Cement

Cement rotary kiln and specialized rotating kilns used for manufacturing for various grades of cement, specialties of refractories used for these are:

• Longer kiln life( min 1year)
• Low specific energy consumption
• Efficiency improvement by installation of multistage pre heater with precalciner
• Use of alternate fuel – bio-waste, waste oil, plastics, tyres etc.
• Reduce emissions of CO2 – to reduce greenhouse gas emissions
• Low Carbon foot print

The main characteristics of refractories for this zone are resistance to spalling, alkali attack and abrasion.
At lower temperature area, conventional fire clay with 35-50% alumina bricks are used but recently light weight insulating bricks is gaining importance as well due to energy saving reasons.
At higher temperature area high alumina bricks are the usual lining. Now a days magnesia-spinel bricks are popular as well.

IFGL offers all kind of alumina bricks and monolithic for 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.