A cement plant in Pakistan had been troubled by a persistent problem, particularly with its preheating zone. The main issues were the tendency for refractory bricks to fall off and the formation of a skin on the brick surface, requiring frequent shutdowns for cleaning. Then this severely impacted production efficiency and increased maintenance costs.
Causes: Strong thermal shock from the airflow in the preheating zone, strong alkali erosion, and insufficient resistance to clinker erosion.
Results: Refractory bricks cracked, became porous, and even fell off; the brick surface formed a skin and adhered with refractory material.
Based on the working conditions of the preheating zone, our engineering team recommended a customized refractory material solution, including:
50% alumina bricks with adequate alkali erosion resistance, preventing pulverization, porousing, and cracking.
Excellent thermal shock stability, preventing cracking and flaking. Avoids thick skin buildup, providing structural stability and minimal skin formation, reducing the need for frequent cleaning.
50% alumina bricks were sufficient for the entire preheating zone, ensuring a normal lifespan and offering the best cost-effectiveness.
After implementation, kiln shutdowns were significantly reduced, and overall thermal efficiency improved. The customer expressed great satisfaction, noting that long-standing maintenance issues had finally been resolved. Ruitai Lianxin‘s technical solutions brought stable and reliable operation to their production line.