basic bricks of different types including dolomite, silicon carbide bricks and special castables with low cement, ultra-low cement and no cement along with new anchoring system to optimize the lining life. The recently reported performance data of periclase spinel bricks in a large capacity kiln reveal that apart from minor problems, the changeover from mag-chrome bricks to these bricks can be carried out successfully. However, the result achieved cannot be generalized as these can be influenced by kiln system, kiln feed and fuel parameters etc. The magnesia spinelide refractory {MSR) brick, with high affinity to protective coating and increased resistance to clinker melt, developed by National Council for Cement and Building Materials {NCB) has now emerged as a dependable indigenous basic refractory for burning zone of CRK system. The brick will soon be available to cement industry as its commercial production is to be launched shortly. The service conditions in transition zone of CRK are many times as severe as those in burning zone. Periclase spinel brick and direct bonded basic bricks have been used in transition zone with varying degree of success. A modified, highly spall resistant high alumina brick has been developed and used abroad in this zone. A brick of this type has also been developed indigenously by NCB. Based on the different experiences in preheating and calcining zones, an effective alternative material for lining of these areas subjected to high thermal and chemical stresses has been developed. It is a new seal tight brick with maximum resistance to alkalis, with requisite mechanical characteristics. For specific applications and to withstand the stresses like high impact, abrasion, alkali attack and coating formation, special castables have been developed. It has been established that the areas, e.g. critical locations in different types of coolers, kiln hoods, tertiary airducts, kiln outlets, preheaters and precalciners etc where shaped products fail, sometimes miserably, an appropriately selected and applied castable provides the best solution to the problem of lining life. Some of these refractory products are described in the paper.
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