Ceramic-Based Success

Sila’s Super Reinforced Ceramic (SRC) technology has been designed to address these industry challenges, delivering results in some of the harshest operational conditions.

Through a series of case studies and real-world applications, this article will showcase how SRC solutions are driving significant improvements in cement production globally.

The challenge of kiln and cooler operations in cement plants

Kiln and cooler operations in cement plants are subject to some of the most demanding conditions imaginable. These critical components face extreme thermal, mechanical, and chemical stresses that can significantly affect plant performance. From high temperatures and abrasive clinker dust to chemical attacks on the refractory lining, maintaining these components is a perpetual challenge.

One of the key issues cement plants face is the durability of refractory materials used in kilns and coolers. Traditional solutions, such as castable and brick linings, often struggle to withstand the extreme conditions, leading to frequent maintenance shutdowns and increased operational costs. In recent years, the introduction of alternative fuels (AFs) into the cement production process has only intensified these challenges, as AFs can lead to more aggressive chemical environments. This is where SRC technology steps in, offering a robust solution that addresses these challenges head-on.

A solution

SRC is a technology developed to address the key issues in kiln and cooler operations. SRC components are designed to provide enhanced resistance to thermal shock, abrasion, and chemical corrosion, making them ideal for use in high-temperature environments. Unlike traditional refractory materials, which can crack or wear down quickly under harsh conditions, SRC is engineered to maintain its integrity over extended periods.

A unique formulation combines advanced ceramics with reinforced structural components, creating a solution that is not only durable but also self-supporting. This means SRC components, such as bullnoses, tip castings and feed lips, can be installed with minimal reliance on traditional steel supports, further enhancing their longevity and performance.

But the real value of SRC technology lies in its ability to significantly extend the operational lifespan of kiln and cooler components, reducing the need for frequent maintenance and minimising unplanned shutdowns. This translates directly into cost savings and increased production efficiency for cement producers.

Case study: ACC India bullnose

A compelling example of SRC technology’s impact is the case of ACC India’s plant, which had been grappling with repeated bullnose failures every 6 to 8 months.

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Read the article online at: https://www.worldcement.com/special-reports/22112024/ceramic-based-success/