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Preheating Zone / Kiln Inlet Zone

The first reaction zone of rotary kiln system is known as the preheating zone. Here the charge gets heated up to about 800℃ before entering the calcining zone. Bricks in this area are prone to chemical attack from gases containing alkali and sulphur. Thermal insulating property of the refractories in this area results in substantial fuel savings. Dalmia’s high strength energy-saving ALITE bricks, specially developed with alkali / sulphur resistance properties are best suited to withstand abrasion from kiln feed.
Solutions for Preheating Zone / Kiln Inlet Zone
These are the solutions for Kiln Inlet Zone:
Bricks:
  • LF 60-20, LF 60-25 (High Alumina Bricks)
Bricks for Critical Areas:
  • ALITE (Energy Saving Alumina Bricks)
  • DALCR-50 (Anti-Coating High Alumina Bricks)
Castables:
  • QUICKPACK LC 45
  • QUICKPACK LC 60
  • QUICKPACK LC 70
  • QUICKPACK LC 70LI (Low Cement Castables)
Castables for Critical Areas:
  • RAPIDENSE 40
  • RAPIDENSE 50
  • RAPIDENSE 60 (Low Cement Based Special Castables)
  • ALBRACOAT 50 (Anti-Coating Castables)
  • DALCORUNDUM 95ARX (High Alumina Based Low Cement Special Castables)
Special Features:
  • Excellent spalling and abrasion resistance
  • Alkali resistance
  • High refractoriness Superior coating-repellent properties Very high thermal stability.
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Calcining Zone

This is the zone within the kiln system where the raw materials undergo calcination. Temperature in this zone varies from 800℃ to 1200℃. Here CaCO³ (Calciumcarbonate) gets converted into free lime and CO² (Carbondioxide) is driven off. Dalmia’s DALCR anti-coating high alumina bricks have excellent resistance to abrasion with coating repellent properties.
Solutions for Calcining Zone
These are the solutions for Calcining Zone:
Bricks:
  • LF 60-20, LF 60-25 (High Alumina Bricks)
Bricks for Critical Areas:
  • DALCR-60 (Anti-Coating High Alumina Bricks)
  • DALKAR-60 (Dual Bonded High Alumina Bricks)
Castables for Critical Areas:
  • DALRESICOAT A
  • DALRESICOAT B
  • DALRESICOAT B TC
  • DALRESICOAT B BP (Anti-Coating SiC Based Castables)
Special Features:
  • Excellent abrasion resistance
  • Superior strength
  • High refractoriness
  • Good pyroplastic properties to absorb thermo-mechanical stress
  • Low porosity and permeability
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Upper Transition Zone

This is the zone where the last of the kiln feed is calcined. The physical Transition Zone is that portion of the kiln that lies between the Calcining Zone and the Burning / Clinkering Zone of the kiln. Temperature of this zone varies from 1200℃ to 1400℃. This is a critical zone of the kiln since liquid formation starts here causing high level of chemical attack on refractory. Very often second tuyere of the kiln is located in this area causing additional mechanical stress on the refractory. Dalmia GSB´s dual-bonded high alumina bricks with low porosity and low permeability are perfectly suited to fight chemical attack.

Solutions for Upper Transition Zone
These are the solutions for Upper Transition Zone:
Bricks:
  • DALBURN, DALSUPREME (High Performance Special Alumina Bricks)
  • DALSINT-B (Dual Bonded High Alumina Bricks)
Bricks for Critical Areas:
  • MAGNEL 85, MAGNEL 80NC (Chrome Free Basic Bricks)
  • MCRK 3 (Magnesia Chrome Basic Bricks)
Special Features:
  • Abrasion resistance
  • Low flux and high refractoriness
  • Resistance to alkali & sulphur attacks
  • Resistance to spalling
  • Resistance to thermal cycling
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Burning Zone

The final stage of clinker compound formation occurs in this zone where some of the reactions are exothermic. Temperature in this zone varies from 1400℃ to 1510℃. Clinker liquid phase is predominantly present in this area and the kiln lining is under coating. Most important property for refractory in this area is coating friendliness, which indicates the ease with which the coating can form on its surface and stick on it. Dalmia’s DALSINT dual-bonded high alumina bricks come with thermal properties like shock resistance and low conductivity.
Solutions for Burning Zone
These are the solutions for Burning Zone:
Bricks:
  • LF 70-20
  • LF 70-25
  • HA 70-30 (High Alumina Bricks)
Bricks for Critical Areas:
  • MCRK 3
  • MCRK 3A
  • MCRK 3B (Magnesia Chrome Basic Bricks)
  • MAGNEL 80NC
  • MAGNEL 85NC
  • MAGNEL 90NC (Chrome-Free Basic Bricks)
  • DALSINT-A
  • DALSINT-B (Dual Bonded High Alumina Bricks)
  • DALBURN (High Performance Special Alumina Bricks)
Special Features:
  • Resistance to spalling and abrasion
  • High refractoriness
  • Superior strength
  • Low porosity and permeability that minimizes penetration of alkali and sulphate salts.
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Lower Transition Zone

This is the zone where cement clinker is formed and is about to enter the cooler. Temperature in this area comes down from 1510℃ to 1300℃. This is another very critical area of the kiln which is subjected to tremendous abrasion from clinker balls and also axial thrust at the retainer area. Outlet tuyere is also located in this area which increases the mechanical stress on refractories. Refractory in this area should have high abrasion resistance, mechanical strength and flexibility. Dalmia’s DALSINT dual-bonded high alumina bricks have excellent resistance to chemical attack along with thermal properties like shock resistance.
Solutions for Lower Transition Zone
These are the solutions for Lower Transition Zone:
Bricks:
  • LF 60-20, LF 60-25 (High Alumina Bricks)
Bricks for Critical Areas:
  • DALSINT-A, DALSINT-B (Dual Bonded High Alumina Bricks)
  • DALBURN (High Performance Special Alumina Bricks)
  • MCRK 3
  • MCRK 3S (Magnesia Chrome Basic Bricks)
  • MAGNEL 85 (Chrome-Free Basic Bricks)
Special Features:
  • High refractoriness
  • Superior strength
  • Resistance to spalling and abrasion
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Outlet Zone / Discharge Area

This is the kiln tip area where clinker falls into the cooler at about 1300℃. This area is often lined with either brick or castable. Refractory in this area should have high thermal shock resistance and high abrasion resistance.
Dalmia GSB´s  anti-coating high alumina bricks are known for their resistance to abrasion and superior coating repellent properties.

Solutions for Outlet Zone / Discharge Area
Castables:
  • QUICKPACK LC 60 (Low Cement Castable)
  • DALRESISTAL 70 GUN
  • DALRESISTAL 80 GUN (Anti-Coating Gunning Castables)
Castables for Critical Areas:
  • DALRESISTAL-80 (Low Cement Based Special Castable)
Special Features:
  • Highly resistant to abrasion and spalling
  • Low porosity, permeability and high cold crushing strength (CCS)
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Kiln Hood

The hood provides a cover to the outlet discharge area of the kiln as well as the hot part of the cooler with bull nose. The burner passes through the kiln hood and extends up to the kiln outlet. This area is subjected to abrasion from dust carried through secondary air and becomes more challenging for refractories when a tertiary air duct is also connected through the kiln hood. Dalmia’s low cement based special castable DALRESISTAL is highly resistant to abrasion and alkali attack.

Solutions for Kiln Hood
These are the solutions for Kiln Hood:
Castables:
  • QUICKPACK LC 60 (Low Cement Castable)
  • DALRESISTAL 70 GUN
  • DALRESISTAL 80 GUN (Anti-Coating Gunning Castables)
Castables for Critical Areas:
  • DALRESISTAL-80 (Low Cement Based Special Castable)
Special Features:
  • Highly resistant to abrasion and spalling
  • Low porosity, permeability and high cold crushing strength (CCS).
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Burner Pipe

The burner pipe passes through the kiln hood at the kiln’s hot end, arranged more or less along the kiln’s centre line. Fuel is projected into the kiln at high velocity through the burner pipe. Very often burner pipe is subjected to tremendous abrasion at the bottom from dust coming up from cooler. Refractory for burner pipe should have high refractoriness, high thermal shock resistance and abrasion. Dalmia GSB´s anti-coating SiC based castables are highly resistant to abrasion and alkali attack making them most suitable for burner pipes resistance.

Solutions for Burner Pipe
These are the solutions for Burner Pipe:
Castables for Critical Areas:
  • RAPIDENSE 60 (Low Cement Special Castables)
  • DALRESICOAT B BP
  • DALCORUNDUM 95 ARX (High Alumina Based Low Cement Special Castables) and DALRESICOAT B BP (Anti-Coating SiC Based Castable)
Special Features:
  • High resistance to abrasion and alkali attack
ENQUIRE NOW
The Fusion of East and West.
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