energy saving basic & high alumina lining concepts for
TRANSCRIPT
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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.
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TECHNICAL SOLUTIONS FOR TODAY AND BEYOND
Historical Concepts of Insulating Basic Linings For Rotary Kilns
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TECHNICAL SOLUTIONS FOR TODAY AND BEYOND
Influence of Structural ComponentsOn Refractory Brick Properties
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TECHNICAL SOLUTIONS FOR TODAY AND BEYOND
Comparison of Properties of an Insulating Magnesia Spinel Brick Compared To a Standard Product
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TECHNICAL SOLUTIONS FOR TODAY AND BEYOND
Structure of an Insulating Magnesia Spinel Brick ComparedTo a Standard Product
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TECHNICAL SOLUTIONS FOR TODAY AND BEYOND
Alkali Resistance of an Insulating Magnesia Spinel Brick Compared To a Standard ProductInsulating brick Standard basic
product
Test Conditions:Reagent K2CO3Temperature 1340 °CDuration5 h
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TECHNICAL SOLUTIONS FOR TODAY AND BEYOND
Thermal Flow Through a Thermally Insulating Brick Compared to a Standard Magnesia Spinel Brick
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TECHNICAL SOLUTIONS FOR TODAY AND BEYOND
Reduction of Kiln Shell Temperature By Using An InsulatingBrick Compared to a Standard Magnesia Spinel Brick
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TECHNICAL SOLUTIONS FOR TODAY AND BEYOND
Applying the same technology to the standard60% Andalusite refractory…………….
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TECHNICAL SOLUTIONS FOR TODAY AND BEYOND
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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 %
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TECHNICAL SOLUTIONS FOR TODAY AND BEYOND
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.
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TECHNICAL SOLUTIONS FOR TODAY AND BEYOND
Thank you for your kind attention!
Refratechnik North America, Inc.Kevin Regan530 Maryville Centre Drive, Suite 420St. Louis, MO [email protected]