CEMENT PLANTS PRESENT UNIQUE CHALLENGES
Our environmentally friendly products present opportunities for the cement industry. Seven supplies customised solutions for burner lances, preheaters, calciners, grate coolers, kiln hoods, nose rings, riser ducts, smoke chambers, and tertiary air ducts.
Seven‘s range of complementary products includes steel and ceramic anchors, bio-soluble and ceramic fibers, and insulating bricks.
„The cement industry has very specific demands on their plants and on any technical supplier. Aside from the obvious need to get the job done in the agreed time and with the optimal outcome, the industry cares deeply about environmental care.“
Sales Manager of Seven Refractories Italy
Some call it cement. We call it the binding force behind skyscrapers.
Our products have been developed for the special operating conditions required in the cement manufacturing process. Nowadays, more and more alternative fuels are burned and special refractory materials are required.
To date, a refractory material suitable for all the operative conditions does not exist. Thus, each plant should be analyzed to find the best technical solutions.
Each step of the cement-making process has special requirements regarding the correct choice of refractory materials. The design of the plant, the raw materials used in the process, and the various fuel options, all have a major influence on the refractories required. Alkali infiltrations, build-ups, abrasions and the use of alternative fuels, must all be carefully evaluated.
We keep a strategic stock of monolithic and insulating castables for the cement customer’s need. In addition we keep a wide stock of all complementary products such as steel and ceramic anchors, bio-soluble and ceramic fibers, and insulating bricks.
With the support of our expert technicians, we supply not only top quality refractories, but also technical solutions and engineering. In cooperation with selected installation companies, we are able to supply turn-key/new projects, along with all the necessary equipment for the lining maintenance of a cement plant.
The burner lance is a critical area with specific needs which depend on kiln and grid cooler design, raw materials used and fuels type. Strong thermal load, abrasions, infiltration and chemical attacks must be considered in the right choice for the monolithic used to line the burner lance.
Cyclones and connecting ducts
The most important step in the efficiency of a modern cement plant is the cyclones system.
Each pre-heating system design is different and unique, and each cyclone system must be analyzed in order to identify the critical refractory zone. We evaluate the effects of build-up, alkali and chloride infiltration, and all other factors which may influence the performance of refractory materials used in the various cyclone systems.
The calciner plays an important role in the cement manufacturing process being the first step of the clinker production process. The main property of the calciner’s refractory lining is to withstand to the chemical attacks coming from the hot gases of the process. Refractory materials must have low porosity and good thermal stability.
The riser duct is a problematic zone due to: build-ups, alkali infiltration and chemical attack to the steel anchors. Following the general rule, we suggest lining the duct with bricks in the round sections and with castables in the square sections.
The smoke chamber is a critical area, where build-ups, frequent use of high pressure water pump which causes thermal shock make it necessary to use special refractories.
The nose ring is also a critical area, requiring special monolithic refractory material which has an excellent resistance to:
- High Thermal Shock
- Mechanical Resistance
- Chemical Attack Resistance
Our Seven Cast AS 30 has been developed by our R&D department to ensure the best performance for this critical area along with a very fast installation time.
Tertiary air duct
For the tertiary air duct we suggest abrasion resistant castables for the most stressed areas. For the other areas we suggest to use fireclay bricks.
The formed clinker falls from the kiln into the grate cooler. The cooler area is also a problematic zone due to high thermal shock and abrasion. We use high quality raw materials and special binders in our monolithics, which are capable of resisting the severe conditions in the grate cooler.
For this area we suggest refractories with low thermal conductivity, good abrasion resistance and good resistance to chemical attack.