Cement

Cement rotary kilns are used to manufacture various grades of cement. The key benefits of using the specialized refractories in these applications are:

• Longer kiln life( min 1 year)
• Low specific energy consumption
• Use of alternate fuel – bio-waste, waste oil, plastics, tyres, RDF, etc.
• Reduce emissions of CO₂ thus reducing greenhouse gas emissions
• Low-Carbon footprint

• The main characteristics of refractories for this zone are resistance to spalling, alkali attack and abrasion.
• At lower temperature areas, conventional fire clay with 35-50% alumina bricks are used.
• At higher temperature areas high alumina bricks are the usual lining.

IFGL offers all kinds of alumina bricks and is monolithic for the cement industry.

• Temperature fluctuations & chemical corrosion are prevalent.
• Abrasion from the charge is a constant hazard.

Properties of the bricks should have:

• resistance to corrosion
• resistance to thermal spalling
• resistance to infiltration of salts
• stability of coating at operating temperature.

High fired direct bonded Mag-Chrome along with 70-80% high alumina bricks are still the most popular bricks for this zone. Magnesia hercynite bricks are a new development in this area.

• The refractories in this zone demands higher resistance to thermal change and salt infiltration.
• The practice since last two decades is magchrome bricks. It gives harmful influences on the environment and also to human health.
• Magnesia Alumina Spinel bricks are quite suitable for this area along with largely used 60% alumina bricks, due to excellent thermal spalling resistance & superior alkali resistance.

• Some part of this zone corresponds to lower transition zone.
• Bricks in lower transition zone encounter thermo-mechanical and pyro-chemical stress as in upper transition zone also undergoes high mechanical stresses.
• High fired Magnesia Alumina Spinel bricks along with 60-70% HA bricks are used are used for this area to sustain these stresses.

Besides this, all kind of alumina conventional castable ranging 40-90% Alumina type, low cement castable, special castable, mortars and gunning castable specialized for cement industry are produced by IFGL.

Besides cement rotary kiln, there are several stationary bodies in a typical dry cement manufacturing plant, and IFGL has full range of Alumina Bricks for those equipments.

The preheater uses hot kiln gases to progressively heat the raw material before it enters the kiln, improving overall thermal efficiency. The pre-calciner performs a major portion of the calcination process before the material enters the rotary kiln, reducing the thermal load on the kiln.

Our product ranges – FGL 425, FGL 452, FGL PBZ 50, FGL515 AR, IF LC 45, IFDENSE 50 AR, IFCAST 40 GUN, IF LC 60 GUN, etc.

The cooler rapidly cools the hot clinker discharged from the rotary kiln while recovering heat for reuse in the process. It improves thermal efficiency and ensures effective clinker cooling before further handling. Our product range includes 45-90% Alumina Castables (FGL LC 45/LC 70/LC 90), 50-80% alumina Bricks(FGL B 52/B72/B82), 70-80% alumina gunning mass(IF 70 GUN/80 GUN) and ranges of mortars.