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Version: 2014/07/10
Tailormade Linings for Every Rotary Kiln
There are many factors which influence the kiln life: e.g. burning process, kiln dimension,
composition of raw materials, fuel, type of clinker and the number of kiln shut downs.
Of course, with such a variety of influences, which in addition interact differently, a standard
lining does not exist. Every rotary kiln requires ist individual lining - ist specific configuration.
With the wide product range of MAGNESITA Refractories GmbH all requirements
can be fulfilled: economical rotary kiln linings for every method of production - worldwide.
Our experts design the lining in cooperation with their partners in the cement plants - in
accordance with the respective production requirements.
In addition the high standard of our quality control guarantees longevity and effiency.
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Linings Tailor-Made for Every Rotary Kiln
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Recommended Brick Grades
1
1 2
2
3
3
4
4
5
5 6
6
Construction
of a
cement rotary kiln
SINDOFORM Z 50
High MAGKOR B2 MAGKOR B2
ALUBAX 83 C SINDOFORM Z 60 ALUDUR 55 C DELTADUR 70
MAGKOR S1 MAGKOR S1
sulphate ALUDUR 55 C
MAGKOR S2
MAGKOR B3
MAGKOR S2
ALUSIC 10 EXAKTA 43
MAGKOR B4
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MAGNESITA Refractories Grades
Fired Doloma and Magnesia Doloma Bricks
The most important requirement on a refractory lining in the sintering zone of rotary
cement kiln is resistance to chemical attack. Fired doloma and magnesia doloma
bricks meet this demand the best.
The silicat phase belite ( C2S ) of the clinker reacts with lime in the basic refractory
lining and alite ( C3S ) is formed.This mineral melts at the very high temperature
2130°C. The reaction between refractory and clinker forms a solid and stable coating
on the hot face of the doloma or magnesia doloma lining. The wear of the refractory
surface is reduced due to the formation of this coating. Furthermore the coating gives
a protection against temperature loss of the clinker in the kiln and reduces the
temperature of the kiln shell.
The increasing use of alternative fuels has raised the demands on the refractory
lining drastically. Our magnesia doloma qualities are an optimum solution for the
sintering zone.
rd
The new magnesia doloma qualities of the 3 generation SINDOFORM Z 40,
SINDOFORM Z 50 and SINDOFORM Z 60 are improved by an optimization of the
granulomtry and the zirconia addition. All three qualities are dense bricks with low
porosity and permeability. Despite the high density one have succeeded to improve
their thermo shock resistance so, that these bricks have thermo-mechanical properties
similar to magnesia spinel bricks. In addition the resistance against chemical
corrosion by gases ( SO3, CI ) of the kiln atmosphere has been clearly improved
through the enrichment with magnesia.
SINDOFORM K
The standard doloma brick for the stable coating area, which has been used world-
wide since more than 50 years.
SINDOFORM Z 40
A magnesia enriched dolomite zirconia grade for less stable coating area with better
resistance against chemical attack.
SINDOFORM Z 50
A magnesia enriched dolomit zirconia grade for unstable coating area with high
resistance against sulphate and alkali attack.
SINDOFORM Z 60
A magnesia enriched dolomite zirconia grade for unstable coating area with high
resistance against sulphate and alkali attack under hiher termal load.
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SINDOFORM Z 60 F
Dolomite zirconia grade with fused magnesia, unstable coating area with hig resistance
against extrmely high sulphate and alkali attack under higher thermal load.
Table of the Characteristic Properties of Fired Doloma Magnesia Bricks for Cement Kilns
Dolomite Magnesia
Dolomite Dolomite Magnesia Dolomite Magnesia
Description of fired brick Dolomite with ZrO2 with ZrO2 with ZrO2
Fused Magnesia
with ZrO2
Chemical Composition
CaO mass % 57.5 56 51 39 37
MgO mass % 40 40 46 58.5 59
SiO2 mass % 0.9 0.8 0.8 0.6 0.8
Fe2O3 mass % 0.8 0.75 0.6 0.7 0.6
ZrO2 mass % 1.45 1.0 1.0 1.8
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Fired Magnesia Spinel Bricks
High quality begins by the proper selection of the raw materials needed.
The dead-burned magnesia sinter named M30B is the basis of all quality products from
MAGNESITA. High purity ( > 98% MgO ) and large crystal size ( > 120µm ) guarantee superior
and high refractoriness.
Dead-burned magnesia sinter and other additives are combined to generate the most
comprehensive line of spinel products for the Cement Industry.
MAGNESITA excels in the engineering of spinel technology to improve the properties of ist
products. Fused spinel grains, in-situ spinel bond and other high purity spinel types are
used according to the final product applications.
As a Global Partner for the Cement Industry MAGNESITA has a range of differents
magnesia spinel products under the unified trademark MAGKOR.
A = standard grades
With addition of other magnesia sinters
B = standard grades
Based on the high purity M30B DBM
S = superior grades
For aggresive conditions
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MAGKOR A1
This quality is formulated with a mixture of M30B and a second magnesia sinter with
> 98% MgO.
MAGKOR A1 is a cost effective solution for the burning and transition zones of
kilns operated with alternative fuel substitution. The low amount of alumina and the high
purity of MAGKOR A1 guarantees hig chemical resistance and high refractoriness.
MAGKOR A2
The major raw material for MAGKOR A2 is Magnesita’s own > 95% MgO dead-burned
magnesia with a total iron of 1.7%. This brick has an enhanced ability to form coating.
MAGKOR A2 is the solution for the burning and upper transition of rotary kilns under
normal operation conditions.
MAGKOR A3
For MAGKOR A3 Magnesita’s own > 98% MgO dead-burned magnesia ( M30B ) and
> 95% Mgo ( M10 ) dead-burned magnesia with an iron of 1.7% are the major raw materials.
This brick has an enhanced ability to form coating with a good chemical resistance and
inproved stability in reducing atmosphere.
MAGKOR A3 is a cost-effective solution for the burning and upper transition zone for
demanding operation conditions.
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MAGKOR B1
This quality is produced from hig purity M30B magnesia and fused spinel, the grade which
presents high resitance to chemical corrosion by alkalis and clinker liquid phase infiltration,
high modulus of elasticity and a very high thermal shock resistance.
MAGKOR B2
This quality is an evolution of MAGKOR B1 with a special spinel matrix bond. In-situ formed
spinel assures higher elasticty of the lining, reduced thermal coductivity and improved
ability to form coating. This quality has excellent thermal shock resistance, excellent high
resistance to clinker phase penetration and corrosion.
MAGKOR B3
It is a magnesia spinel grade with the same ceramic concept as MAGKOR B1 and B2.
MAGKOR B3 takes benefit of a minor addition of spinel. The increase of magnesia sinter
share improves the chemical resistance against clinker vapours and clinker liquid phase
infiltration. This quality has an excellent high resistance to reducing atmosphere and friendly
coating behaviour in the central burning zone.
MAGKOR B4
It is a magnesia spinel grade with a higher content of spinel in conparison to MAGKOR B3.
This quality has a very high chemical resistance, exellent resistance to reducing atmosphere
and friendly coating behaviour.
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MAGKOR S1
MAGKOR S1 is composed of M30B magnesia sinter and fused spinel, with a special
spinel matrix bond. This spinel bond is reinforced by the addition of fine zirconia.
It is the brick quality with the highest thermal shock resistance, the grade with the best hot
modulus of rupture at 1500°C which is not reduced by alkali salt infiltration, excellent high
thermal elasticity, excellent high resistance to clinker phase penetration and corrosion and
excellent high resistance against chemical attack.
MAGKOR S2
MAGKOR S2, produced from M30B magnesia sinter and fused spinel,present a very
dense microstructure. The permeability is on a very low level and the mechanical strength is
increased with no negative influence of the flexibility of the brick.
The low permeability helps by face operation conditions with high shares of alternative fuels.
The infiltration of volatiles into the brick is prevented by ist dense microstructure. This
prevents a deeper infiltration of clinker liquid phases.
MAGKOR S3
MAGKOR S3 is a special brick extremely resistant to the most corrosive rotary kiln
environments. The high percentage of sintered magnesia is the key for a very good chemical
resitance against alkali vapours and clinker liquid phases. The use of a proprietary additive
package in-house deveoped assures reduced permeability and in-situ spinel formation.
This product presents in use a reduced sensitively against infiltration of liquid and gaseous
compounds, maintaining high flexibilityeven in the infiltrated stage.
MAGKOR S4
MAGKOR S4 is composed of M30B magnesia sinter and high amount of fused spinel.
A third component is used to form spinel during the life cycle of the brick, thus keeping the
modulus of elasticity at very low levels, despite alkali infiltration.
This quality is recommended for zones with high mechanical constraints and fast alkali
infiltration. Ist highly flexible brick stucture ensures the necessary life time.
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Table of the Characteristic Properties of Fired Magnesia Spinel Bricks for Cement Kilns
Standard Grades with addition of other magnesia sinter
Chemical Composition
MgO mass % 89.5 87.5 87.0
Al2O3 mass % 9.0 7.5 8.0
Fe2O3 mass % 0.4 1.7 1.5
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Table of the Characteristic Properties of Fired Magnesia Spinel Bricks for Cement Kilns
Standard Grades based on the high purity dead-burned magnesia sinter ( M30B )
Description of fired brick Magnesia Spinel Magnesia Spinel Magnesia Spinel Magnesia Spinel
Chemical Composition
MgO mass % 86.0 87.5 91.5 91.0
Al2O3 mass % 12.0 10.2 6.5 7.2
Fe2O3 mass % 0.5 0.4 0.5 0.4
CaO mass % 0.8 0.95 0.8 0.8
SiO2 mass % 0.4 0.25 0.4 0.3
ZrO2 mass %
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Table of the Characteristic Properties of Fired Magnesia Spinel Bricks for Cement Kilns
Superior Grades for aggressive conditions
Description of fired brick Magnesia Spinel Magnesia Spinel Magnesia Spinel Magnesia Spinel
Chemical Composition
MgO mass % 84.5 85.5 88.5 85.0
Al2O3 mass % 11.0 12.5 9.5 13.0
Fe2O3 mass % 0.4 0.5 0.5 0.5
CaO mass % 1.0 0.8 0.8 0.7
SiO2 mass % 0.25 0.3 0.3 0.3
ZrO2 mass % 1.75
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Fireclay and Alumina Bricks
In the short outlet zone of a rotary cement In areas of high alkali loading our In the inlet zone abrasion-resistant, dense
Kiln, where alumina bricks based on bauxite andalusite qualities ALUDUR 55 C or special fireday qualities DELTADUR 70 and
are installed, we recommend the quality ALUSIC 10 with a content of 10% EXAKTA 33 are the recommended qualities.
ALUBAX 83 C, which have achieved exellent silicon carbide are recommended. The benefit of these products lies in their low
perfomance. porosity, which reduces the infiltration of
For cooler zones of the kiln we would liquid and gas phases. The low Al2O3 content
recommend qualities of 45% alumina minimises a possible reaction with alkali, the
For the safety zone ( above the upper content, for examle EXAKTA 43. low thermal conductivity reduces temperature
transition zone ) more exposed to have, we losses.
recommed bauxite-based qualities
ALUBAX 70.
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Recommende Lining Concept
2600
2mm Stahlblech 55
2200
2 198 2 198 2
2 198 198 2 2 198 2 198 2 198 2
200
200
11 2 1
4 3 2 1 13 12 6 5 4 3
35
40x170
X-ray fluorescence analysis 1 DIN EN 993-1 DIN EN 993-1 DIN EN 993-5 DIN EN 993-5
ALUBAX 83 C 83 11 1.5 2.87 17 90 1.450
The figures are standard values of our running production, which might vary a little.They are not guaranteed values. Only specific, written agreement qualifies them as
guaranteed values. In general, either whole bricks or samples cutfrom finished products are used for the tests, which are based on DIN/ISO standards and
PRE-recommendation, supplemented by our own measuring methods. As our production is subject to permanent development and technical progress, these data
might change.
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Casting and Gunning Mixes
MAGNESITA Refractories experts offer All materials mentioned in the tables are
their expertise and assistance for the only a small part of the product range of
choice of the most suitable products for MAGNESITA Refractories castables,
the respective application. gunning mixes or ramming mixes. Please
contact one of our offices directly to obtain
more information.
SITAL-CAST 052 95.5 0.1 3.8 0-8 6.0 2.50 60 12 C/V hydraulic
SITAL-CAST 182 82.0 1.5 2.0 0-5 5.0 2.80 100 6 C/V hydraulic
SITAL-CAST 392 61.0 0.6 2.0 0-8 5.5 2.60 70 6 C/V hydraulic
Application Areas
SITAL-CAST 052 burner pipe, kiln inlet resistant against high temperatures
SITAL-CAST 182 kiln outlet, planetary cooler highly abrasive resistant exellent thermal shock resistance
SITAL-CAST 392 burner pipe, cooler, preheater resistant against alkali attack and abrasion
SITAL-CAST 512 kiln hood, cooler, calciner resistant against high temperatures
SITAL-VIBROMIX 552 cooler, preheater, tertiary air duct highly resistant against alkali attack
SITAL-GUN 322 cooler, kiln hood, calciner repair mix for all purposes
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Mortars
Mortars
Grades Al2O3 Fe2O3 SiO2 MgO CaO Water Shelf life Bond
required
% % % % % % months
X-ray fluorescence analysis 1
MAGNEBOND 847 2.5 1.0 4.0 88.0 - 30 12 chemical ceramic
MARPASIT S 40.5 45.0 1.3 50.0 - - 30 12 inorganic/chemical ceramic
Installation
Radial Mortar Axial
Joint Mortars
dry as received ( if needed ) cardboard each ring
1mm -
DOLOMITE 2.0
DHL-Mortar
1mm -
MAGNESIA 1.5
MAGNEBOND 847
1mm -
MAGNESIA SPINEL 1.0
MAGNEBOND 847
1mm - 1mm
HIGH ALUMINA
MARPASIT B 68.5 MARPASIT B 68.5
The figures are standard values of our running production, which might vary a little.They are not guaranteed values. Only specific, written agreement qualifies
them as guaranteed values. In general, either whole bricks or samples cutfrom finished products are used for the tests, which are based on DIN/ISO standards
and PRE-recommendation, supplemented by our own measuring methods. As our production is subject to permanent development and technical progress,
these data might change.
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Rotary Kiln Shapes - VDZ-series
a
h
D
l
The figures are standard values of our running production, which might vary a little.They are not guaranteed values. Only specific, written agreement qualifies
them as guaranteed values. In general, either whole bricks or samples cutfrom finished products are used for the tests, which are based on DIN/ISO standards
and PRE-recommendation, supplemented by our own measuring methods. As our production is subject to permanent development and technical progress,
these data might change.
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Rotary Kiln Shapes - ISO-series
a
h
D
l
The figures are standard values of our running production, which might vary a little.They are not guaranteed values. Only specific, written agreement qualifies
them as guaranteed values. In general, either whole bricks or samples cutfrom finished products are used for the tests, which are based on DIN/ISO standards
and PRE-recommendation, supplemented by our own measuring methods. As our production is subject to permanent development and technical progress,
these data might change.
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Key Bricks
a
D
l
MAGNESITA Refractories grades
b
Code Dimension in mm Volumen Magnesia Dolomite High Alumina
a dm³ Spinel
b h l D
P 180 87 77 180 198 3132 2.92
P 181 65 60 180 198 4680 2.23
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Packaging
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