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 Cement production

Since 2006, our company has been actively collarborating with the cement factories of the RF and the CIS. A special line of refractory materials was developed for cement industry. We offer power saver circuits of monolithic linings (made of refractory concretes), combined (refractory concretes and fireclay bricks), and modular lining circuits (made of molding workpieces based on the customer's drawings).


The list of supplies includes the entire range of refractory materials: 

  • refractory concretes;
  • lightweight concretes;
  • fireclay bricks;
  • anchorage;
  • heat insulation materials;
  • special electrodes.

Carrier-gas heat exchanger

We offer various materials with extended service life and advanced reliability for the lining of carrier-gas heat exchangers. They are designed for operation both at high and relatively low (up to 400 °C) temperatures in aggressive chemical environments and high abrasive wear. 

High-aluminous concretes and andalusite-based gunned castables with silicone-carbide (SIC) admixtures, concretes based on fire-clay grog and bauxite proved to be highly efficient. We suggest producing the heat insulation layer from lightweight concretes or a calcium silicate slab.  

Feed pipeline

The feed pipeline lining is exposed to high abrasive actions associated with a large amount of undersized materials and thermal loads. High-aluminous and andalusite-based materials with silicone-carbide (SIC) admixtures, concretes based on high-aluminous fire-clay grog or bauxite are suitable for the lining of these assemblies. Heat insulation is made of calcium silicate slabs; however, considering installation complexity for this unit, is it highly recommended to use lightweight concretes applied by smearing technique. Use of lightweight concrete substantially reduces the time of installation and enhances the overall lining resistance.

Decarbonizer 

The refractory lining of the decarbonizer is exposed to considerable thermal effects (the design of some decarbonizers implies installation of additional burners), as well as the action of chemically aggressive substances (alkali, sulfates, chlorides). Andalusite-based high-aluminous refractories with silicon carbide admixtures (SiC) are well-suitable for operation under these conditions. These concretes have a low adhesion degree of dust fused on the clinker; they are resistant to the action of alkalis and abrasive wear, and have high thermal resistance values. We suggest producing the heat insulation layer from lightweight concretes or a calcium silicate slab.

Feed chute

The feel chute lining is exposed to substantial temperature loads, high abrasive wear related to a considerable volume of undersized materials, including the actions of chemically aggressive substances (alkali, sulfates, chlorides). Andalusite-based high-aluminous refractories with silicon carbide admixtures (SiC) are well-suitable for operation under these conditions. These concretes have a low adhesion degree of dust fused on the clinker; they are resistant to the action of alkalis and abrasive wear, and have high thermal resistance values. The heat insulation layer is to be made of lightweight concretes or calcium silicate slabs.

Rotary kiln

KERALIT LLC offers refractory concretes for the lining of separate sections of rotary kilns. These solutions are applicable to both the 'wet' and 'dry' production techniques of clinker production. Use of refractory concretes enhances the mechanical and thermal resistance of the lining. Concretes based on corundum and high-aluminous concretes are suitable for the furnace baffle lining; andalusite-based concretes for the chain section lining. A modular lining made of monolithic blocks that were prefabricated and dried at KERALIT LLC plant was developed for the furnace baffle lining.

Rotary kiln head

KERALIT has a wide experience of using their products for this type of unit by appying a variety of methods: vibropacking of dense refractory concretes (castables) and application of gunned castables, including use of heat insulation lightweight gunned castables. Andalusite- and bauxite-based high-aluminous concretes with silicone carbide, as well as refractory units made by vibratory casting, pursuant to the customer's drawings for the unit lining.

Air-quenching cooler

Present-day high-performance cooling systems shall be protected with high-quality refractories. The effect of hot gases, chemically aggressive substances, operating contingencies, intensive abrasive wear, and the complexity of geometrical shapes require searching for new solutions in order to create refractories that meet these requirements. Our technical solutions are applicable to various sections of the lining of air-quenching coolers may be established using a variety of technologies: vibropacking, mortaring, and a modular lining.

Burner

High-aluminous concrete with silicone carbide (SiC) was developed for the lining of the burner “hood” (the first meter of the burner). The lining of the burner 'body' is made of bauxite or fire-clay grog concrete.

Tertiary air conduit

The lining of the tertiary air conduit is normally designed combined; brickwork is provided on straight pipe runs along with expansion joints, areas with a complex geometric shape and a flap are made of refractory concrete. Special concrete brands were developed to resist high abrasive wear, effects of alkalis, sulfates, and chlorides. We suggest making the heat insulation layer from lightweight concretes or a calcium silicate slab.