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Longer lasting linings for a more sustainable tomorrow

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World Cement,

Daniel Hansted-Martin, HASLE Refractories, describes the benefits of precast modular refractory lining and reviews its role in sustainable cement production.

Longer lasting linings for a more sustainable tomorrow

Global population growth and economic development have created an upswing within the building industry worldwide. According to the International Energy Agency (IEA), cement production is predicted to increase between 12 – 23% by 2050, particularly in India, Africa and other emerging markets, as these regions experience economic development and build new infrastructure.

Cement is a product in demand. And with demand also comes responsibility – a responsibility to secure a place for cement in the building industry of tomorrow. A step on the way to achieving this is to focus on the sustainable use of raw materials, i.e. using refuse-derived fuels and optimising the use of natural resources.

HASLE Refractories has developed a precast Modular Lining used in cement factories throughout the world, as well as in boilers and incineration plants. In cement factories, this lining is typically installed in the smoke chamber, riser duct, cooler roof and bull nose, and represents a step towards sustainable cement production.

Lowering the use of natural resources

The low porosity, smooth impact surface and choice of raw materials for the precast Modular Lining make it highly resistant to alkali attack and build-up. The lining is therefore strong enough for cement factories to use alternative fuels without risking the unscheduled shut-downs needed to clean the burn chambers.

Due to the high strength of the lining, its lifetime can exceed many in-situ castings. Not only does it require less material per installation to create a HASLE precast Modular Lining compared to an in-situ castable solution, but this lining can often last at least twice as long. Consequently, cement factories can lower their use of natural resources per produced unit, simply by changing to Modular Lining, thus reducing the number of needed re-linings and repairs.

As the lining is cast at HASLE’s factory in a highly efficient process, the use of water is reduced to a minimum. Also, instead of relying on a stocked monolithic castable, which can become unfit for use over time, this lining has an unlimited shelf-life, eliminating any material wastage.

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