The science of refractories is broad and complex. An unplanned stoppage due to refractory failure costs productivity and therefore turnover. It is proven that knowledge and understanding of refractories can save a lot of money.So it is essential for us to convey comprehensive and practice-orientated refractory expertise to our customers, in order to further improve the availability and productivity of cement kilns.
· Theory and praxis of correct installation of refractory material for the cement industry
· Everyone who is involved with refractories
· Persons who select, buy, are responsible for, install, handle, as well as guarantee the quality of installation of refractories, such as refractory coaches (key accounts), plant manager, production manager, maintenance managers, technicians, installation teams, purchasers, warehousemen, etc.
Kiln shell test measurementRefractory materials are wear parts which are subject to three main types of wear:
· Chemical wear
· Thermal wear
· Mechanical wear
Post-mortem investigation and general process analysis can help to evaluate the chemical and thermal loads on the refractory material.On the basis of our measurement,
it is possible to give recommendations for preventive measures for improvement upon our conclusions of mechanical conditions.
Post mortem investigation of brick samplesIn order to be able to recommend the most suitable refractory material, detailed knowledge about the process conditions in the respective lining area is indispensable. For this reason it is important to receive as much information as possible, for example data for clinker chemistry, hot meal and raw meal composition as well as types of fuels used.
In addition to all this information, the examination of a used refractory sample from a specific lining area can provide the most representative information.
On the basis of a post-mortem investigation the main wear mechanism can be determined. This result serves as the main criterion for a product recommendation and improvement of refractory performance.
Process analysesThe major causes of unsatisfactory lining service life is complex. Therefore detailed analyses of process conditions are a helpful tool to achieve a significant improvement of performance of refractory lining.
During our evaluation of the process parameters we always consider the possible simultaneously effective wear parameters from the point of view of:
· severe thermo-chemical stress
· undesired, frequently changing coating conditions
· excessively mechanical stress
· higher thermal load
Process analyses, which consider raw materials, fuel and clinker properties and the stability of their values, show the appropriate way to adjust the refractory lining. Even adjustments to clinker chemistry with respect to economic efficiency can lead to higher performance of refractory material and therefore higher productivity of the cement kiln.
Several process analyses show that a detailed look at process conditions, the mechanical condition of kiln and the selection of refractories can save a lot of investment and production costs.
Analyses of clinker samplesWe could investigate not only refractory and raw materials, but also clinker and coating samples from our customers of the cement industry.
This investigation can support our customers to better understand the process conditions or reasons for the formation of process-disturbing build-ups.
Refractory Lining recommendationWe optimize the refractory lining in the cement rotary kiln taking into account lining history, process conditions and fuel characteristics.
Several years of experience and knowledge are the basis of improving the performance of refractories in the cooler, preheater tower and all other aggregates. Selecting the right products for their right application is essential.