Refractories: Lime Recovery

Lime recovery kilns used by pulp producers pose some unique challenges to the refractory supplier. While operating temperatures are comparatively low, aggressive chemical attack from alkalis, the lack of a process coating necessitating the use of low thermal conductivity refractories and kiln shells which require lighter weight refractory solutions, culminate in very specific refractory requirements. DSF materials fulfill all these requirements resulting in longer lining lives and reduced running costs.

In the calcining zone of the rotary kiln, failures are typically due to three problems; spalling as the front face converts to mullite, hot face gaps due lack of expansion and brittle fracture in oval and flexing kiln shells. DSF 72R is used successfully in the calcining zone; controlling the amount of non-mullite aggregate converting to mullite during use, DSF 72R eliminates these failure mechanisms, tightening the rings without spalling off. With a high strain to failure ratio, DSF 72R can deform under kiln flexing avoiding brittle fracture. DSF 72R is a robust material used in numerous rotary kiln operations and has never spalled in any application.

In the backing lining of the calcining zone, we offer DSF Cemlite 36P, a semi-insulating material which can resist the expansion pressures of the main lining, as well as the abrasive wear if ring slippage does occur.

In the intermediate or pre-heat zone, DSF offer a novel material DSF Cemlite 44P supplied as a one-piece lining. This phosphate bonded semi-insulating lightweight brick has excellent wear resistance and importantly excellent insulating properties.

The success of Cemlite products in rotary kilns is particularly visible around problem areas of the kiln; over tyres or when kiln ovality exists. The Cemlite range offers exce/llent stress/strain properties; the flexible nature of the brick allowing the lining to flex as required without cracking and spalling often seen in these applications.

DSF also supply low cement castables, which are tried and tested for lining the shaped areas of rotary kilns. Durocast LC60 and LC40 are typically supplied and have been used successfully for many years in a range of applications such as dams, outlet/inlet cones and chain sections. These materials have high refractoriness, corrosion and abrasion resistance and low porosity.

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Friden, Newhaven, Nr Buxton
Derbyshire, UK, SK17 0DX

+44 (0) 1629 636 271

info@dsf.co.uk

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