Cement Kiln Refractory
Resco Products has been serving cement plants and rotary cement kilns for decades. Our experts are well-versed in the best practices for refractory product selection and rotary cement kiln installation: charging, calcining, burning, and discharge zones.
The raw materials for cement production are principally limestone and clay, along with other minor additives. These materials are ground and blended in a raw mill to produce kiln feed. Years ago, the majority of cement plants operated wet process kilns. Since the industry modernized over the past 30 years, almost all cement produced in North America today is made in dry-process kilns, including kilns with preheater towers.
Refractories for Rotary Cement Kiln
Resco Products provides refractories for rotary cement kilns within the preheaters, burning zone, and discharge zones. Recommended products for these zones include Seneca 60P for its superior resistance to alkali spalling, Rescomag 85 the standard magnesite-spinel brick, and Rescal 70D for its abrasion and thermal shock resistance.
Cement kilns with preheater towers have three major refractory zones: the calcining zone, the burning zone (sintering zone), and the discharge. The calcining zone brick lining can exhibit alkali spalling; Seneca 60 P addresses that condition with superior resistance. On the other hand, the calcining zone refractories require higher alumina content for greater thermal resistance; Rescal 70D and Alumex P-8 are often best for this service.
Rotary Cement Kiln Burning Zone
The burning zone requires basic refractory for chemical compatibility with the clinker. Resco's basic brick plant was a North American pioneer in the manufacturing of magnesite-spinel brick. Rescomag 85 is our standard magnesite-spinel brick offering for this zone. Rescomag 92 FMS is best for the most severe conditions. Z-DOL is Resco's offering for burned dolomite brick burning zones.
Rotary Cement Kiln Discharge Zone
Brick refractories in the discharge zone require abrasion and thermal shock resistance. Rescal 70D is our standard offering. For improved brick life especially when used against a retainer ring, Alumex P-7 and Alumex P-8 are favored selections due to their higher strengths. Low-cement castables, including Kricon 32-70, QuikTurn 32-70, and the R-Max product family, offer exceptional service for the castable nose ring.
Cement clinker is discharged from the kiln into the clinker cooler. The clinker is moved from the cooler inlet to the discharge by the reciprocating motion of perforated grates. In the cooler, air is blown through the bed of hot clinker, cooling it back to near-ambient temperatures. Cooler linings are preferable medium to high alumina castables, preferably low-cement types with good abrasion resistance.
For all rotary cement kiln questions, get in touch with Resco Products.