Refractories: Enabling Green Cement Production
Published by Alfie Lloyd-Perks,
Editorial Assistant
World Cement,
As the global cement industry intensifies its focus on sustainability and decarbonisation, the role of refractories in supporting these efforts has become increasingly vital. With stricter environmental regulations and growing demand for green cement, refractory manufacturers are developing innovative solutions to address the unique challenges posed by alternative fuels (AFs) and new production technologies.
As a primary supplier to some of the world’s largest cement producers, numerous experts within Calderys Group (which includes its EMEA and APAC operations and HWI, a member of Calderys in the Americas) are working to support cement customers’ goals to reduce their carbon footprint.
This article examines how the refractory industry is adapting to support cement producers’ sustainability goals, highlighting key innovations, case studies, and collaborative efforts with the company’s cement customers globally.
The challenge of alternative fuels
One of the primary strategies cement producers employ to reduce their carbon footprint is the increased use of AFs. While offering environmental and cost benefits, AFs introduce new challenges for refractory materials used in cement kilns. The varying chemical compositions and inconsistent burn profiles of these fuels create more aggressive environments within kilns, demanding higher performance from refractories.
In India, the rise of AFs like petcoke, sewage sludge, and municipal solid waste in cement kilns presents both economic benefits and significant challenges for refractory materials. The fluctuating quality and chemical composition of these fuels creates extreme conditions within the kiln, demanding advanced solutions.
The challenges posed by AFs include chemical attacks from sulfur and chlorine, thermal shocks due to inconsistent burn profiles, and intensified corrosion and abrasion from volatile compounds. These factors significantly reduce the lifespan of refractory linings.
To address these issues, Calderys developed the SUPRAMON HS series, chemically bonded castables specifically designed for kilns utilising AFs. SUPRAMON HS (SS 37) offers enhanced chemical resistance, superior mechanical properties, and improved thermal stability. The inclusion of nano-sized particles and a mullite matrix strengthens its resistance to chemical attack, while its high cold crushing strength ensures better abrasion resistance. Additionally, its optimised formulation provides enhanced spalling resistance, which is crucial for maintaining kiln lining integrity despite thermal shocks.
Field results from cement plants in Rajasthan, India, and Riyadh, Saudi Arabia, which utilise high percentages of petcoke, demonstrate significantly extended refractory life in critical areas such as the calciner cone and smoke chamber. The SUPRAMON HS series has proven to be a reliable, high-performance solution for cement manufacturers aiming to optimise kiln operations while overcoming the challenges posed by AFs, ultimately enhancing efficiency and profitability.
In Turkey, the shift towards AFs in cement production has introduced significant challenges, particularly with alkali-related wear on refractory materials. To address these issues, Haznedar Durer Refractories, a member of Calderys, developed HAZAL T2 AR, a unique refractory brick designed to withstand the harsh conditions caused by AFs without relying on costly materials like silicon carbide or zircon.
HAZAL T2 AR is characterised by its low porosity, high durability, and enhancedl resistance to alkalis, wear, thermal shock, and acid gases. Unlike conventional alumina silicate refractories, HAZAL T2 AR can effectively handle the severe chemical and thermal stresses that arise when using waste materials as fuel or raw materials in cement production.
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Read the article online at: https://www.worldcement.com/special-reports/09102024/refractories-enabling-green-cement-production/
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