HANDBOOK

FOR

REFRACTORIES
PART 3 REFRACTORIES FOR CEMENT KILN SYSTEM

BUREAU Of INDIAN STANDARDS

MANAK BHAVAN,-9 BAHADUR SHAH ZAFAR MARG..
NEW DELHI 110002
SY :37,(Part 3 ) - 1987
First Published : NOVEMBER 1987
First Reprint : JANUARY 1989

UDC 666’94.041

@ BUREAU OF INDIAN STANDARDS

PRICErRs 50.00
-

PRINTED IN INDIA
AT PRINTOGRAPH, NEW DELHI
AND PUBLISHED BY
BUREAU OF INDIAN STANDARDS, NEW DELHI 110 002
 CONTENTS

Page

FOREWORD ... 7

1. INTRODUCTION ... 9

2. PROCESSOPTIONS AND KILN SYSTEMS ... 9

3. ZONATION OF KILN SYSTEMS ... 13

4. SELECTION OF REFRACTORIESFOR TYPICAL AND IMPORTANT ZONES ... 13

.5. LINING THICKNESSIN ROTARY KILNS ... 15

6. INDIAN STANDARD SPECIFICATIONSFOR CEMENT KILN REFRACTORIES . . . 15

7. PRESENT CONWMPTION TRENDS ... 15

8. REFRACTORY INSTALLATION PRACTICES .. . 15

APPENDIX A LIST OF INDIAN STANDARDSON REFRACTORIES . . 18

As in the Original Standard, this Page is Intentionally Left Blank
 SP : 37 ( ,Part 3 ) - 1987

REFRACTORIES SECTIONAL COMMITTEE, SMDC 18

CHAIRMAN REPRESENTING
SHRI I. C. MODI Steel Authority of India Ltd ( Rourkela Steel
Plant ), Rourkela

MEMBERS
SIIRI’R. K. SANGHI ( Allernate to
Shri I. C. Modi )
SHRI P. S. V. ANANTHANA- Engineering & Mineral Industrial Research
RAYANA Laboratory, Bangalore
SHRI B. N. GHOSII Tata Iron and Steel Co Ltd, Jamshedpur
SURI S. K. MITRA ( Al/ernate )
SF~RIT. K. GHOSH Tata Refractories Ltd, Beliahar
SI-~RIA. V. HINGORANI Steel Authority of India Ltd (Bhilai Steel Plant ),
Bhilai
SHRI B. S. VENKATARAMIAM
( Altefnate )
SHRI S. K. JHUNJHUNWALA Orissa Industries Ltd, Rourkela
SARI M. M. SAH~J( Alternate )
SHRI MANMOHAN SINGH Steel Authority of India Ltd ( Bokaro Steel Plant ),
Bokaro
SHRI A. S. KHALKHO ( Altcrnate )
SI~RI N. C MUKHERJEE India Firebricks & Insulation Co Ltd, Marar
SIXRI S. K. MUKHEKJEE Bharat Refractories Ltd, Hokaro
SHRI J. R. K. MURTHY Harry Refractories & Ceramic Works Pvt Ltd,
Calcutta
SHRI N. C. SAFIA ( Alternate )
SHRI R. C. NANDY M.N. Dastur B Co (P) Ltd, Calcutta
SHRI A. K. GHOSH ( Alternate)
DK J. D. PANDA Dalmia Institute of Scientific and Industrial
Research, Rajgangpur
DR N. SAROO ( Alternate )
DR T. V. PRASAD Engineers India Ltd, New Delhi
CDR M. S. BALI Directorate of Production & Inspection ( Naval ),
Ministry of Defence ( DGI ), New Delhi
J>T-CDR B. K. MISHRA
( Alternate )
SHRI D. N. BANERJEE Indian Iron & Steel Co Ltd, Burnpur
SHRI A. K. MUKHERJF,E
( Alternate )
DK G. BANERJEE Central Glass & Ceramic Research Institute
( CSIR ), Calcutta
SHRI S. P. BANERJEE( Alternate )
SHRI BHARA’~ BHASKAR Ishwar Industries Ltd, New Delhi
SHRI RAJEEV BHASKAR ( Alternate )
DR A. K. CHATTERJEE Associated Cement Companies Ltd, Bombay
SHRI S. K. BISWAS ( Alternate )
SHRI B. K. CHATTERJ~Z. Ministry of Defence ( DGOF )
~HRI D. K. MUKHERJEE
( Alternate )
SIIRI S. K. CHATTERJEE Steel Authority of India Ltd ( Durgapur Steel
Plant ), Durgapur
SHRI S. K. DUTTA ( Alternate )
SHRI M. H. DALMIA Orissa Cement Ltd, Rajgangpur
SHRI K. K. PRASAD ( Alternate )
‘RI S. K. DAS Directorate General of Supplies & Disposals ( Ins-
pection Wing ), New Delhi
SHRI R. N. SAHA ( Alternate )
SHRI A. C. DEY Steel Authority of India Ltd ( Alloy Steel Plant ),
Durgapur

5
SP : 37 ( Part 3 ) - 1987

MEMBERS REPR ESE.Nl-ING

SHRIB. RAMACHANDRAN Metallurgical & Engineering Consultants ( India )
Ltd, Ranchi
SHRI T. B. SINGH( Alternate)
SHRI A. K. RAY All India Glass Manufacturers’ Federation, New
Delhi
SHRI R. P. SRIVASTAVA( Alternate)
REPRESENTATIVE National Metallurgical Laboratory ( CSIR ),
Jamshedpur
SHRI A. K. SAHA National Test House, Calcutta
SHRI D. KANUNGO( Alternale )
SHRI 0. P. SANDIR Steel Authority of India Ltd ( Research & Develop-
ment Wing ), New Delhi
SHRI K. 6. CHATTERJ~B( &teroate )
SHR.IR. SANKARAN Bharat Heavy Electricals Ltd, Tiruchchirapalli
SHRI S. V. BHARGAVA.( Alternale I )
SHRI C. S. R. ADHITHYAN

Sn~r~r$%%~I METALLUR - Ministry of Railways

GIST, WHBBL& AXLEPLANT
CHEMIST& METALLURGIST,
CLW, CIIITTARANJAN ( Alternate)
DR N. R. SIRCAR Indian Refractory Makers Association, Calcutta
SHRI K. K. PRASAD( Alternate )
DR B. V. SUBBARAO Ministry of Defence ( DRDO ), Hyderabad
SHRI R. THANJAN Directorate General of Technical Development,
New Delhi
SHRI I. K. KAPUR ( Alternate )
SHRI H. N. TRIPATHI Kumardhubi Fireclay & Silica Works Ltd, Calcutta
DR G. D. SINGH ( Afternate)
SHRI B. MUKHERJI, Director General, BIS ( Ex-o$icio Member )
Director ( Strut 8~ Met )

Secretary
SHRI S. M. BHATIA
Joint Director ( Metals ), BIS

PANEL FOR HANDBOOK FOR REFRACTORIES,

SMDC 18 : P6
CONVENER
DR-T. V. PRASAD Engineers India Ltd, New Delhi
MEMBERS
DR A. K. CHATTERJEE Associated Cement Companies Limited, Bombay
SI-IRIS. K. BISWAS( Alternate
)
SHRI B. N. GHOSH Tata Iron and Steel Co Ltd, Jamshedpur
SHRI A. S. KHALKHO Steel Authority of India Ltd ( Bokaro Steel Plant ),
Bokaro
SHRI K. K. PRASAD Orissa Cement Ltd, Rajgangpur
DR S. L. KOLHATKAR( Alternate )
SHRI B. K. RAUT Engineers India Ltd, New Delhi
SHRI B. G. SENGUPTA Tata Engineering & Locomotive Co Ltd,
Jamshedpur
SHRI K. M. GODIWALA( Alternate )

6
 FOREWORD

Refractories are the’primary materials used in the construction of ail furnaces

in the ferrous and non-ferrous industries. These are used in the lining of laddles,
hot metal mixers, metal retaining vessels, and flues and stacks through which hot
gasses pass. Refractories are also used for lining of boilers, pressure vessels, kilns
and vessels using hot fldids at various temperatures. In short, refractories can be
termed as the mate,rial of construction exposed to high temperatures and corroding
atmospheres, and they retain their shapes and characteristics without reacting
with the molten material or the corroding atmospheres.

Refractory materials are costly and a sudden failure of any refractory may
result in g.reat loss of time, product and equipment. Therefore, the selection of
refractories suitable for a particular application is of paramount importance.
Cost-benefit-analysis is often the basis of selection of such refractories. A refractory
best suited for an application may not necessarily have the longest life. In
selecting the proper refractory, a balance is struck between the initial installed
cost and in-service performance.

Steel industry uses over 70 percent of the refractories consumed in the country.
However, integrated steel plants employ a team of refractory engineers and
specialists for selection and use of refractories. On the other hand,-non-ferrous
sector, glass industry, and other high temperature and corrosion intensive
industries Cl0 not always employ refractory specialists. The application of
refractories in such industries is nevertheless very critical and any premature
failure may lead to long down times and loss of production.

With the above problems of unorganized sector in mind, the Refractories

Sectional Committee ( SMDC 18 ) decided to bring out a handbook for refrac-
tories which could be used as a reference book by the unorganized sector. The
Refractories Sectional Committee, allotted this work to a specially constituted
Panel ( SMDC 18 : P6 ) consisting of experts from various fields of activities
which the handbook will eventually cover. The work of this panel would also
lead to improvement of refractory engineering practices and overall conservation
of materials and energy.

The Handbook will be published in parts; each part dealing with particular
industry/process. It is intended to cover the refractories used in the following
industries:

a) Cement kiln systems ( large plants );

b) Mini-cement plants;
c) Petroleum and petro-chemical industry;
d) Pulp and paper industry;
e) Lime kilns - rotary type and shaft type;
f) Primary processing of non-ferrous materials, such as, aluminium, copper,
zinc, lead, etc;
g) Manufacture of ferro-alloys;
h) Pouring practices for ferrous and non-ferrous materials;
j) Incinerators;
k) Ceramic and refractory industry;
m) Nuclear fuel plants;
n) Glass industry;
p) Glass fibre industry; and
q) Iron and steel industry.
 Each part of the Handbook will cover the following aspects of the refractory
engineering:
a) Process of manufacture used;
b) Types of boilers/furnaces systems;
c) Objectives of the refractory lining;
d) Design engineering features of the furances;
e) Principal zones and sections of the furnaces;
f) Service conditions in different zones including service temperatures;
g) Details of lining used in various zones and sections;
h) Refractory installation practices used for the boilers/furnaces;
j) Consumption pattern of refractories,
k) Applicable standards, namely, Indian and other standards, design, codes,
stress considerations, etc; and
m) Miscellaneous aspects not covered from (a) to (k) above.

This part of the Handbook covers the typical characteristics of refractories

used in the different zones of the cement kiln systems of the large cement plants. It
also covers the temperature and other service conditions prevailing in the
different zones and the recommendations for the use of refractory lining in
various zones.

No handbook of this type can be made complete for all times to come at the
very first attempt. During the course of use of this Handbook, it may be
possible to make suggestions with regard to improving its utility. All such
suggestions may be passed on to the Bureau of Indian Standards. These
suggestions ,wiIl be taken into consideration while revising the Handbook. The
suggestions/with regard to presentation of the Handbook will help in improving
the presentation of other parts which will be printed subsequently. A complete
list of Indian Standards for refractories is also given ( see Appendix A ) for the
convenience of the user.
 SP : 37 ( Part 3 ) - 1987

HANDl3OOK FOR REFRACTORIES

PART 3 REFRACTORIES FOR CEMENT KILN SYSTEM

1. INTRODUCTIQN lining are taken into account. The significance of

refractory lining in cement kilns has to be viewed in
1.1 Portland cement is obtained from clinker pro- this perspective.
duced by burning a finely ground and blended
mixture of limestone and clay with or without some
corrective materials, such as, bauxite, laterite or iron 2. PROCESS OPTIONS AND KILN SYSTEMS
ore, at temperatures ranging from 1 400 to 1 500°C
in either vertical shaft kilns or rotary kilns: These kilns 2.1 The manufacturing process options in clinker-
are metallic constructions lined with suitable refrac- making are related primarily to the raw material
tories. The refractory lining in these kilns i; inten- characteristics and economic viability of the total
ded to protect the metallic shells as well as the system alternatives. This leads to a possibility of
operators from the effects of high temperature, to adoption of a wide variety of kiln system. The
reduce heat losses to the outside environment, and process and system options are broadly classified in
to provide the necessary thermochemical conditions Fig. 1. Depending on the process route adopted,
inside the kilns for the appropriate firing of the the kiln systems are broadly classified as follows:
charge material.
a) wet process kilns ( wet slurry feeding ),
I.2 The cost of refractory lining of kiln system,
inclusive of materials and installation, amounts to b) semi-wet process kilns ( nodulised feed from
less than five percent of the total cost of production. wet slurry preparation ),
This cost is ‘low compared to other cost inputs c) semi-dry process kilns ( nodulised feed from
Nevertheless, it has an overriding effect on the dry mix preparation ), and
economic operation of a plant, if the production
losses that occur due to the premature failure of d) dry process kilns ( dry mix powder feeding).

1 [KILN SK*
l- ----l ,

L---___-__J

FIG. 1 PROCESSOPTIONSAND KILN SYSTEMSIN CEV~NT MANUFACTURE

SP : 37 ( Part 3 ) - 1987

2.2 In actual operation, the semi-wet and semi-dry b) lepol preheater kilns, and
process kilns turn out to be of identical nature and c) suspension preheater kilns ( with or without
hence the broad classification of kiln systems is precalciners ).
reduced to the following three main types:
2.3 The broad characteristics or the three kiln
a) long wet/dry kilns, systems-are given below.

Parameters Long Kilns Lcpol, Kilns Suspension Preheater Kilns

r_--h-__7 f------- h- ___ __~
Wet Dry Without With
Precalciner Precalciner
L/D ratio 32-42 27-34 11.5-12’5 16-20 15-18
Heat consumption, 1380-1700 950-I 150 950- 1050 760-850 760-850
( kcal/kg of clinker )
Surface load ( t/ma/d ) 0’45-0.72 0.55-o-95 l-3- 1’5 1.42-2.2 2.8-4.2
Kiln slope 2’5-3.8 2.5-3.6 3.2-3’5 3.0-3.6 3.5-4.2
Speed of rotation (rev/min ) 0’8-1’5 l-0-1.8 1.1-1’2 1.6-2’7 3.0-4.0
Specific volume of exit -3.92 -2’ 1 ~1.65 -1.65 -1.60
gases ( Nme/kg of clinker )
Exit gas temp/“C 130-300 410-530 90-I 10 300-360 315-372

NOTE 2 The schematic diagrams of the above kiln systems are given in Fig. 2.

PRECALCINER KILN

LOdG WE-7 OR DRY PdOCESS KILN

I m
I I

Fro 2 ZONINGAND LINING OF CEMENT KILNS

 SP : 37 ( Part 3 ) - 1987

FIRING HOOD IISCHARGE ZONE I COOLING 1 BURNING ZONE ISINlERINGl TRANSITION ZONE DRYING ZONE INCLUDING INLET ZONE
GAS TEMPERATURE : 1100-llOO°C GAS TEMPERATURE : 1300 -t600°C CALCINING OR PREBURNINGI CHAIN SECTION
GAS TEMPERATURE:!OOO-120O’C
: SLIGHT CHEMICAL ATTACK GAS IEMPERATtJRE:!fOO-1300°C GAS TEMPERATURE :180 -850% GAS TEMPERATURE: 100-800°C
CHEMICAL ATTACK: SLIGHT CHEMICAL AlTACK : VERY SEVERE
: MODERATE CHEMICAL ATTACK :SEVERE CHEMICAL ATTACK : SLIGHI CHEMICAL ATTACK : SLIGHT
SLAG ACTION i NONE SLAG ACTION SLAG ACllON : VERY SEVERE
THERMAL SPALLING: MODERATE lHERMAL SPALLING : VERY SEVERE SLAG ACTION : MOOERATE SLAG ACTION : N0N.E SLAG ACTION : POSSl8LE DUE
THERMAL SPALLING : VERY SEVERE
AW?ASION : HODERAIE THERMAL SPALLING : SEVERE THERMAL SPALLING : SLIGHT TO VOLATILES
ABRASION : VERY SEVERE ABRASION : SEVERE
ABRASION : MODRATE TO ‘ABRASION : SEVERE THERMAL SPALLING : MODERATE
SEVERE ABRASION : SLIGHT

h t-.
u
J
COOLER
GAS TEMPERATURE : lOOO- LOO’C
CHEMICAL ATTACK : NONE
SLAG ACTION : NONE
THERMAL SPALLING :‘MODERATE TO SEVERE
ABRASION : SEVERE

FIG. 3 &NATION IN TYPICALWEE PROCESS

ROTARY KILN SYSTEM
As in the Original Standard, this Page is Intentionally Left Blank
 SP t 37 ( Part 3 ) - 1987

CYCLONE
STAGE I

SUSPENSION PREHEATER
I4 STAGE )
GAS TEMPERATURE : 330-1100%
CHEMICAL ATTACK :ALKALI,SULPHAlE
AN0 CHLORIDE
SLAG ACTION : POSSIBLE OUE 10
VOLATILES
THERMAL SPALLINO : MODERATE
TRANSIlfON ZONE
ABRASION : SEVERE DISCHARGE ZONEXOOLING~
(CALCINING OR PREEURNINGI
GAS IEMPERAlURE:liOO-1300? GAS TEMPERA~URE:l~OO-ll~c,
CHEMICAL AlTACK:SEVERE CHEMICAL ATTACK :SLIGHl
CYCLONE
SLAG ACTION : MOCXRPJE SLAG ACllON :MODERAlE
STAGE III
THERMAL SPALLING:SEVERE
ABRASION :MODERAlE
TO SEVERE
I ITHERMAL WALLING :VERY
S&ERE
:VERV
SEVERE
PRE- HEATING ZONE

I
BURNING ZONEISINTERINGI
GAS TEMPERATURE : @JO-1100°C
IGAS TEMPERATURE 1300-16Od)C 1
CHEMICAL ATTACK : MODERUE
. MODERAlE CHEMlCAL ATTACK :VERY SEVERE
SLAG ACTION
RISER THERMAL SPALLING : SLIGHT SLAG ACTION : VERY SEVERE
DUCT ABRASION : HODCRATE THERMAL SPALLING:VERY SEVERE
ABRASION :SEVERE

I I _: II
s_E==--??z =_I .__._-P
COOLER
GAS lEMPERAlURE:1000-400°C
CHEMICAL ATTACK : NONE
SLAG ACTION I NONE
THERMAL SPALLING : MODERATE 10
SEVERE
ABRASION : SEVERE

FIG. 4 ZONATIONIN TYPICAL DRY-PROCESS

ROTARY KILN SYSTEM

3. ZONATION OF KILN SYSTEMS 3.1.3 The typical service conditions in different

zones and parts of the rotary kiln systems are given
3.1 The concept of kiln zonation has arisen out of in Table 1 and specifically illustrated in Fig. 3
the fact that the process of cement manufacture and 4 with respect to a typical wet process and
follows the following stages of thermal treatment: suspension preheater kiln of dry type which is the
common form of kiln in use in the industry.
a) drying,
4. SELECTION OF REFRACTORIES FOR
b) preheating, TYPICAL AND IMPORTANT ZONES AND
c) calcining, LOCATIONS
d) sintering, and 4.1 Drying Zone - This zone is exclusively pre-
e) cooling. sent in long wet process kilns and is usually equip-
ped with cross and/or chains for effective heat
3.1.1 The sintering zone, as depicted in Fig. 2, transfer. The lining is subjected to wear and
is often extended to cover a transition zone inclusive abrasion. While standard fireclay bricks or clinker
of a security zone, the later often being considered bricks have been in use, special fire clay bricks with
as a part of the transition zone itself. high cold crushing strength ( CCS ) ( say, 600 -
700 kgf/cm2 ) have proved satisfactory. In chain
3.1.2 The division into zones and choice of ref- sections, special bricks of complicated shape might
ractories are based, as far as drying, preheating and be required to brick round the ends of the chain
calcining are concerned, on the type of kiln or kiln anchoring. For this reason increasing preference is
system, since for these stages of the process, there given to concrete lining having wear resistance >nd
are considerable structural differences in the various creep resistance properties at operational tempera-
parts of the installation. ture range.

IS
 SP : 37 ( Part 3 ) - 1937

TABLB I SERVICE CONDITIONS IN CEMENT ROTARY KILN SYSTEMS

( Clalur3.1.3 )

KILNZONE GAS IMATERIAL CREMICAL SLAo THERMAL ABRASIOX~

TEMPERATURE TEMPERATURE ATTACK ACTION SPALLINQ
( “C ) ( “C )

(1) (2) (3) (4) (5) (6) (7)

Grate preheater 100-I 000 Up to 700 Alkali, sulphate Possible due to Moderate Slight
and chloride volatiles
*Suspension preheater 330-I 100 Up to 800 Alkali, sulphate Possible due to Moderate Severe
( 4-Stage ) and chloride volatiles
Drying zone including 180-850 Up to 250 Slight None Slight Severe
chain, etc
Preheating zone 850-I 100 550-600 Moderate Moderate Slight Moderate
Transition zone ( calcining 1 100-l 300 upto1:OO Severe Moderate Severe Moderate
or preburning ) to severe
Burning zone 1 300-I 600 Up to 1 450 Very severe Very severe Very severe Severe
( sintcring )
Discharge zone 1 400-l 100. up to 1 100 Slight Moderate Very severe Very severe
( cooling )
Firing hood 1 000-l 200 - Slight - Moderate Moderate
Cooler spout 1 000-l 100 900-l 000 None None Modtrate to Very severe
severe
Coolers 1 000-400 80-300 None None Moderate to Severe
severe

*With precalciner, the gas temperature will be 350 to 1 100°C and the material te.nperature will be up to 900°C.

4.2 Preheating Zone - Far this zone the choice 4.3 Calcining Zone
of refractories mainly depends on the process.
4.3.1 In the calcining zone of long or suspension
4.2.1 Lqng Wet Process Kilns .- Abrasion and pre- preheater kilns as well as in the lower cyclones of
sence of moisture requires the use of a dense, low- precalciner kilns; dense, low porosity, low iron
porosity aluminous firebricks for long wet process bricks or castables with good alkali resistance are
kilns. Use of insulating bricks, particularly chemi- preferred. The break-up insulation lining can also
cally bonded, presents a risk due to moisture be considered.
penetration, 4.32 Precalciner vessels are also lined with hrgh-
strength, dense, high-alumina spalling resistant
4.2.2 Long Dry Process Kilns - The use of hot face brick;. .The back-up insulation is possible. A
insulating bricks is preferred in the long dry process high-strength castabie is required for* the burner
kilns. quarl.

4.2.3 Lepol Grate Prtheatcrs - In the lepol grate 4*4 Burning and Transitioxa Zone
preheaters, for the drying and heating chambers,
low porosity aluminous firebricks are used above 4.4.1 Refractories for the burning and transition
the grate levei. A backing of low ‘conductivity zones must be able to withstand high thermal loads,
insulating bricks may help in reducing heat losses. temperature fluctuations, chemical attack and
To form a stable platform high strength castables, abrasion. The transition part of the burning zone
anchored to the shell, are required. Below the is subject to large variations in temperature as the
grate level, high strength insulating bricks may be protective coatmg is taxed to its limit in this area.
preferred. Low duty firebricks are recommended
4.4.2 Depending on the kiln size and severity of
for the lining of suction chambers.
operations, thelining material for this zone is
selected from the following types:
4.2.4 Suspension Preheaters - The top three cyc-
lones and riser pipes of suspension preheaters are a) High alumina bricks of 70 to 75 percent
usually lined wit-h dense low porosity aluminous alumina content
firebricks or equivalent monolithics. A back-up b) Silicate bonded magnesite-chrome bricks
insulation lining is often preferred for reduction of
heat losses. Chutes are also lined with dense low c) Direct bonded magnesite-chrome bricks
porosity firebricks. Where it is difficult to instal d) Sintered and tar-impregnated dolomite
brick work; a dense, medium duty refractory cast- bricks
able is used, e) Magnesite-alumina spine1 bricks.

14
 SP : 37 ( Part 3 ) - 1987

4.5 Discharge ( Cooling ) Zone entire cement kiln systems. The standard has also
adopted the IS0 specification for wedge shaped
4.5.1 With variation in protective clinker cooling, bricks for use in cement kilns ( IS0 5417-1986
the lining in this zone is subjected to hot clinker, Refractory bricks for use in rotary kilns -
flame and dust-laden secondary air, thermal shock Dimensions, which was at the draft stage at the time
and high.temperature abrasion. High-alumina of formulation of IS : 10607-1983 ). The relevant
bricks with good elasticity and strength characteris- part of IS : 10607-1983 is given in Table 3.
tics form the standard lining of discharge zone.
4.5.2 For end-discharge kilns, silicon carbide 7. PRESENT CONSUMPTION TRENDS
bricks have proved satisfactory for the nose ring
owing to their particularly high resistance to wear. . 7.1 Based on a survey of the Indian cement industry
Alternatively, monolithic castables with comparable for the period 1980-85, it has been observed that
properties, securely anchored to the shell by heat- the specific consumption (kg/t of clinker ) of
resistant steel anchors, may be used with advantage. refnactories for kilns with more than 60 percent
capacity utilization is as follows:
4.6 Coolers
Spccijc Consumption of Refractories
4.6.1 The refractory linings of cooling c&s, no ( kg/t of Clinker )
matter how difficult their design may be, have C__-_-_-h_- M-v--_ ~
similar requirements for resistance to thermal shock, Process Burning <one Other <ones
impact, abrasion and erosion. The only lining
materials that can be considered, therefore, are fire- Wet 1’03 0’65
clay bricks and high alumina bricks of high strength Dry 0.95 0.57
or suitable castables.
7.2 As compared to the international norms, there
4.7 Firing Hood and Burner Pipe is enough scope for reduction in refractory con-
sutnption through improved practices and materials.
4.7.1 Although brick-lining is not uncommon for
firing hoods, abrasion resistance and elimination of
8. REFRACTORY INSTALLATION
complicated brick cutting can be satisfied by using
PRACTICES
monolithics. The lining of burner pipes is restricted
to high strength refractory castables for abrasion
8.1 The adoption of refractory practices primarily
resistance to dust-laden gases.
depends on the following three factors:
5. LINING THiCKNESS IN ROTARY KILNS a) Operational safety,
5.1 The thickness of the lining of rotary kilns b) Proper installation, and
primarily depends on the diameter. The following c) Minimization of placement time.
lining thicknesses have been recommended by the
Development Panel of the DGTD for Refractory 8.2 Depending on whether a rotary kiln needs to
Industry: be rotated or ;a:? be kept stationary at the time of
lining, the instal!ation practices are further classi-
Kiln Dia (m) Lining Thickness (mm) fied as:
> 5.2 250 a) Rotary methods, and
> 4’2 < 5.2 220 b) Formwork methods.
> 3.6 < 4.2 200
> 3.0 < 3’6 180 8.2.1 Rotary Me/hods - In the rotating methods
the work is carried out at the kiln bottom and the
5:; 3-o 160 lining proceeds on intertittent rotation of the kiln.
The fixation of the bricks on rotation is done by
6. INDIAN STANDARD SPECIFICATIONS
any one of the following techniques:
FOR CEMENT KILN REFRACTORIES
a) Screw-jack method,
6.1 The Jndian Stnndarcl for refractories for cement
rotary kilns ( IS : 10607-1983 Specification for refrac- 1~) Glueing, and
tories for cement rotary kilns ) aims at rationalizing c) Bolting.
the rcqrrircnrcnts of refractory bricks and castables.
This stnnrlnrd ditl not itlc~lutle tile basic: bricks for 8.2.2 Formloo)-k Method ‘-- The curved fosmwork
use in cctneut kilns tlrre to non-availability of usage tnethods are safer in operation and permit very
data at the tirtrc of formulation of the standard. accurate installation af bricks. In these methods
The relevant extracts ofthis standard are given in the lower half of shell is lined without any parti-
Table 2. ‘I’his Indian Standard has recommended cular aids and then the upper half is lined with the
the use of 3 grades of high alumina and alumino- aid of curved formwork. There is a wide choice
silicate bricks. ‘l’hree grades of dense castables of equipment from simple wooden form to
and one grade of insulating castable for lining the hydraulically operated mechanized forms.
 T&m 2 REQUIREMENTS FOR REFRACTORIES FOR DIFFERENT ZONES OF CEMENT I(ILNS
( Chsc 6.1 j

CHARACTERISTICS/ 35 PERCENT 55 PERCENT 70 PERCENT Gsam - 300 GRADE - 400 GRADE - 500 INSULATING io
CObfPOSITIOJ ALTIXINA
BRICKS
ALUMINA
BRICKS
AL’OXINA
hW3KS
REFRACYORY
CASTABLE
REFRACTORY
CASTABLE
REFRACTORY
CASTABLE
CASTABLE s
i%l,O* percent, Min 35 55 70 50 50 90 -

FL,O, percent, Max 2.5 2’5 3.5 6.0 2.0 0.5 3.5

30 34 36 - - -
PCE ( ASTM ), Min

PLC, percent, Afax

- - -
( 135i45h ) ( 1 40%,2h ) ( 1 50%“@2h ) ( 1 3&&&5h )

RUL, ta, Min 1 300°C 1400°C 1 450°C - - - -

A.P. percent, Max 25 25 23 - - - -

CCS, kg/cmr, Min 250 300 400 - - - -

CCS, kg/cm’ - - 300 400 500 30-40

110°C drying
800-l 000”c - - - 250 300 350 -

Bulk density - - - - - ioo-i 200

Use Grate preheater, Transition Burning zone, Grate preheater, dry- Hot face and Discharge zone Backing of sus-
suspension prehe- zone discharge zone, ing zone, siae wall sealing areas including pension prehe-
ater, drying zone, inciuding extension and roof in roof ducts cooler spouts, ater, back-up of
preheating zone, cooler spouts of grate coolers, of suspension target wall of precalciner
grate coolers and kiln firing. hood of preheater, pre- grate coolers
cooler tubes precalciner heating zone, dam ring cooler
side wall of inlet, tip casting,
grate cooler, kiln outlet of
bottom roof, gas precalciner
duct damper,
tumbler ledges
of precalciner
NOTE - Reference may be made to IS : 10607-1983.
 SP : 37 ( Part 3 ) - 1987

TABLE 3 SIZES OF WEDGE SHAPED HIGH ALUMINA BRICKS FOR CEMENT KILNS

Si7,E DIMENSIONS ( mm ) SIZE DIMENSIONS ( mm )

DESIUNATION r__.____-_*-__--_-_? DESIONATION r__ ___---_A -_-_ _ __
A B H L A B H L-
216 86’0 620 962
316 92.0 720 97.0
416 945 160 820 97’8
516 96.5
716 98.3 322
422
218
318
84.0
90.5 180
522
622
940 _
95.5 220
418 93.5 722 96’5
518 95.5 822 97.3
618 97.0
718 97.7
425 90.0
220 82.0 525 92’7
320 89.0 625 945 250
420 92.5 725 95.5
520 103 94.7 200 198 825 96’5

17
 APPENDIX k
LIST OF INDIAN STANDARDS ON REFRACITORIES

IS:

6-1983 Specification for moderate heat duty fireclay refractories, Group A

( fiurth revision )
7-1980 Specification for moderate ‘heat duty fireclay refractories, Group B
( j&rth revision )
8-1983 Specification for high heat duty fireclay refractories (fourth revision )
195-3963 Specification for fireclay mortar for laying fireclay refractory bricks
( second revision )
483-1972 Specification for fireclay refractories for oil-fired boiler furnaces of
naval ships ( jrst revision )
454-1980 Specification for silica refractories for general purposes ( second revision )
1292-1958 Specification for mortar for laying silica bricks
1522-1967 Specification for fireclay glass tank blocks (,/;rst revision )
1523-1972 Specification for bottom-pouring refractories for steel plants ( jrst
revision )
1524-1968 Specification for refractory sleeves ( jirst revision )
1525-1968 Specification for ladle refractories for steel plants ( jrst revision )
1526.1960 Specification for sizes and shapes for fire bricks ( 230 mm series )
1527-1972 Methods for chemicai analysis of high silica refractory materials ( jrst
revision )
1528 Methods of sampling and physical tests for refractory materials:
1528 ( Part 1 )-I980 Determination of pyrometric cone equivaients ( PCE ) or
softening point ( second revision )
1528 ( Part 2 )- 1974 Determination of refractoriness under load ( f;rst revLion )

1528 ( Part 3 )-1983 Determination of spaliing resistance ( second revision )

1528 ( Part 4 )-1974 Determination of cold crushing strength (Jirst revision )

1528 ( Pait 5 )-1974 Determination of modulus of rupture ( Jirst revision )

1528 ( Part 6 )-1974 Determination of permanent change after reheating (first
revision )
1528 ( Part 7 l-1974 Methods of sampling and criteria for conformity (Jirst
revision )
I528 ( Part 8 )-1974 Determination of apparent porosity ( ,first revision )
1528 ( Part 9 )-1980 Deterlnination of true specific gravity and true density
( second reuision )
1528 ( Part 10 )-1974 Determination of sizes of refractory bricks (Jirst IelrZon )
1528 ( Part 11 )-1971 l)etc:rltlinat ioll of warpage (Jrst revision )
1528 ( Pal I 12 )-1’374 I)cctc,rrllill;ltiorl of bulk density (Jut retlision )
1528 ( Part 13 )-I!)74 l)c’tcrtllil~atiarl of resistarrcc to 1111: tlisintegration effect
of cat bon monoxide (Jr.51 yraision )
1528 ( Part 14 )-I!)74 l)efer~r~ir~;~tio~t 01 sieve analysis (Jr51 rcni.rimr )
152!L1972 Sl)ecific:;ltion f111II;~U: tc:rrac.toricbs for s~rel i)lants (first r&sion )
fi)r IJ~;I:%I
1748-1981 Specification for aizcs IBI’gt.;ii)hittr cr!lc:il)lcs (,/ir.\t r-cvitiof~ )
1749-1984 Specification li)r rnagrlesite I oli.;lctor.ic~s ( .Wofrd rcrli.vior/)
1750-1983 Specification for dead-burnctl pea m;lgllesite ( secorzrfrellisiotz )
1751-1!)84 Specification lbr fircclay cupola rcfractotics ( sccor~~frwision )
2042-1972 Specification for insulating bricks ( jrst Icrixior~ ).
2043-1984 Specification for siliceous lireclay refractories ( Jrst revision )
2044-1981 Specification for sillimanite refractories for g!ass melting tank furnaces
( jirst revision )
3304-l 965 Specification for burnt magnesite-chrome refractories for general
purposes
3305-1965 Specification for burnt chrome-magnesite refractories for general
purposes
4041-1967 Glossary of terms relating to refractory materials
4564- 1968 Specification for fireclay nozzles
4565-1963 Specification for fireclay stoppers
4801-1980 Specification for chemically-boned magnesite-chrome refractories for
roof lining ( jrsf revision )
4812-1972 Specification for silica refractories for coke oven (Jut revision )
4813-1980 Specification for chemicalJy-bonded chrome-magnesite refractories for
general purposes (Jirst revision )
4814-1980 Specification for chemically-bonded magnesite-chrome refractories for
general purposes ( jrst rmision )
5495- 1969 Specification for sizes and shapes forifirebricks ( 300 mm and higher
series )
6727-1972 Specification for fireclay checker-bricks for open-hearth furnace
6728-J 972 Specification for recuperator tubes, tiles and collars for soaking pits in
steel plants
7199-1974 Specification for blast furnace stove refractories
895%1978 Specification for 62 percent alumina bricks for blast furnace
8966-1978 Specification for magnesite nozzles
8977- 1978 Specification for clay bonded graphite crucibles
gOlo- 1978 Specification for super heat duty fireclay refractories
9929-1981 Method for determining life of graphite crucibles
9930-1981 Specification for zircon refractories for glass furnaces application
10047-1981 Methods of testing refractory ramming masses
10551-1983 Specification for zircon mullite refractories for glass firrnaces appli-
cation
10570-1983 Methods of testing refractory castables
10607-1983 Specification for refractories for cement rotary kilns
11036- 1984 Specification for clay graphite stopper heads
11452-1985 Methods of testing air-setting refractory mortars