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$: INNOVATIVE REFRACTORY SOLUTIONS FOR THE CEMENT … Solutions for... · INNOVATIVE REFRACTORY SOLUTIONS FOR THE CEMENT INDUSTRIES Calderys India Refractories Ltd. ... The combustion$
REFRACTORY SOLUTIONS FOR - CEMENT PLANTS

INNOVATIVE REFRACTORY SOLUTIONS

FOR THE CEMENT INDUSTRIES

Calderys India Refractories Ltd.

We offer a full range of refractory solutions that result in efficient lining life. Progress has been made through the research and development of innovative product families such as ACCMON ASZ, ACCMON CRC, ACCMON CAR the LCC (Low Cement Castables) and their alkali resistant version which are specially dedicated to cement clinker manufacturing process conditions.

Calderys’ own team of experienced engineers can provide: • TOTAL monolithic refractory lining solutions • MIXED lining solutions combining bricks and monolithics • Gunning solutions

We can offer TURNKEY projects including: • Refractory solution design and engineering • Job site preparation • Time and delivery schedules • Planning of resources • Refractory & material supplies • Management of manpower • Supervision and installation • Curing and drying

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GUNNING


Calderys invented and patented Low Cement Castable (LCC) technology. Furthermore, we have developed a family of these products for Cement Inductry as they present very impressive mechanical characteristics. In addition to regular gunning castables, Calderys continued to innovate by inventing a new gunning installation technique for LCC with specific formulations and gunning machines. These gunning mixes, named "Low Porosity Dense Gunning (LPGM)," have mechanical properties matching their corresponding LCCs; exceptional Cold Crushing Strength and abrasion resistance, very good deformation under load values, great thermal shock resistance, and excellent corrosion resistance. In addition to these characteristics, LPGMs have proven to offer a service life comparable to that of cast-vibrated LCCs. Calderys, with its specific lances for gunning machines, has demonstrated that installation efficiency on job sites is approximately 50% greater when using LPGMs compared to brick linings.

Abrasion

The lining is progressively worn off in the lower part of the pre-heater by hot meal, and in the lower static 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



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 hot combustion gas coming from the rotary kiln. In these cyclones, temperatures vary from 300°C (upper part) to 930°C (lower part). The choice of the appropriate refractory material is made according to thermal and chemical conditions experienced in the area. The wall installation may have two layers of castables with an appropriate anchoring system.

Upper Cyclones/ Insulating Mid Cyclones/ Lower Cyclones/

Gas Ducts Materials Gas Ducts/Meal Pipe Gas Ducts/Meal Pipes

FIRECRETE SPL

INSULYTE 9

ACCMON CAR CPH

Standard conditions

ACCMON GUN BF

ACCGUN INS 8

FIRECRETE SPL

ACCMON 45 SPL

AC 30

CALCIUM SILICATE BLOCK

FLOWMON 45L

ACCMON CAR PH

AC 35

ACCMON GUN BF

ACCMON GUN BF

ACCGUN 45

AC 35

AC CAR

AC 40

WHYTHEAT C SPL

WHYTHEAT C SPL Severe conditions

ACCMON GUN CAR PH

FLOW MON 45L ACCMON GUN BF AC CAR ACCMON AF2 ACCMON 45



SOLUTIONS FOR

PREHEATER TOWER

CALCINER


The installation of a calciner in the cyclone heat exchanger enables preheating and calcination of the raw meal using combustible materials like coal, pet coke etc resulting in a reduction of the entire combustion process. In these areas, due to a high temperature process of about 1100-- 1250°C, as well as chlorine-alkali circulation, the refractory material is exposed to severe thermal and chemical conditions. Here, alkali- resistant products are required.

Calciner Standard conditions

ACCMON 45 SPL ACCMON CAR H ACCMON GUN BF Severe conditions

ACCMON AF1 ACCMON AF2 ACCMON GUN BF AC CAR ACCMON GUN 60 S5

Insulating Materials INSULYTE 9 Calciner

Riser

ACCGUN INS 8

Duct

CALCIUM SILICATE BLOCK

SOLUTIONS FOR

PREHEATER TOWER -

RISER DUCT

Kiln Riser Duct Standard conditions

ACCMON AF2 ACCMON 45 ACCMON GUN BF AC CAR Severe conditions

ACCMON 45 AH ACCMON CRC ACCMON GUN BF AC CAR AC 45S ACCMON GUN 60 S5

Tertiary Air Duct All conditions

ACCMON CAR CALDE SUPERGUN B AC CAR

TAD Elbow All conditions

ACCMON CAR CALDE SUPERGUN B AC CAR ACCMON GUN 60 S5

Insulating Materials INSULYTE 9 ACCGUN INS 8 CALCIUM SILICATE BLOCK ACCMON GUN 60 S5



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 intricate 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 to arrangements around the shock blower

nozzle, this type of lining can only be carried out with a monolithic refractory product in: cast, gunning and spray casting version.

Inlet Chamber/ Feed Tile Kiln Inlet Standard conditions

ACCMON AF 1 ACCMON AF2 ACCMON 45 SPL ACCMON GUN BF AC CAR

Severe conditions ACCMON 45 AH ACCMON AF2 ACCMON CRC ACCMON GUN BF AC CAR AC 45S ACCMON GUN 60 S5 ACCMON ASZ

Insulating Materials INSULYTE 9 ACCGUN INS 8 CALCIUM SILICATE BLOCK

FRONT VIEW SECTION A - A



SOLUTIONS FOR

KILN HOOD & COOLER

BURNER PIPE - 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 lot of factors. The burner pipe 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, line design anchoring and installation technique guarantee long lasting operation time.

Kiln Inlet Cone Burner Pipe Standard & severe

conditions ACCMON CRC ACCMON BP ACCMON ASZ

Inlet Zone Standard & severe conditions

ACCMON AF1 ACCMON AF2 ACCMON CRC

Nose Ring/ Tip casting Standard & severe conditions

ACCMON AF2 ACCMON ASZ ACCMON TC

Industry-Cement Plants

SOLUTIONS FOR

KILN HOOD & COOLER

KILN HOOD

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 clinker, high abrasion, thermal shock chemical resistant materials should be used. Calderys long-term experience allows providing you with the solutions combining: the right selection of the future long service life, materials - depending on the chemical and 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

ACCMON 45 ACCMON CAR PH ACCMON AF1 ACCMON GUN 55 ACCMON GUN 60 S5 Severe conditions

ACCMON AF1 ACCMON CAR AC CAR AC 55S ACCMON GUN 55 CALDE SUPERGUN B ACCMON GUN 60 S5 ACCMON ASZ

Insulating Materials Standard & severe conditions

INSULYTE 9 ACCGUN INS 8 CALCIUM SILICATE BLOCK



SOLUTIONS FOR

KILN HOOD & COOLER

COOLER


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

Impact Zone Standard & severe conditions

ACCMON CAR ACCMON AF2 CALDE SUPERGUN B

Insulating Materials Standard & severe conditions

INSULYTE 9 ACC GUN INS 8 CALCIUM SILICATE BLOCK

SECTION A - A

PLAN



SOLUTIONS FOR

KILN HOOD & COOLER

COOLER

Bullnose Standard & severe conditions

ACCMON CRC ACCMON CRC BN ACCMON ASZ

Cooler Medium Zone Standard & severe conditions

Zone Wall : AC 40 ACCMON 45 SPL ACCMON CAR PH ACCMON GUN 55 AC CAR

Cooler Cold Zone Standard & severe conditions ACCMON 45 SPL ACCGUN BF WHYT HEAT C SPL AC 40

Insulating Materials INSULYTE 9

ACCGUN INS 8 CALCIUM SILICATE BLOCK

SECTION A - A

PLAN




ROTARY KILN


Tip Casting Standard & Severe conditions

ACCMON CRC TC/ACCMON ASZ MAG-AL SPINEL

Lower Transition Zone

Calcinin Zone Standard & Severe conditions

AC 55 S AC 50 S AC 60 S

Standard & Severe conditions

AC 70 L SPL AC 70 – 20 MAG-AL SPINEL

Burning Zone Standard & Severe conditions

AC 70 L SPL MAG-AL SPINEL AC 70 - 20 AR

Preheating Zone Standard & Severe conditions

ACE REFRATHERM AC 40 S AC 40

Inlet Cone Standard & Severe conditions

ACCMON AF1 ACCMON AF2 ACCMON CRC

Upper Transition Zone Standard & Severe conditions

AC 70 L SPL AC 70 - 20 AR MAG-AL SPINEL



TECHNICAL DATA OF MONOLITHICS


Product Name Maximum Recommended Chemical Analysis (wt %) Refractoriness/Pyrometric Material Required

Temperature (ºC) Al2O Fe3O CaO Cone, Orton / °C (MT/ m3)

FIRECRETE SPL 1350 45.3 4 8.35 20 2.2

ACCMON CAR PH 1200 1 32 2.39

ACCMON CAR 1400 1.3 36 2.88

ACCMON AF1 1400 1 32 2.46

ACCMON AF2 1400 1 32 2.45

ACCMON CRC 1400 0.8 32 2.43

ACCMON CRC TC 1400 0.85 32 2.46

ACCMON 45 1550 46.5 0.9 1.8 32 2.3

FLOWMON 45 L 1550 44 0.9 1.3 32 2.2

ACCMON GUN BF 1400 45.2 1.4 3.5 32 2.18*

ACCMON GUN 55 1600 50.8 0.7 3 32 2.22*

WHYT HEAT C SPL 1500 51 4.6 1 30 2.18

ACCMON 45 SPL 1500 42.5 5.1 1.8 32 2.25

INSULYTE 9 1200 5.3 13 0.96

ACCGUN INS 8 900 1.25 13 0.76*

CALDE SUPERGUN B 1700 0.80 1.5 37 2.7

ACCMON ASZ 1700 1.65 37 2.75

ACCGUN 45 1450 43.66 2.23 9.48 16 2.12

ACCGUN INS 8 900 5.3 12 0.78

ACCMON 45 AH 1500 43 1.8 31 2.28

ACCMON BP 1700 50.5 0.7 37 2.75

ACCMON CAR CPH 1000 20 2.38

ACCMON CAR H 1200 46 1 31 2.33

ACCMON CRC BN 1600 32 2.46

ACCMON GUN 60 S5 1500 57.4 0.9 3 33 2.36

ACCMON TC 1700 50.5 0.75 37 2.7 * Gunning loss is not included in gunning products



TECHNICAL DATA OF BRICKS


Product Name Maximum Recommended C.C.S Chemical Analysis(wt%) Refractoriness Material Required Required Temperature (C) (kg/cm

2)

Al2O3 Fe2O3 Pyrometric Cone, Orton (MT/ m

3)

AC - 30 1350 355 32 2.38 28 2.11

AC 35 1350 360 34.7 2.36 28 2.15

AC 40 1400 365 39.5 2.56 29 2.18

AC 40S 1420 395 40.5 2.15 30 2.21

AC 45S 1450 420 45 2.05 30 2.26

AC 50S 1450 465 49.5 2.05 32 2.3

AC 55S 1460 495 54.6 2.5 34 2.38

AC 60S 1480 545 59.2 2.5 35 2.42

ACE-REFRATHERM 1300 215 20.8 2 17 1.85

AC CAR 1400 570 1.68 29 2.25

AC 70 – 20 - 675 70 2 37 2.65

AC 70 L SPL 1480 780 67.8 2.5 36 2.64



REFERENCE LIST OF CEMENT PLANT PROJECTS


Plant/ Customer Location Clinker Capacity

OEM Consultant Year of

TPD order

RELIANCE CEMENT CO. PVT. LTD Maihar, Madhya Pradesh 10000 POLISIUS HOLTEC 2012

ULTRATECH CEMENT LTD (RAJSHREE) Gulbarga 10000 KHD HOLTEC 2011

ULTRATECH CEMENT LTD (RAWAN) Rawan (Raipur) 10000 KHD HOLTEC 2011

JP SUN PROJECT SIDHI II Sidhi (Madhya Pradesh) 4500 FLS HOLTEC 2011

DUNGSAM CEMENT Bhutan 3000 KHD HOLTEC 2011

CEMENT MFG CO. LTD (STAR CEMENT) Meghalya 6000 KHD HOLTEC 2011

JP BALAJI CEMENT Andhra Pradesh 12000 FLS HOLTEC 2010

JP SUPER CEMENT Uttar Pradesh 6000 KHD HOLTEC 2010

GREEN VALLEY CEMENT Meghalaya 1000 WIL WIL 2010

PRISM CEMENT II Satna, Madhya Pradesh 7000 FLS 2010

BIRLA CORPORATION, CHITTORGARH Rajasthan 4500 FLS 2010

JP GUJARAT ANJAN CMENT PROJECT SP -II Gujarat 4500 L&T HOLTEC 2009

BHILAI JAYPEE CEMENT Madhya Pradesh 3300 L&T HOLTEC 2009

ACC BARGARH Orissa Major Modification ACC 2009

ACC WADI (UPGRADATION TO 12000) Wadi 12000 FLS - 2009

PENNA CEMENT Karnataka 4000 FLS FLS 2009

BIRLA CORPORATION SATNA UNIT I Madhya Pradesh Major Modification BIRLA 2009

RAIN COMMODITIES LTD. Andhra Pradesh 3500 FLS 2008

ZUARI CEMENT (INDIA) ITALCEMENTI Yeraguntlla 6500 FLS HOLTEC 2008

JUD CEMENT LIMITED Meghalaya 1000 WIL WIL 2008

CHETTINAD CEMENT India 4000 FLS HOLTEC 2008

BIRLA CORPORATION SATNA UNIT II Madhya Pradesh Major Modification BIRLA 2008

JK CEMENT WORKS Mudhol (Karnataka) 6500 FLS 2008

ORIENT CEMENT DEVAPUR Andhra Pradesh 3500 FLS HOLTEC 2008






TPD order

NATIONAL CEMENT COMPANY Yemen 6000 2008

THANGUEN CEMENT PLANT Vietnam 4000 IHI 2008

AMBUJA CEMENT BHATAPARA (DESIGN) Chattisgarh 4500 POLISIUS 2008

NCL INDUSTRIES LTD. Jagyapet/Andra Pradesh 2000 FLS 2008

JP GUJARAT ANJAN CEMENT SP - I Gujarat 4500 L&T HOLTEC 2007

JP HIMANCHAL (BAGA) Himanchal Pradesh 10000 KHD HOLTEC 2007

JP DALLA KILN 5 Uttar Pradesh 4500 POLISIUS HOLTEC 2007

JP SIDHI CEMENT I Madhya Pradesh 4500 L&T HOLTEC 2007

DEEPAK CEMENT GUJARAT Gujarat 2100 ENRON ENRON 2007

LHAKI CEMENT BHUTAN Bhutan 450 HALLMARK

VASAVADATTA CEMENT Karnataka 4000 FLS 2007

CAMPHA CEMENT COMPANY Vietnam 6000 KAWASAKI 2007

JP DALLA CEMENT FACTORY (KILN 4) Uttar Pradesh 2000 POLISIUS HOLTEC 2007

ACC MADUKARAI Tamilnadu 2800 ACC 2006

ACC CHAIBASA Jharkhand 4200 FLS FLS 2006

MOMBASA CEMENT Africa 2000 POLYSIUS DEVELOPMENT 2006

CONSULTANT

ARM CEMENT KENYA Kenya 3000 POLYSIUS HOLTEC 2006

LAFARGE ASHAKA CEMENT Nigeria 2000 KHD 2006

REYSUT CEMENT Oman 4000 KHD 2006

OCL (DESIGN) Orissa Major Modification KHD 2006

ACC LAKHERI Rajasthan Major Modification ACC 2006

ACC GAGAL UNIT II Himachal Pradesh Major Modification POLYSIUS ACC 2005

ACC KYMORE Madhya Pradesh 4200 FLS FLS 2004

LAFARGE CEMENT BANGLADESH Bangladesh 3000 FLS L&T 2004






TPD order

ACC GAGAL UNIT I Himachal Pradesh Major Modification POLYSIUS ACC 2004

CEMENT MFG CO. LTD (STAR CEMENT) Meghalaya 3000 WNIL HOLTEC 2004

PRISM CEMENT Satna, Madhya Pradesh 7000 FLS 1998

LAFARGE SONADIH ( TISCO ) Chattisgarh 4200 1995


ISO 9001:2008 DAR VERIFIED

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