Energy Saving Basic & High Alumina Lining Concepts For

TECHNICAL SOLUTIONS FOR TODAY AND BEYOND

Energy Saving Basic & High Alumina LiningConcepts For Rotary KilnsHans-Jürgen Klischat, Refratechnik Cement GmbHKevin Regan, Refratechnik North America, Inc.Garret Pair, Refratechnik North America, Inc.

Historical Concepts of Insulating Basic Linings For Rotary Kilns

Influence of Structural ComponentsOn Refractory Brick Properties

Comparison of Properties of an Insulating Magnesia Spinel Brick Compared To a Standard Product

Structure of an Insulating Magnesia Spinel Brick ComparedTo a Standard Product

Alkali Resistance of an Insulating Magnesia Spinel Brick Compared To a Standard ProductInsulating brick Standard basic

product

Test Conditions:Reagent K2CO3Temperature 1340 °CDuration5 h

Thermal Flow Through a Thermally Insulating Brick Compared to a Standard Magnesia Spinel Brick

Reduction of Kiln Shell Temperature By Using An InsulatingBrick Compared to a Standard Magnesia Spinel Brick

Applying the same technology to the standard60% Andalusite refractory…………….

REFRALUSIT® ES the tailor made solution for the Pulp & Paper Industry

Double‐Layer‐Lining REFRALUSIT 61 REFRALUSIT 63 REFRALUSIT ES RL ES vs. RL 63ISO 320 375 Stk. / 3721 kg 375 Stk. / 3778 kg 375 Stk. /3365 kgISO 620 155 Stk. / 1596 kg 155 Stk. / 1620 kg 155 Stk. / 1443 kgKG Extra‐E 1‐64‐198 490 Stk. / 673 kg 490 Stk. / 673 kg 490 Stk. / 673 kg

5990 kg 6071 kg 5481 kg ‐ 10 %cal.kiln shell temperature 174 °C 176 °C 166 °C ‐ 10 °CTi = 1200 °C, Ta = 20 °C Q = 2602 W/m2 Q = 2657 W/m2 Q = 2395 W/m2 ‐ 10%

Single‐Layer‐Lining REFRALUSIT 61 REFRALUSIT 63 REFRALUSIT ES RL ES vs. RL 63ISO 325 355 Stk. / 4322 kg 355 Stk. / 4389 kg 355 Stk. / 3908 kgISO 625 195 Stk. / 2488 kg 195 Stk. / 2526 kg 195 Stk. / 2250 kg

6810 kg 6915 kg 6158 kg ‐ 11%cal.kiln shell temperature

267 °C 274 °C 239 °C ‐ 35 °CTi = 1200 °C, Ta = 20 °C Q = 5606 W/m2 Q = 5902 W/m2 Q = 4571 W/m2 ‐ 23%

Material cost/ton, Euro/FCA 795 835 875Cost per running meterEuro/FCA 5.414 5.774 5.357 ‐ 7 %

Conclusion

• The latest development of both insulating basic and high alumina bricks (ALMAG® ES & REFRALUSIT ES) now offers new opportunities to save energy without any compromise regarding performance.

• The cement, lime, and pulp&paper industries have developedadvanced technologies for their respective productionprocesses; Significant steps for the further reduction of energy losses and CO2 by additional breakthroughtechnologies are unlikely for the immediate future.

• Improved refractories with reduced conductivity offerpossibilities to reduce energy consumption.

• Historical installation methods such as clog bricks, combination bricks or dual-layer linings were done, with various measures of success.

• The latest development of both insulating basic and high alumina bricks (ALMAG® ES & REFRALUSIT ES) now offers new opportunities to save energy without any compromise regarding performance.

Thank you for your kind attention!

Refratechnik North America, Inc.Kevin Regan530 Maryville Centre Drive, Suite 420St. Louis, MO 63141kevin.regan@refra.com

Energy Saving Basic & High Alumina Lining Concepts For

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