Monolithic

concept
solutions for

Cement
Industry

Monolithic Refractories in Cement Industry

Introduction of modern heat exchangers, calciner &
tertiary air ducts, rotary systems for the sintering zone,
discharge sections with the kiln hood and burner
lances, and clinker cooler have allowed Calderys to
implement innovative, state-of-the-art monolithic
products and de-sign solutions, which have proven to
be superior to brick linings in the Cement Industry.
Progress has been made through the development of innovative solutions such as LCC (low cement castables)
and ULCC (ultra low cement castables) that are alkaline
resistant and specially dedicated to cement production
conditions. The combination of recent product design with
modern installation techniques, such as Spraycast
(shotcrete) and low porosity gunning allows Calderys to
be a pioneer in refractory technology and solutions.
These solutions, developed in partnership with our customers, extend the reliability and the
availability of the installations. Calderys own team of experienced engineers can provide

total monolithic refractory lining solutions,

including custom-designed anchoring systems, selection of correct materials, professional
supervision and installation/project management.
A modern cement unit includes a cyclone pre-heater, a calciner with tertiary air duct, a
rotary system and a clinker cooler.

Calderys relies on decades of experience in the complete monolithic

refractory lining of static areas but
also provides solutions for the dynamic parts such as the inlet cone
and the nose ring of the kiln or
rotary cooler.

Our engineering solutions are well-known and trusted both by plant operators and designers, many of whom cooperate closely with Calderys for their day-to-day refractory needs.
Calderys is well-known and respected for its high quality products and services. Our presence in local markets is essential in helping our customers to meet ever-increasing
produc-tion demands. Decades of experience in refractory technology and development,
coupled with modern production facilities, means that Calderys can truly be regarded as a
high quality, reliable supplier.

Stresses in cement units

Higher temperatures

Better chemical resistance:

New products need to be not only resistant to high temperatures but also chemically inert to alkali and
sulphur and have a maximum infiltration resistance. The cement industry has undergone a change in
the use of fuel from oil and natural gas to low-grade coal and combustion of waste materials including
rubber tyres, plastics, solvents, coke, wood, used oil etc.
Selecting the most suitable monolithic material requires experience and knowledge of existing production conditions to avoid further reaction or chemical infiltration.

Alkali resistant

Alkali non resistant

Bursting effect

Calderys monolithic products selection will have a strong impact on reducing the build up effect in the
different parts of cement unit.

Alternative fuels and the Low Cement castables pore size:

Depending on the composition of the alternative fuels, compounds containing alkalis, chlorine
and sulphur, etc are introduced into the kiln system. Salt compounds are also used in coalfired cement kilns.
The use of alternative fuels results in increased salt concentration in the structure of the
refractory lining, depending on the temperature level. Materials with the lowest pore size and
permeability have to be considered to avoid excessive infiltration of chemicals. Compared to
bricks, properly de-signed monolithic materials will develop these densification properties
resulting in very small pores.

Low Cement Castable: GIBRAM after firing at 800C

Standard bricks

Installation technique:
The introduction of gas suspension pre-heaters andcalciners, with their complex geometry, has further encouraged the installation of monolithic refractories in place of
brick linings. In these new installations, sections of the
cyclones, pipe lines, inlet chamber, kiln hood and the
cooler were installed with the LCC castables.

Monolithic solution simplify thermal control of the

lining, result in increased efficiency, faster delivery
times and ultimately a reduction in the total cost of
installation. The most economical option is achieved
by applying a combination of dry or wet gunning
products together with conventional castables, selfflowing castables and LC castables.

Solutions for the Monolithic

Installations Concepts
Dense gunning & Spraycast solution
Due to the fast development of the thermal industries and high increase of
the demand coming from our customers, Calderys was the first to came to
the market with the new range of products like: Spraycast and Low Porosity
Gunning Mixes. Those products are Low Cement containing materials,
combining high chemical and mechanical resistance with cost effective
installation.
In most situations, by using a wet gunning option, it is possible to achieve installation rates which are 3-10 times faster compared to traditional products,
whilst still achieving a service life which is similar to, or above that of regular
castables. An additional advantage is a limited amount of rebounds, no dust
during installation, no moulds required and most importantly, these products
can be applied as wet gunning material, castable as well as pumping material.

Global rates of up to 2.5 T/h (including

preparation, gunning, cleaning...) can be
achieved by dry dense gunning (Low
Poros-ity Gunning Mixes = LPGM) or up to
10T/H by wet gunning Spraycast
(shotcrete), compared to a maximum 1T/h
for standard gunning. Products installed
using standard gunning techniques also
achieve good performan-ces and can be
installed 2-3 times faste than traditional
brick linings.

MID. CYCLONES
AH 404 | AH 410 | SPRAYCAST F 50 R

KERLITE | PLICAST LW-Mix |

BASACAST ISO

LOWER CYCLONES
AH 405 | AH 410 | AH 411 |
AH 413 | SPRAYCAST F 50 R

AS INSULATION

MEAL PIPE

TERTIARY AIR DUCT

ELBOW

SPRAYCAST F 50 R
(cast)

AH 404 | SPRAYCAST F 50 R

AH 411 | SPRAYCAST F 50 R

FIRING-HOOD
AH 405

PRECALCINER

| AH 410 | AH 420 | SPRAYCAST F 50 R

|
SPRAYCAST BX 85

NOSE-RING

AH 405 | AH 410 | SH 411 | AH 13 |

SPRAYCAST F 50 R | SPRAYCAST F 40 S30

SPRAYCAST F 50 R
|
SPRAYCAST BX
85

INLET CHAMBER
COOLER TOP

AH 411 | SPRAYCAST F 40 S30 |

SPRAYCAST F 50 R

FEED TILE
SPRAYCAST F 40 S30 (cast) |
SPRAYCAST F 50 R

AH 411 | SPRAYCAST F 50 R

CHUTE-WALL
AH 410 | SH 420 | SPRAYCAST F 50 R |
SPRAYCAST BX 85

BULL-NOSE
CONUS
AH 411 SR | SPRAYCAST F 50 R

AH 411 | SPRAYCAST F 50 R |
SPRAYCAST BX 85

COOLER-MID BOTTOM

COOLER BOTTOM END

AH 405 | SPRAYCAST F 50 R

AH 404 | SPRAYCAST F 50

Solutions for the

Preheater Tower
Cyclones - Gas Ducts - Meal Pipes
Meal enters through the uppermost hot air duct and is
preheated within the various levels of the cyclones by hot
combustion gas coming from the rotary kiln. In these
cyclones, temperatures vary from 300C (upper part) to
930C (lower part).
The choice of the appropriate monolithic lining material is
made according to thermal and chemical conditions experienced in the area. The wall installation may have several
layers of castables with an appropriate anchoring system.
The following installation methods can be applied:

Casting with:

PLICAST, PHLOCAST, BASACAST,

INTRACAST, ULTRACAST, GIBRAM

Standard gunning with:

PLIGUN, KERGUN, BASAGUN

Dense gunning with:

SPRAYCAST or
LPGM (AH/SH/HC products)

UPPER CYCLONES/
GAS DUCTS
Standard
and severe
conditions

PLICAST 18 C/G
KERGUN C 20 SR

MID CYCLONES/
GAS DUCTS/MEAL PIPES
All
conditions

PLIGUN Strong-Mix
PLICAST Strong-Mix
KERGUN C 28 HR SR

LOWER CYCLONES/ GAS

DUCTS/MEAL PIPES
Standard
conditions

PHLOCAST M 28 HR SR

PLIGUN FL 40
PLICAST FL 40
PHLOCAST M 28 HR SR
KERGUN C 28 HR SR

INSULATING
MATERIALS

Severe
conditions

BASACAST LC 35-407
PLICAST LZ 106
PHLOCAST SiC 30 SR

BASACAST ISO
PLICAST LW-Mix 124 C/G
PLICAST LW-Mix 106 C/G

BASAGUN 40-407
SPRAYCAST & LPGM
(AH products)

Solutions for the

Preheater Tower
Calciner - Combustion Chamber - Riser Duct
The installation of a calciner in the cyclone heat
exchanger enables preheating and calcination of the
cement dust using for burning different kind of
combustion materials, therefore resulting in a reduction of
the entire combustion process.
In these areas, due to a high temperature process of
about 1100 - 1250C, as well as chlorine-alkali
circulation, the re-fractory material is exposed to severe
thermal and chemical conditions.
Here, alkali-resistant products are required:

COMBUSTION
CHAMBER
RISER DUCT
CALCINER
Standard
conditions

PLICAST FL 40
PHLOCAST M 28 HR SR
PLIGUN FL 40
KERGUN C 28 HR SR

Severe
conditions

PLICAST ML 55 S5
BASACAST LC 35-407
PLIGUN MM 55 S5
BASAGUN 40-407
PLISTIX Zircon
PLIBRICO Redd Ram
SPRAYCAST & LPGM
(AH products)

INSULATING
MATERIALS
Standard
and severe
conditions

BASACAST ISO 13-135 0-5

PLICAST LW-Mix 124 C/G

PLICAST LW-Mix 106 C/G

Solutions for the

Preheater Tower
Inlet Chamber - Kiln Inlet
Due to the fast development in the cement industry,
furnace builders have to consider new construction
concepts with much more sophisticated design. The
best and the most flexible solution is to apply
monolithic refractories.
The most intricated part is the inlet arch with the
skewback transition to the intake chute.
The mix runner profile is cut into the back wall to allow
precise guiding of the raw meal. Due to the complex
shape of the casing and to the angular arrangements
around the shock blower nozzle, this type of lining can
only be carried out with a monolithic refractory product
in : cast, gunning and spraycasting version.

INLET CHAMBER
FEED TILE
KILN INLET
Standard
conditions

PLICAST FL 40
PHLOCAST M 28 HR SR
PLIGUN FL 40
KERGUN C 28 HR SR

Severe
conditions

PLICAST LZ 106
INTRACAST 440 SR
BASACAST LC 35-407
PHLOCAST SiC 30 SR
MONROX SiC 60 SR
PLISTIX Zircon
PLISTIX ZM 30 S15
PLIGUN MM 55 S5

INSULATING
MATERIALS

BASAGUN 40-407 0-6

BASAGUN 40-205
SPRAYCAST & LPGM
(AH products)

Standard
and severe
conditions

BASACAST ISO
PLICAST LW-Mix 124 C/G
PLICAST LW-Mix 106 C/G

Solutions for the

Kiln Hood & Cooler

Burner Lance - Nose Ring
Areas such as nose ring, burner lances, kiln
hoods and cooler ducts, lined with
monolithic material, operateunder the most
severe conditions.
The use of multi-fuel burners is becoming
more common practice in cement plants, a
pattern that is likely to increase in the near
future due to the large amount of alternative
and residual fuels available. Unfortunately,
these emerging problems influence coating
formation, clinker quality and refractory lifetime. The combustion problems in a cement
kiln are very complex and affected by a lot of
factors.

BURNER PIPE
Standard
and severe
conditions

PLICAST ML 55 S5
BASACAST LC 60-717 F
GIBRAM SR
MONROX AX SR

The burner lance tips, for example, are always

exposed to alkalis corrosion and abrasion by
the clinker. They also experience vibration and
exposure to high temperature.

Calderys solutions concerning the choice of

material, dimensioning, anchoring and
instal-lation technique guaranty long lasting
opera-tion time.

PLIFLOW A 50 Z/S
PLIBRICO Superal-X AB
PLIBRICO 90 AB

NOSE RING
Standard
and severe
conditions

PLICAST LX 68
GIBRAM SR
BASACAST MC 55-305 F 0-6
BASACAST LC 60-717 F

Solutions for the

Kiln Hood & Cooler

Kiln Hood - Tertiary Air Duct
The proper selection of the refractory material for the
kiln hood is of the highest importance. Due to the big
temperature differences and to avoid erosion caused
by the coming clinker, a high abrasion, thermal shock
and chemical resistant materials should be applied.
Calderys long-term experience allows providing you
with the solutions combining: the right selection of the
materials depending on the chemical problems, the
actual speed of the kiln and the temperature level;
detailed design, anchoring system and installation
techniques to guarantee future long service life.

KILL HOOD
Standard
conditions

PLICAST LX 58
PHLOCAST M 28 HR SR
PLIGUN MM 55 S5
KERGUN C 28 HR SR
BASAGUN 60-500

Severe
conditions

BASACAST LC 60-717 F
PLICAST LZ 106
PLICAST ML 55 S5
KERGUN C 28 HR SR
PLIGUN MM 55 S5
PLIGUN GX A 60 S7
SPRAYCAST & LPGM
(AH products)

TAD ELBOW
Severe
conditions

SPRAYCAST & LPGM

(AH products)

TERTIARY
AIR DUCT
All
conditions

KERGUN C 28 HR SR
BASAGUN 55-503

PLIGUN MM 55 S5
GIBRAM SR

INSULATING
MATERIALS

PLIGUN FL 40
PLIGUN MM 55 S5
SPRAYCAST & LPGM
(AH products)

Standard
and severe
conditions

BASACAST ISO
PLICAST LW-Mix 124 C/G
PLICAST LW-Mix 106 C/G

Solutions for the

Kiln Hood & Cooler

Grate Cooler - Hot Zone
The function of the clinker cooler is to cool clinker from 1300C down to near 100C and to complete its 3 CaO SiO2 transformations to the main component of Portland cement.
In this area, the refractory material is exposed to high temperature changes, difficult mechanical
conditions in the sidewalls (high wear), and severe chemical attack due to the presence of
alkalis released by the clinker cooling process.

COOLER WALL/ROOF
Standard
conditions

PLICAST FL 40
PHLOCAST M 28 HR SR
KERGUN C 28 HR SR
BASAGUN 60-500
PLIGUN FL 40

Severe
conditions

IMPACT ZONE
Standard
and severe
conditions

ULTRACAST 387 SR
PLICAST LX 58 W2
GIBRAM SR

BASACAST MC 55-305 F
BASACAST LC 60-717 F
ULTRACAST SiC 30 SR

INSULATING
MATERIALS

PLICAST LX A-51 S 5
PLIGUN GX A-60 S 7
SPRAYCAST & LPGM
(AH products)

Standard
and severe
conditions

BASACAST ISO
PLICAST LW-Mix 124 C/G
PLICAST LW-Mix 106 C/G

Solutions for the

Kiln Hood & Cooler

Grate Cooler

BULL NOSE
Standard
& severe
conditions

PLICAST LX A-51 S 5
BASACAST MC 55-305 F

GIBRAM SR
BASACAST 50-501
PLIGUN GX A-60 S 7
SPRAYCAST &
LPGM (AH products)

COOLER COLD ZONE

Standard
& severe
conditions

KERGUN C 20 HR SR
PLICAST 18 C/G

COOLER MID. ZONE

Standard
& severe
conditions

PLICAST FL 40
PHLOCAST M 28 HR SR

INSULATING
MATERIALS

KERGUN C 28 HR SR
PLIGUN FL 40
SPRAYCAST & LPGM
(AH products)

BASACAST ISO
PLICAST LW-Mix 124 C/G
PLICAST LW-Mix 106 C/G

Solutions for the

Kiln Hood & Cooler

Planetary Cooler
For the monolithic lining of grate, rotary and planetary
coolers, Calderys offers advanced materials like:
CAST, GUN or SPRAYCAST, which are the most
suitable for this application.

PLANETARY COOLER
INLET
Standard
& severe

GIBRAM SR

conditions

BASACAST MC 55-305 F
MONROX B SR

BASACAST LC 60-717 F

SPRAYCAST & LPGM

(AH products)

PLANETARY COOLER REST

Standard
& severe
conditions

PHLOCAST M 28 HR SR
PLIGUN MM 55 S5
SPRAYCAST & LPGM
(AH products)

Products characteristics by type of installation

Product name

Type

Raw Material
(base)

Working
Temperature
(C)

Chemical Analysis (%)

Density
3

Al2O3

SiC

ZrO2

(g/cm )

CCS 110 C
(Mpa)

Castable
BASACAST LC 35-407

LCC

chamotte

1350

44

na

na

2.3

95

BASACAST LC 60-717 F

LCC

bauxite

1600

76

na

na

2.8

50

BASACAST MC 55-305 F

LCC

chamotte

1550

31

35

na

2.4

120

INTRACAST 440 SR

LCC

andalusite

1650

50

10

10

2.85

120

GIBRAM SR

LCC

bauxite

1600

82

na

na

2.95

125

PHLOCAST M 28 HR SR

LCC

chamotte

1550

46

na

na

2.25

100

PHLOCAST SiC 30 SR

MC

SIC

1500

33

na

2.35

95

PLICAST FL 40

LCC

chamotte

1450

40

na

na

2.26

70

PLICAST LX 58

LCC

andalusite

1650

57

na

na

2.5

95

PLICAST LX A-51 S 5

LCC

andalusite

1600

51

5.0

na

2.42

90

PLICAST LZ 106

ULCC

zircon

1600

29

na

43

3.2

50

PLICAST ML 55 S5

LCC

High Alumina

1550

55

5.0

na

2.48

95

PLICAST Strong-Mix

ULCC

Chamote

1320

40

na

na

2.0

65

ULTRACAST 387 SR

ULCC

Tabluar Alumina

1750

92

na

na

3.2

120

ULTRACAST SiC 30 SR

ULCC

SIC

1500

34

31

na

2.46

60

Self-flow
PLIFLOW A 50 Z/S

LCC

zircon

1650

60

10

10

2.79

90

MONROX AX SR

LCC

andalusite

1650

52

10

2.78

110

MONROX B SR

LCC

bauxite

1600

85

na

na

2.85

60

MONROX SiC 30 SR

LCC

SIC

1500

33

35

na

2.42

80

MONROX SiC 60 SR

LCC

SIC

1500

25.5

59.5

na

2.55

85

Product name

Type

Raw Material
(base)

Working
Temperature
(C)

Chemical Analysis (%)

Density
3

Al2O 3

SiC

ZrO2

(g/cm )

CCS 110 C
(Mpa)

Standard Gunning
PLICAST 18 C/G

MC

chamotte

1300

34

na

na

1.87

30

PLIGUN FL 40

LCC

chamotte

1450

42

na

na

2.08

30

PLIGUN GX A-60 S 7

LCC

andalusite

1550

51

na

2.17

28

PLIGUN MM 55 S5

MC

High Alumina

1500

57

na

2.35

90

PLIGUN Strong Mix C/G

chamotte

1320

37

na

na

1.95

60

BASAGUN 20-305

chamotte

1200

35

17

na

2.2

40

BASAGUN 40-205

MC

SIC

1400

26

52

na

2.3

55

BASAGUN 40-407 0-6

MC

chamotte

1400

43

na

na

2.1

45

BASAGUN 55-503

MC

chamotte

1550

55

na

na

2.3

70

BASAGUN 60-500

MC

High Alumina

1600

57

na

na

2.25

70

KERGUN C 20 SR

MC

chamotte

1350

38

na

na

2.05

40

KERGUN SiC 30 HR SR

MC

chamotte

1400

35

34

na

2.25

80

KERGUN C 28 HR SR

MC

chamotte

1500

53

na

na

2.17

90

PLISTIX Zircon

MC

zircon

1350

37

na

30

2.8

40

PLISTIX ZM 30 S15

MC

zircon

1350

31

14

26

2.8

40

Dense Gunning & Shotcrete

AH 404 SR

LCC

chamotte

1500

48

na

na

2.25

60

AH 410 SR

LCC

andalusite

1650

58

na

10

2.7

98

AH 411 SR

LCC

andalusite

1650

51

10

10

6.7

70

AH 413 SR

LCC

chamotte

1500

43

10

na

2.2

70

SH 420 SR

LCC

SIC

1500

31

na

2.35

63

SPRAYCAST F 50 R

LCC

chamotte

1550

51

na

na

2.4

45

SPRAYCAST BX 85

ULCC

bauxite

1700

84

na

na

2.9

50

SPRAYCAST F 40 S30

LCC

chamotte

1600

44

30

na

2.45

60

Ramming
PLIBRICO 90 AB

ceramic

Corundum

1750

90

na

na

2.77

15

PLIBRICO Redd Ram

ceramic

High Alumina

1650

69

na

na

2.5

44

PLIBRICO Superal-X AB

ceramic

bauxite

1650

73

na

na

2.42

13

NOTES: CALDERYS does not warrant the accuracy, fitness for purpose or update of any information disclosed herein. The recipient shall refer to instructions
and advice provided under any technical documentation. This document and the information contained herein are the exclusive property of CALDERYS.
Reproduction, alteration, copy, release, publication or distribution, in whole or in part, is not allowed.
References, trademarks and specifications of the products may change according to the geographical area to be supplied. Please check the availability of
the products with the sales area manager.