01:20 pm
Challenges for a Cement Producer
Dr. Volker Wagner | HeidelbergCement AG | Germany
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Author:
Dr. Volker Wagner | HeidelbergCement AG | Germany
Refractories play a vital role for us as a cement producer. Yearly we are consuming a significant amount of bricks and monolithic materials. Changing clinker production conditions as caused by continuously increasing alternative fuel rates or new production technologies were the basis of new developments in the field of refractories. Based on a good cooperation between HeidelbergCement and some refractory suppliers several excellent solutions have been verified over the past few years.
However, old and solved problems are always replaced by new challenges. Our plants are looking for a continuous production without any unplanned stoppages. A reliable refractory lifetime predictability for any application area is required. But the tools available are still on a very basic level. So far, a deeper look into the refractory material and therefore the detection of potential damages/pre-damages is not possible at all. This paper shows specific areas where we as HeidelbergCement are focusing upon.
01:40 pm
Near-customer engineering management for advanced applications in the cement industry
Bastian Vesenberg | EKW GmbH | Germany
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Authors:
Bastian Vesenberg | EKW GmbH | Germany
Nicole Schlimm | EKW GmbH | Germany
Daniel Cölle | EKW GmbH | Germany
Dr. Thomas Weiss | IKN GmbH | Germany
Lennart Hapke | IKN GmbH | Germany
An engaging route to the realization of a technologically advanced alkali-resistant and particularly abrasion-resistant high-temperature material with reliable thermal shock behavior is outlined, from the idea through the development process to the final product. Novel testing methods are integrated into the development like alkali tests at 1100 °C using potassium carbonate and sodium carbonate on the one hand and potassium sulfate and sodium sulfate on the other mark reliable results for the functional stability of the refractory ceramics in corrosive process routines. The design and prototyping of preformed components was used to successively optimize the material properties under real conditions close to the customer. A particular challenge was the adjustment of certain structural properties in order not to lose the resistance of the refractory ceramics to erosively acting particle streams and gases in favor of a robust behavior against abruptly occurring load peaks, for example abrupt temperature changes or locally occurring pressures. For this purpose, a test procedure was developed to test the so-called impact behavior under hot conditions, and both interventions in the bonding system of the refractory material and in construction elements led to improved robustness of impact zones. The aim of optimizing the material, from an economical point of view in particular, was fulfilled, which was confirmed by the successful application on the customer's plant site. Last but not least, the potential transferability of the product solution to other industries is demonstrated, e.g. in the aluminum industry.
02:00 pm
Effective CO2-Reduction for Rotary Kiln Burning Processes by Using Energy Efficient Linings
Dr. Hans-Jürgen Klischat | Refratechnik Cement GmbH | Germany
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Authors:
Dr. Hans-Jürgen Klischat | Refratechnik Cement GmbH | Germany
Dr. Stefan Puntke | Refratechnik Cement GmbH | Germany
Holger Wirsing | Refratechnik Cement GmbH | Germany
Peter Groger | Refratechnik Cement GmbH | Germany
The Carbon Challenge is a major topic especially for cement and lime production, as carbon is released from the raw material and from the material burning process. To reduce the latter, new lining concepts have been developed by designing a new fine-ceramic microstructure. These novel basic and non-basic brick grades with porosities up to 25% reduce the heat losses due to their exceptional low heat transfer. All other properties, including refractoriness, strength, structural elasticity, permeability, and thermal shock resistance are kept at values which are well-proven for the application in rotary kiln linings. Emphasis was also laid to kiln linings which are exposed to increased alkali atmosphere, as a result silicon carbide containing high alumina bricks are an essential part of this energy saving concept. The installation of these new products is as easy as for standard products, no additional effort like two-layer-linings is necessary. The results of recent installations show a significant decrease of the kiln shell temperature. The reduction in overall CO2-emission is calculated to 2%, which is enormous considering the already well-matured rotary kiln process and the installation in passing. Beneath a lower lining weight, even reducing the operating power, the reduction of 10% in material use is responsible for an improved sustainability and reduced carbon footprint not only for the kiln operator, but also for the refractory producer, and the environment: Carbon Challenge accepted.
02:20 pm
Energy-saving Refractory Bricks for Sustainable Lining of Rotary Kilns
Mustafa Cavac | Germany
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Authors:
Dr. Ufuk Akkasoglu | KUMAS Manyezit Sanayi A.Ş. | Turkey
Gorkem Yanik | KUMAS Manyezit Sanayi A.Ş. | Turkey
Nuri Sarioglu | KUMAS Manyezit Sanayi A.Ş. | Turkey
Mustafa Cavac | Germany
Reducing carbon footprint is a significant challenge for energy-intensive industries- including cement and lime- due to the usage of extensive thermal processes in production. One possible way to decrease energy consumption is using an energy-saving lining in which the thermal conductivity is reduced by increased porosity. However; mechanical, chemical and thermal limitations of the rotary kilns should be considered in brick design since porosity will degrade relevant properties. In this study, novel basic refractory bricks with reduced thermal conductivity were developed to reduce kiln shell temperature and hence reduce energy consumption. Different pore-forming agents and their influence on microstructure as well as physical, mechanical and thermal properties were investigated. A novel energy-saving basic refractory brick with reduced thermal conductivity by induced porosity is developed without compromising the refractoriness as well as mechanical and thermal properties.