HW Refractories for the Lime Industry

REFRACTORIES FOR THE
LIME INDUSTRY
Product Applications
Harbison-Walker offers Long Brick
(ref. Cat# HW 131) for rotary kiln
applications. Use of these brick
can eliminate double cuts during
installation of closure courses.
Harbison-Walker Refractories offers a full line of products and solutions to
meet the challenges of the Lime Industry.
Utilize long brick for increased
strength and stability in retaining
rings due to larger mass than
standard kiln liners.
Preheater Refractories
H-W has refractory brick and monolithic
solutions to address build-up, abrasive
conditions and chemical attack.
Installation Procedures
Refer to our brochure for Rotary Kiln Blocks (ref. Cat# HW 137)
for proper installation procedures for curved back RKBs.
As shown in the figures below, the branded face is always the top of the brick and is slightly larger than the
bottom face, which creates a slight taper in the sides of the brick. This taper is known as draft and is
necessary for the brick manufacturing process.
A common mistake, this can be overlooked during installation, but is easily corrected by alternating or
Reversing the Branded Face during installation, shown below.
Refractories for Coolers & Firing Hoods
H-W monolithic refractories include complete lines
of castables, plastics, gunning mixes and shotcrete
products.
Continual process improvement is key to serving our customers. When problems occur, H-W Refractories
has the resources and experience to address most refractory solutions. We offer a broad range of products
and services. For copies of the product brochures mentioned above, or other information, please contact your
H-W Refractories sales or technical representative.
Heat Exchangers and Tumblers
Kiln Brick and Special Shapes
Harbison-Walker Refractories Company
400 Fairway Drive
Moon Township, PA 15108
Phone: (412) 375-6600 • 1-800-377-4497
Fax: (412) 375-6846 • www.hwr.com
© Harbison-Walker Refractories Company. All Rights Reserved.
Cover Photo Courtesy of Carmeuse
Cat# HW 135 (04/10)
H-W offers both basic and high alumina
brick linings, as well as
special shapes designed
for shell temperature
reduction.
Improved Fuel Efficiency and Heat Transfer
Effective heat transfer in rotary lime kilns improves the efficiency of the firing process, reducing fuel
consumption and production costs.
H-W Refractories Company has a longstanding history of product solutions for the lime industry based on
scientific investigation and sound engineering principles. We offer a wide range of products to address
problems of lime producers such as abrasion under rams and build-up in preheaters. H-W Refractories staff
of sales representatives, engineers and research scientists are available to assist in the development of
specific customer solutions.
Patented H-W Prefoil
Heat exchange systems have been used for many years in rotary lime kilns to increase heat transfer to the
load. The arch or leg design splits the material stream as it passes through the heat exchanger, optimizing
material contact with the hot refractory and gasses in the kiln. The increased contact with the hot surfaces
improves heat transfer to the product load.
H-W THERMAX and RIBBACK Shapes
Both H-W THERMAX and RIBBACK shapes are effective for shell temperature reduction in rotary kilns. At
first glance, these shapes are very similar in nature. While the principles behind their insulating properties are
comparable, there are differences between the two products as follows:
H-W THERMAX
HIGH ALUMINA BRICK
WIDER, 5/8” DEPTH NOTCH
USED WITH OR WITHOUT CERAMIC
INSULATING PAD
CALCINING AND TRANSITION ZONES
RIBBACK
BASIC BRICK
NARROWER, 3/8” DEPTH NOTCH
H-W Prefoil Benefits and Advantages:
•
Catenary arch design offering structural stability.
•
Monolithic components precast under controlled conditions.
NOT USED WITH INSULATING PAD
BURNING ZONE
Shared Features And Benefits:
•
Cold face notch imparts insulating characteristics, while avoiding shortcomings of dual linings.
•
Reduced heat transfer through refractory lining.
•
Reduced shell temperatures.
•
Lower fuel consumption.
•
Optimized strength development
•
Cured, dried and ready to install
•
Interlocking hub design minimizes leg separation.
•
Faster installation than previous brick trefoil designs.
Mixing for Reduced Load Slippage
Precast Lifters And Tumblers
Lifters and tumblers are typically brick or precast blocks of refractory, installed in rows, extending above the kiln
lining in the preheating zone. Lifters are designed to increase the tumbling action of the material; elevating and
cascading the feed as it progresses through the zone, minimizing feed slippage. The enhanced mixing action
of the lifters improves the consistency of the feed, resulting in a more homogenous product.
Benefits and Advantages of H-W Precast Lifters:
H-W THERMAX SHAPE
RIBBACK SHAPE
THERMAX In Service:
9” KRUZITE-70 THERMAX KW Blocks with Insulating Pads
Avg Shell Temp = 450°F (232°C)
9” KRUZITE-70 RKB’s
Avg Shell Temp = 501°F (261°C)
Δ Avg Shell Temp = 51°F (29°C)
•
Precast under controlled conditions for optimal physical properties
•
Unique interlocking design secures lifters in place.
•
Versatile design, adaptable to most kiln diameters.
•
Increases tumbling action of feed, promoting homogeneous mixing and even heating
Precast lifters and prefoils should not be used near tires or riding rings, nor in kilns with
excessive ovality or load restrictions.
Improved Fuel Efficiency and Heat Transfer
Effective heat transfer in rotary lime kilns improves the efficiency of the firing process, reducing fuel
consumption and production costs.
H-W Refractories Company has a longstanding history of product solutions for the lime industry based on
scientific investigation and sound engineering principles. We offer a wide range of products to address
problems of lime producers such as abrasion under rams and build-up in preheaters. H-W Refractories staff
of sales representatives, engineers and research scientists are available to assist in the development of
specific customer solutions.
Patented H-W Prefoil
Heat exchange systems have been used for many years in rotary lime kilns to increase heat transfer to the
load. The arch or leg design splits the material stream as it passes through the heat exchanger, optimizing
material contact with the hot refractory and gasses in the kiln. The increased contact with the hot surfaces
improves heat transfer to the product load.
H-W THERMAX and RIBBACK Shapes
Both H-W THERMAX and RIBBACK shapes are effective for shell temperature reduction in rotary kilns. At
first glance, these shapes are very similar in nature. While the principles behind their insulating properties are
comparable, there are differences between the two products as follows:
H-W THERMAX
HIGH ALUMINA BRICK
WIDER, 5/8” DEPTH NOTCH
USED WITH OR WITHOUT CERAMIC
INSULATING PAD
CALCINING AND TRANSITION ZONES
RIBBACK
BASIC BRICK
NARROWER, 3/8” DEPTH NOTCH
H-W Prefoil Benefits and Advantages:
•
Catenary arch design offering structural stability.
•
Monolithic components precast under controlled conditions.
NOT USED WITH INSULATING PAD
BURNING ZONE
Shared Features And Benefits:
•
Cold face notch imparts insulating characteristics, while avoiding shortcomings of dual linings.
•
Reduced heat transfer through refractory lining.
•
Reduced shell temperatures.
•
Lower fuel consumption.
•
Optimized strength development
•
Cured, dried and ready to install
•
Interlocking hub design minimizes leg separation.
•
Faster installation than previous brick trefoil designs.
Mixing for Reduced Load Slippage
Precast Lifters And Tumblers
Lifters and tumblers are typically brick or precast blocks of refractory, installed in rows, extending above the kiln
lining in the preheating zone. Lifters are designed to increase the tumbling action of the material; elevating and
cascading the feed as it progresses through the zone, minimizing feed slippage. The enhanced mixing action
of the lifters improves the consistency of the feed, resulting in a more homogenous product.
Benefits and Advantages of H-W Precast Lifters:
H-W THERMAX SHAPE
RIBBACK SHAPE
THERMAX In Service:
9” KRUZITE-70 THERMAX KW Blocks with Insulating Pads
Avg Shell Temp = 450°F (232°C)
9” KRUZITE-70 RKB’s
Avg Shell Temp = 501°F (261°C)
Δ Avg Shell Temp = 51°F (29°C)
•
Precast under controlled conditions for optimal physical properties
•
Unique interlocking design secures lifters in place.
•
Versatile design, adaptable to most kiln diameters.
•
Increases tumbling action of feed, promoting homogeneous mixing and even heating
Precast lifters and prefoils should not be used near tires or riding rings, nor in kilns with
excessive ovality or load restrictions.
REFRACTORIES FOR THE
LIME INDUSTRY
Product Applications
Harbison-Walker offers Long Brick
(ref. Cat# HW 131) for rotary kiln
applications. Use of these brick
can eliminate double cuts during
installation of closure courses.
Harbison-Walker Refractories offers a full line of products and solutions to
meet the challenges of the Lime Industry.
Utilize long brick for increased
strength and stability in retaining
rings due to larger mass than
standard kiln liners.
Preheater Refractories
H-W has refractory brick and monolithic
solutions to address build-up, abrasive
conditions and chemical attack.
Installation Procedures
Refer to our brochure for Rotary Kiln Blocks (ref. Cat# HW 137)
for proper installation procedures for curved back RKBs.
As shown in the figures below, the branded face is always the top of the brick and is slightly larger than the
bottom face, which creates a slight taper in the sides of the brick. This taper is known as draft and is
necessary for the brick manufacturing process.
A common mistake, this can be overlooked during installation, but is easily corrected by alternating or
Reversing the Branded Face during installation, shown below.
Refractories for Coolers & Firing Hoods
H-W monolithic refractories include complete lines
of castables, plastics, gunning mixes and shotcrete
products.
Continual process improvement is key to serving our customers. When problems occur, H-W Refractories
has the resources and experience to address most refractory solutions. We offer a broad range of products
and services. For copies of the product brochures mentioned above, or other information, please contact your
H-W Refractories sales or technical representative.
Heat Exchangers and Tumblers
Kiln Brick and Special Shapes
Harbison-Walker Refractories Company
400 Fairway Drive
Moon Township, PA 15108
Phone: (412) 375-6600 • 1-800-377-4497
Fax: (412) 375-6846 • www.hwr.com
© Harbison-Walker Refractories Company. All Rights Reserved.
Cover Photo Courtesy of Carmeuse
Cat# HW 135 (07/10)
H-W offers both basic and high alumina
brick linings, as well as
special shapes designed
for shell temperature
reduction.
Basic Brick
MAGNEL ® RS
MAGNEL® RSV
NOKROME® 87LK
185 (2960)
186 (2980)
180 (2880)
Bulk Density, lb/ft3 (kg/cm3)
Apparent Porosity
Crushing Strength, lb/in2 (MPa)
16.0%
15.5%
18.0%
5,600 (39)
5,600 (39)
5,100 (35)
Modulus of Rupture, lb/in2 (MPa)
At 70oF (21oC)
At 2300oF (1260oC)
800 (6)
800 (6)
800 (6)
1,200 (8)
1,100 (8)
1,200 (8)
Chemical Analysis, Approximate wt%
(Calcined Basis)
Silica (SiO2)
0.7%
0.7%
10.7
0.8%
9.2
8.4
Titania (TiO2)
0.1
0.1
--
Iron Oxide (Fe2O3)
0.5
0.5
0.5
Alumina (Al2O3)
Lime (CaO)
Magnesia (MgO)
Alumina Brick
3
3
Bulk Density - lb/ft (kg/cm )
Apparent Porosity
2
Crushing Strength lb/in (MPa)
1.9
2.1
2.4
85.9
87.4
87.9
KRUZITE®-70
CORAL BP ®
KX-99-BF®
UFALA®
KALA®
160 (2,560)
176 (2,820)
140 (2,240)
155 (2,480)
151 (2,420)
18.5%
15.9%
14.7%
15.0%
14.6%
8,000 (55)
13,000 (90)
6,500 (45)
7,000 (48)
7,000 (48)
1,500 (10)
2,600 (18)
1,600 (11)
2,400 (17)
1,700 (12)
Modulus of Rupture, lb/in2 (MPa)
at 70oF (21oC)
Chemical Analysis, Approximate wt.%
(Calcined Basis)
Silica (SiO2)
27.3%
Alumina (Al2O3)
67.5
2.9
Titania (TiO2)
9.7%
52.6%
37.7%
46.3%
82.4
42.2
58.1
50.0
2.4
2.3
2.5
2.2
Iron Oxide (Fe2O3)
1.4
1.2
1.4
1.3
1.2
Lime (CaO)
0.3
0.2
0.2
0.1
0.1
Magnesia (MgO)
0.2
0.1
0.3
0.2
0.1
Phosphorus Pentoxide (P2O5)
—
3.9
—
—
—
Alkalies (Na2O & K2O)
0.4
0.1
0.9
0.1
0.1
The data given in this brochure are based on averages of test results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable.
Variation from the above data may occur in individual tests. These results cannot be taken as minima or maxima for specification purposes. All statements, information and
data given herein are believed to be accurate and reliable, but are presented without guarantee, warranty or responsibility of any kind, expressed or implied.
MAGNEL® RS —A combination of high-purity synthetic
magnesite, fused spinel and a matrix of reinforced spinel
(RS) give this product its excellent physical properties. The
high amount of fused spinel provides low thermal conductivity and low thermal expansion. The matrix spinel aids in the
formation and retention of coating. Suited for all areas of
the basic zone of lime kilns.
MAGNEL® RSV —A combination of high-purity synthetic
magnesite, fused spinel and a matrix of reinforced spinel
give this product its excellent physical properties at a cost
effective price. The moderate amount of spinel yields a
product with excellent resistance to molten attack while
maintaining lower thermal conductivity and thermal expansion than similar products of the same classification. Can
be used in all basic zones, but best suited to transition and
burning zones of lime kilns.
NOKROME 87 LK —Has a very low thermal conductivity
and lends itself to applications over tires to reduce shell
temperature. It is a standard product for applications in
upper and lower transition zones under normal operating
conditions.
KRUZITE®-70 —A 70% Alumina brick manufactured from
domestic calcines and imported bauxitic calcines. Ideally
suited for calcining and cooling zones where normal
operating conditions are present.
CORAL® BP—High Alumina, phosphate bonded brick with
low porosity, high strength and volume stability at high
temperatures. Can be used in lime kiln transition zones
where greater refractoriness is required.
UFALA® —A 60% alumina brick manufactured from
domestic calcines. Exhibits low porosity, excellent alkali
resistance and good thermal shock resistance.
KALA® —A high purity 50% alumina brick with low porosity
and excellent high temperature strength. Suited for use in
preheating and calcining zones.
KX-99-BF®—High fired, Superduty firebrick. Exhibits low
porosity, high strength, good alkali resistance and resistance to carbon monoxide disintegration. Ideal brick for
zoning in lower wear areas of preheater floors.
H-W Refractories for the Lime Industry
VERSAGUN®
60Z ADTECH®
VERSAGUN® 60
ADTECH®
TUFSHOT® LI/OT
ADTECH®
VERSAFLOW®
55/AR C PLUS
EXPRESS® -27 C
PLUS
Maximum Service Temperature, °F (°C)
2900 (1593)
3000 (1650)
2600 (1425)
2800 (1538)
2700 (1482)
Weight Required for Installation, lb/ft3 (kg/cm3)
151 (2,420)
142 (2,280)
116 (1,860)
149 (2,390)
137 (2,190)
--
142 (2,280)
--
--
134 (2,150)
1,230 (9)
1,100 (8)
400 (2.8)
2,100 (15)
1,300 (9)
10,700 (74)
6,400 (44)
2,700 (19)
11,600 (80)
9,000 (62)
-0.2
-0.2
-0.3
-0.3
-0.3
Monolithic Refractories
3
3
Bulk Density, lb/ft (kg/cm )
After 1500°F (815°C)
2
Modulus of Rupture, lb/in (MPa)
After 1500°F (815°C)
2
Crushing Strength, lb/in (MPa)
After 1500°F (815°C)
Permanent Linear Change, %
After 1500°F (815°C)
Chemical Analysis, Approximate wt. %
(Calcined Basis)
Silica (SiO2)
31.8%
32.3%
40.3%
38.0%
43.7%
Alumina (Al2O3)
58.5
62.4
45.9
56.0
48.1
1.8
1.7
2.4
2.0
2.0
Titania (TiO2)
Iron Oxide (Fe2O3)
0.8
0.8
1.1
0.9
1.0
Lime (CaO)
2.8
2.6
9.4
2.8
4.2
Zirconia (ZrO2)
4.0
—
—
—
—
Magnesia (MgO)
—
—
0.4
0.1
0.2
Alkalies (Na2O & K2O)
0.3
0.2
0.5
0.2
0.8
The data given in this brochure are based on averages of test results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable.
Variation from the above data may occur in individual tests. These results cannot be taken as minima or maxima for specification purposes. All statements, information and
data given herein are believed to be accurate and reliable, but are presented without guarantee, warranty or responsibility of any kind, expressed or implied.
—Line of dense, low cement gunning
mixes with improved rebound and
gunning characteristics. Products range from 50% - 80%
alumina content, all exhibiting high strength, good abrasion
resistance and good hot strength. Available in many variations including VERSAGUN® 60 and 60Z ADTECH® and
VERSAGUN® 50 ADTECH®. Applications include preheaters, firing hoods and rotary kilns.
—Line of dense, low cement castables
exhibiting high mechanical strength and
excellent abrasion resistance. Can be vibcast, conventionally cast or pumped into place. Uses include preheater
shelves, feed end linings, precast lifter sections, cast dams,
nose/tail rings. Produ ct s incl ud e VERSAF LO W ® 45 C,
VERSAF LO W ® 55 AR/ C, VERSAFL OW ® 60 ,
VERSAF LO W ® 70 and VERSAF LOW ® 80 C.
Harbison-Walker’s new generation
of phos-bonded plastic refractories.
Designed to be more pliable, with
much longer shelf life than traditional phos-bonded plastics.
Available in 3 workability ranges. PLASTECH ® 85P, the
workhorse of the family, has 85% alumina content, 3100°F
service temperature and 5.5 cc abrasion loss.
EXPRESS® 27 C PLUS —Self flowing, 2700° F dense
refractory castable. It has the unique property that vibration
is not required to remove air voids. It can be either cast or
pumped. Its density together with very good abrasion resistance make it an ideal hot face lining material.
TUFSHOT® LI/OT ADTECH®—An extra-strength, low iron,
fireclay gunning mix, characterized by low rebound. This
product is often used in preheater towers.
THOR AZSP and THOR AZS-PT—Fused Zirconia-Mullite
based low cement castables. Premium anti-buildup products for high alkali environments. Available with and without
Silicon Carbide for use in both oxidizing and reducing
conditions. THOR AZS-PT ADTECH® is the ideal product in
—Next generation of shotcrete prodpreheaters experiencing calcium sulfate build-up. May be
ucts engineered for ease of installation pumped for rapid installations.
while maintaining outstanding physical properties. Available
in compositions from 45 to 85% Alumina. SHOT-TECH ®
60Z contains a zirconia addition for demanding areas where
alkali and abrasive conditions exist.
LO-ABRADE® GR PLUS —Conventional cement, 2600°F
abrasion resistant gunning castable. Can be used for general purpose repairs in all areas. Also available in castable
version.
© Harbison-Walker Refractories Company. All Rights Reserved.
Insert Cat# HW 135 (04/10)