Lime Rotary Kiln Refractories - Resco Products

Lime Kiln

Rotary lime kilns typically have four refractory zones with varying types of refractory. Long process kilns require abrasion resistant, high strength alumina brick for the charging zone. The charging zone is where the abrasion of the stone can be particularly severe. Short preheater kilns normally do not have a charging zone that sees high abrasion as the preheated stone is partially softened.

In the calcining zone, limestone (calcium carbonate) is heated in preparation for the burning zone. 70% alumina class refractory brick is the most common refractory lining. The burning zone maintains the highest temperatures and drives the decarbonization reaction to completion producing quicklime that is, calcium oxide (CaO).

The rate of calcination is related to retention time inside the kiln and the operating temperature. Refractory internals can assist in improving kiln efficiency by recovering heat from the kiln exhaust gas. 

This process increases productivity and reduces the fuel ratio for the lime product.

The discharge zone of a modern lime kiln usually contains a dam construction. Dam construction is used to increase the retention time of the lime in the kiln.

Refractories for Lime Kiln

A lime kiln utilizes both basic brick, alumina brick, and fire clay brick.  Rescomag 85 is the best basic brick option for harsh conditions within the burning zone.  Seneca 60P is the most ideal alumina brick in the calcining zone for abrasion resistance.

Basic Brick Refractory for the Burning Zone:

Basic magnesia brick is more compatible with lime, resist flexing, and offer extended lime rotary kiln lining reliability. Greenfree KF features a high content of spinel and gives significantly lower shell temperatures due to improved thermal conductivity. Rescomag 85 is the best option for harsh conditions within the burning zone.

Alumina Brick

60% to 70% alumina brick linings are the most common brick types in the calcining zones. Rescal 70D offers consistent, economic performance while maintaining good alkali resistance and positive reheat property for improved lining stability. Seneca 60Ps high quality offers improved abrasion resistance at a competitive cost.

Phosphate-bonds give alumina brick high mechanical strength and exceptional abrasion resistance at high temperatures. Alumex P-85-HS is an 80% alumina class burned phosphate-bonded brick. Alumex P-85-HS is effective in charging zones of long rotary lime kilns. Alumex P-85-HS is also effective for the kiln shell linings where heat exchangers are employed.

 
RELATED PRODUCTS
Magnesia Brick

Greenfree 92Arrow icon

GREENFREE 92 is a high fired, chrome free magnesia brick with excellent resistance to chemical attack and high thermal loading. GREENFREE 92 has good structural flexibility which provides enhanced thermal shock properties and makes the product suitable for cement burning zones or burning zone/transition zone margins and burning zones of rotary lime kilns.
GREENFREE 92 is a high fired, chrome free magnesia brick with excellent resistance to chemical attack and high thermal loading. GREENFREE 92 has good structural flexibility which provides enhanced thermal shock properties and makes the product suitable for cement burning zones or burning zone/transition zone margins and burning zones of rotary lime kilns.
Magnesia Brick

Greenfree KFArrow icon

GREENFREE KF is a chrome free magnesia brick with increased insulating value for lower rotary kiln shell temperatures. GREENFREE KF has good structural flexibility and provides enhanced thermal shock properties and makes the product suitable for cement kiln upper transition zones and burning zones of rotary pebble lime and lime recovery kilns.
GREENFREE KF is a chrome free magnesia brick with increased insulating value for lower rotary kiln shell temperatures. GREENFREE KF has good structural flexibility and provides enhanced thermal shock properties and makes the product suitable for cement kiln upper transition zones and burning zones of rotary pebble lime and lime recovery kilns.
Low Cement Castable

Kricon 32-70Arrow icon

KRICON® 32-70 is a 77% alumina, low iron castable with a 3200°F temperature limit. It offers improved slag resistance and positive reheat expansion at steel making temperatures to insure tight, crack-free linings in cast ladles and tundishes.
KRICON® 32-70 is a 77% alumina, low iron castable with a 3200°F temperature limit. It offers improved slag resistance and positive reheat expansion at steel making temperatures to insure tight, crack-free linings in cast ladles and tundishes.
Low Cement Castable

Kricon 32-70 (UK)Arrow icon

KRICON® 32-70 is a 77% alumina, low iron castable with a 3200°F temperature limit. It offers improved slag resistance and positive reheat expansion at steel making temperatures to insure tight, crack-free linings in cast ladles and tundishes.
KRICON® 32-70 is a 77% alumina, low iron castable with a 3200°F temperature limit. It offers improved slag resistance and positive reheat expansion at steel making temperatures to insure tight, crack-free linings in cast ladles and tundishes.
Alumina Brick

Patriot HFArrow icon

High fired, super duty, carbon monoxide resistant brick
High fired, super duty, carbon monoxide resistant brick
Low Cement Castable

Quikturn 32-70PCArrow icon

QUIKTURN 32-70 PC is a low cement, 70% alumina castable that can be installed by vibration cast, pumping, and shotcreting methods. After the final set, this unique castable can be heated without the traditional ramp-and-hold heatup schedule. Refer to the recommended QUIKTURN heatup schedule for the initial heatup.
QUIKTURN 32-70 PC is a low cement, 70% alumina castable that can be installed by vibration cast, pumping, and shotcreting methods. After the final set, this unique castable can be heated without the traditional ramp-and-hold heatup schedule. Refer to the recommended QUIKTURN heatup schedule for the initial heatup.
Low Cement Castable

QUIKTURN 60C (UK)Arrow icon

QUIKTURN 60C is a 59% alumina, mullite based, ultra-low cement castable designed for vibration casting. This product is recommended for new and full lining repairs using anchored construction. After the initial set, the furnace lining can be returned to operation without curing or the traditional controlled heating schedule. QUIKTURN 60C has excellent strength, alkali and abrasion resistance.
QUIKTURN 60C is a 59% alumina, mullite based, ultra-low cement castable designed for vibration casting. This product is recommended for new and full lining repairs using anchored construction. After the initial set, the furnace lining can be returned to operation without curing or the traditional controlled heating schedule. QUIKTURN 60C has excellent strength, alkali and abrasion resistance.
Chemically Bonded Castables

Rescobond 3000 (UK)Arrow icon

RESCOBOND 3000 is a chemically-bonded, air-setting, single component refractory castable. This product bonds to existing refractory and can be used in a variety of different applications including patching. To use, mix RESCOBOND 3000 with water and cast. It develops a quick set and can be heated shortly after installation.
RESCOBOND 3000 is a chemically-bonded, air-setting, single component refractory castable. This product bonds to existing refractory and can be used in a variety of different applications including patching. To use, mix RESCOBOND 3000 with water and cast. It develops a quick set and can be heated shortly after installation.
Chemically Bonded Castables

Rescobond 3000GArrow icon

RESCOBOND 3000G is a chemically-bonded, air-setting, single component gunning mix. This product can be installed by conventional gunning and handpacking methods and bonds to existing refractory. When gunning, predampening is NOT suggested for this gun mix. This product develops a quick set and can be heated shortly after installation. RESCOBOND 3000G should NOT be installed by vibration casting methods.
RESCOBOND 3000G is a chemically-bonded, air-setting, single component gunning mix. This product can be installed by conventional gunning and handpacking methods and bonds to existing refractory. When gunning, predampening is NOT suggested for this gun mix. This product develops a quick set and can be heated shortly after installation. RESCOBOND 3000G should NOT be installed by vibration casting methods.
Conventional Castable

Rescocast 15GM (UK)Arrow icon

RESCOCAST 15GM is a 2600°F general duty castable that can be installed by vibration casting methods. It is designed for refractory use in powerplant ash-hopper applications as well as other applications where high strength, moderate abrasion resistance, and medium insulating values are required. RESCOCAST 15GM is also an excellent gunning product that can be troweled too.
RESCOCAST 15GM is a 2600°F general duty castable that can be installed by vibration casting methods. It is designed for refractory use in powerplant ash-hopper applications as well as other applications where high strength, moderate abrasion resistance, and medium insulating values are required. RESCOCAST 15GM is also an excellent gunning product that can be troweled too.
Magnesia Brick

Rescomag 85Arrow icon

RESCOMAG 85 is a burned magnesite-spinel kiln liner made of high purity, raw materials and a high content of synthetic spinel grain. RESCOMAG 85 exhibits exceptionally good thermal shock and spall resistance and volume stability at high temperatures. RESCOMAG 85 is an ideal liner for the upper and lower transition zones of rotary cement kilns
RESCOMAG 85 is a burned magnesite-spinel kiln liner made of high purity, raw materials and a high content of synthetic spinel grain. RESCOMAG 85 exhibits exceptionally good thermal shock and spall resistance and volume stability at high temperatures. RESCOMAG 85 is an ideal liner for the upper and lower transition zones of rotary cement kilns
Magnesia Brick

Rescomag 85-CArrow icon

RESCOMAG 85-C is a burned magnesite-spinel kiln liner made of high purity, raw materials and a high content of spinel grain. RESCOMAG 85-C exhibits exceptionally good thermal shock, thermal conductivity and mechanical resistance. RESCOMAG 85-C is an ideal liner for the upper and lower transition zones of rotary cement kilns.
RESCOMAG 85-C is a burned magnesite-spinel kiln liner made of high purity, raw materials and a high content of spinel grain. RESCOMAG 85-C exhibits exceptionally good thermal shock, thermal conductivity and mechanical resistance. RESCOMAG 85-C is an ideal liner for the upper and lower transition zones of rotary cement kilns.
Low Cement Castable

R-Max CArrow icon

R-MAX C is a Abrasion-Resistant, Low Cement 70% Alumina Castable. This castable should be installed by vibration casting only; specifically form vibration.
R-MAX C is a Abrasion-Resistant, Low Cement 70% Alumina Castable. This castable should be installed by vibration casting only; specifically form vibration.
Low Cement Castable

R-Max C (ESC)Arrow icon

R-MAX C is a Abrasion-Resistant, Low Cement 70% Alumina Castable. This castable should be installed by vibration casting only; specifically form vibration.
R-MAX C is a Abrasion-Resistant, Low Cement 70% Alumina Castable. This castable should be installed by vibration casting only; specifically form vibration.
Low Cement Castable

R-Max GArrow icon

R-MAX G is a 3200°F high performance gunning mix designed to provide maximum abrasion resistance and excellent strengths throughout all operating temperatures. R-Max G should be installed using conventional gunning methods.
R-MAX G is a 3200°F high performance gunning mix designed to provide maximum abrasion resistance and excellent strengths throughout all operating temperatures. R-Max G should be installed using conventional gunning methods.
Low Cement Castable

R-Max G (ESC)Arrow icon

R-MAX G is a 3200 °F high performance gunning mix designed to provide maximum abrasion resistance and excellent strengths throughout all operating temperatures. RMax G should be installed using conventional gunning methods. The data shown are average test results following the guidelines set forth in ASTM C-903; “Preparing Refractory Concrete Specimens by Cold Gunning”.
R-MAX G is a 3200 °F high performance gunning mix designed to provide maximum abrasion resistance and excellent strengths throughout all operating temperatures. RMax G should be installed using conventional gunning methods. The data shown are average test results following the guidelines set forth in ASTM C-903; “Preparing Refractory Concrete Specimens by Cold Gunning”.
Low Cement Castable

R-Max G (UK)Arrow icon

R-MAX G is a 3200°F high performance gunning mix designed to provide maximum abrasion resistance and excellent strengths throughout all operating temperatures. R-Max G should be installed using conventional gunning methods.
R-MAX G is a 3200°F high performance gunning mix designed to provide maximum abrasion resistance and excellent strengths throughout all operating temperatures. R-Max G should be installed using conventional gunning methods.
Low Cement Castable

R-Max G QTArrow icon

R-MAX G QT is a high performance gunning mix designed to provide high abrasion resistance and excellent strengths. R-Max G QT should be installed using conventional gunning methods. After the final set, this unique gun mix can be heated without the traditional controlled heating schedule. Ideal applications for this product include areas of severe abrasion, where refractory heatup is difficult to control or a shorter heatup schedule is desired.
R-MAX G QT is a high performance gunning mix designed to provide high abrasion resistance and excellent strengths. R-Max G QT should be installed using conventional gunning methods. After the final set, this unique gun mix can be heated without the traditional controlled heating schedule. Ideal applications for this product include areas of severe abrasion, where refractory heatup is difficult to control or a shorter heatup schedule is desired.
Low Cement Castable

R-Max G QT (UK)Arrow icon

R-MAX G QT is a high performance gunning mix designed to provide high abrasion resistance and excellent strengths. R-Max G QT should be installed using conventional gunning methods. After the final set, this unique gun mix can be heated without the traditional controlled heating schedule. Ideal applications for this product include areas of severe abrasion, where refractory heatup is difficult to control or a shorter heatup schedule is desired.
R-MAX G QT is a high performance gunning mix designed to provide high abrasion resistance and excellent strengths. R-Max G QT should be installed using conventional gunning methods. After the final set, this unique gun mix can be heated without the traditional controlled heating schedule. Ideal applications for this product include areas of severe abrasion, where refractory heatup is difficult to control or a shorter heatup schedule is desired.
Low Cement Castable

R-Max PCArrow icon

R-MAX PC is a Pumpable, Abrasion-Resistant, 70% Alumina Castable. This castable can be installed by vibration casting, pumping, or shotcreting methods
R-MAX PC is a Pumpable, Abrasion-Resistant, 70% Alumina Castable. This castable can be installed by vibration casting, pumping, or shotcreting methods
Low Cement Castable

R-Max PC (UK)Arrow icon

R-MAX PC is a Pumpable, Abrasion-Resistant, 70% Alumina Castable. This castable can be installed by vibration casting, pumping, or shotcreting methods
R-MAX PC is a Pumpable, Abrasion-Resistant, 70% Alumina Castable. This castable can be installed by vibration casting, pumping, or shotcreting methods
Low Cement Castable

R-Max PC QT (UK)Arrow icon

R-MAX PC QT is a Pumpable, Abrasion-Resistant, 80% Alumina Castable. This castable can be installed by vibration casting and pumping methods. Ideal applications for this castable are severe abrasion areas where refractory heatup is difficult to control.
R-MAX PC QT is a Pumpable, Abrasion-Resistant, 80% Alumina Castable. This castable can be installed by vibration casting and pumping methods. Ideal applications for this castable are severe abrasion areas where refractory heatup is difficult to control.
Alumina Brick

Seneca 60 PArrow icon

Burned, high alumina brick
Burned, high alumina brick
Low Cement Castable

Vibrocast 60PCArrow icon

VIBROCAST 60PC is a Pumpable, Low Cement, 60% Alumina castable based on a mullite aggregate, that can be installed by vibration cast, pumping, and shotcreting methods.
VIBROCAST 60PC is a Pumpable, Low Cement, 60% Alumina castable based on a mullite aggregate, that can be installed by vibration cast, pumping, and shotcreting methods.
Low Cement Castable

Vibrocast 60PC (UK)Arrow icon

VIBROCAST 60PC is a Pumpable, Low Cement, 60% Alumina castable based on a mullite aggregate, that can be installed by vibration cast, pumping, and shotcreting methods.
VIBROCAST 60PC is a Pumpable, Low Cement, 60% Alumina castable based on a mullite aggregate, that can be installed by vibration cast, pumping, and shotcreting methods.