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in cement industry - dalmiaseven.com€¦ · DALMIA SEVEN is not only a new name, but a new promise: to bring tradition and innovation together for the purpose of serving the Indian

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Page 1: in cement industry - dalmiaseven.com€¦ · DALMIA SEVEN is not only a new name, but a new promise: to bring tradition and innovation together for the purpose of serving the Indian

in cement industry

Page 2: in cement industry - dalmiaseven.com€¦ · DALMIA SEVEN is not only a new name, but a new promise: to bring tradition and innovation together for the purpose of serving the Indian

Our servicesWe keep a strategic stock of monolithic and insulating castablesfor the cement customer’s need. In addition we keep a wide stock of all complementary products such as steel and ceramic anchors, bio-soluble and ceramic fibres, and insulating bricks. With the support of our expert technicians, we supply not only top quality refractories but also technical solutions and engineering. In cooperation with selected installation companies, we are able to supply turn-key/new projects, along with all the necessary equipment for the lining maintenance of a cement plant.

Our products have been developed for the special operating conditions required in the cement manufacturing process. Nowadays, more and more alternative fuels are burned and special refractory materials are required.

To date, a refractory

material suitable

for all the operative

conditions does not

exist.Thus, each plant

should be analyzed to

find the best technical

solutions.

AdvAnced refrActories technology

Our solutionsEach step of the cement-making process has special requirements regarding the correct choice of refractory materials. The design of the plant, the raw materials used in the process, and the various fuel options, all have a major influence on the refractories required. Alkali infiltrations, build-ups, abrasion and the use of alternative fuels, must all be carefully evaluated.

DALMIA SEVEN is not only a new name, but a new promise: to bring tradition and innovation together for the purpose of serving the Indian market in an optimal and unprecedented way.It is a joint venture between Dalmia Refractories, India’s trusted and leading refractory maker and Seven Refractories of Europe, a young European manufacturer, which unites innovative technology with multi-national experience across various refractory industries.

DALMIA SEVEN understands your specific requirements and serves them innovatively with the most advanced technology.

2

Page 3: in cement industry - dalmiaseven.com€¦ · DALMIA SEVEN is not only a new name, but a new promise: to bring tradition and innovation together for the purpose of serving the Indian

The burner lance is a critical area with specific needswhich depend on kiln and grid cooler design, raw materials used, and fuel type.Strong thermal load, abrasion, infiltration and chemicalattack must be considered in the right choice for the monolithic used to line the burner lance.

The most important step in the efficiency of a moderncement plant is the cyclones system.

Each pre-heating system design is different and unique, and each cyclone system must be analysed in order to identify the critical refractory zone.

We evaluate the effects of build-up, alkali,chlorine infiltration, and all other factorswhich may influence the performance of refractory materials used in the various cyclone systems

Brand name Type of product Operating condition

MONOLITHICS – CASTABLES

DS Cast 95 RR VK RCC Medium

DS Cast 80 NH LCC Hard

DS Flow 80 NH SFC Hard

DS Cast 50 RD 01 W LCC Hard

DS Plast 90 AKR PLASTIC Medium

DS RESICOAT-B-BP SiC based LCC

Brand name Type of product Operating condition

MONOLITHICS – CASTABLES

DS Cast 45 NM LCC Soft (Stages I,II)

DS Cast 50 NM LCC Medium (Stages I,II,III)

DS Cast 40 NM 01 W LCC Medium(Stages III,IV,V)

DS Cast 30 N SIC M LCC Hard (Stages III,IV,V)

MONOLITHICS – GUNNING MIXES

DS Gun 50 RNDS Gun 50 NM

RCG LCG

Soft/Medium (Stages I,II,III)

DS Gun 40 RM 01 WDS Gun 45 NM 01 W

RCG LCG

Medium (Stages III,IV,V)

DS Gun 32 N SIC NDS Gun 30 R SIC M

RCG LCG

Medium/Hard (Stages III,IV,V)

Stage Process temperature

I 300 °C

II 500 °C

III 650 °C

IV 800 °C

V 900 °C

Burner lance

Preheater (Cyclones and connecting ducts)

Kiln Burners. DS Cast corrundum.

Kiln Burners. DS Cast 80.

II

III

IV

V

I

Cyclones system.

Cyclone – Bricks installation.

1.

2.

3

Page 4: in cement industry - dalmiaseven.com€¦ · DALMIA SEVEN is not only a new name, but a new promise: to bring tradition and innovation together for the purpose of serving the Indian

The Calciner plays an important role in the cement manufacturing process being the first step of the clinker production process. The main property of the calciner’s refractory lining is to withstand to the chemical attacks coming from the hot gases of the process. Refractory materials must have low porosity and good thermal stability.

The riser duct is a problematic zone due to: - build-ups, alkali infiltration, and chemical attack to the steel anchors. Following the general rule, we suggest lining the duct with bricks in the round sections and with castables in the square sections.

Calciner

Riser duct

Brand name Type of product Operating condition Application zone

Process temperatures = ~ 900-1100 °C

MONOLITHICS – CASTABLES

DS Cast 50 NM LCC Medium B

DS Cast 40 NM 01 W LCC Medium B

DS Cast 55 NH 01 V-10 LCC Hard B

DS Cast 50 RD 01 W LCC Hard B

DS Cast 30 NC SIC LCC Hard A

DS Cast 57 N SIC H LCC Hard A

DS Cast 50 ND 15 Y LCC Hard A

DS Cast 45 U ZIR LCC Hard A

DS Cast 160S Regular Castable

DS Cast 11 LW Insulating Castable

DS Cast 11LI LW Insulating Castable

DS Cast 13 LW Insulating Castable

MONOLITHICS – GUNNING MIXES

DS Gun 50 RMDS Gun 50 NM

RCGLCG Medium B

DS Gun 40 RM 01 WDS Gun 45 NM 01 W

RCGLCG Medium B

DS Gun 57 RH 01 V CO RCG Hard B

DS Gun 32 N SIC M LCG Medium A

DS Gun 50 ND 15 Y LCG Hard A

DS Gun 60 R SIC M RCG Hard A

DS Gun 11 LW

Brand name Type of product Operating condition

MONOLITHICS – CASTABLES AND GUNNING MIXES

DS Cast 50 NM LCC Medium

DS Cast 45 NM LCC

DS Gun 50 RMDS Gun 50 NM

RCGLCG Medium

DS RESICOAT-B SiC based LCC

B

A

Calciner – Shot Creting application

Calciner.

Calciner – Gunning application (Gas Tight)

3.

4.

4

Page 5: in cement industry - dalmiaseven.com€¦ · DALMIA SEVEN is not only a new name, but a new promise: to bring tradition and innovation together for the purpose of serving the Indian

Brand name Type of product Operating condition

MONOLITHICS – CASTABLES

DS Cast 30 N SIC M LCC Medium

DS Cast 30 NC SIC LCC Hard

DS Cast 57 N SIC H LCC Hard

DS Cast 45 U ZIR LCC Hard

DS Cast 50 ND 15Y LCC Hard

MONOLITHICS – GUNNING MIXES

DS Gun 32 N SIC M LCG Medium

DS Gun 50 ND 15Y LCG Hard

DS Gun 60 R SIC M RCG Hard

Brand name Type of product Operating condition

MONOLITHICS – CASTABLES

DS Cast 50 RD 01 W Low cement Medium

DS Cast 30 NC SIC Low cement Hard

DS Cast 78 NB Low cement Medium

DS Cast 80 NX Low cement Hard

DS Cast 90 NX LCC

DS RESICOAT-B-BP SiC based LCC

Brand name Type of product Operating condition

MONOLITHICS – CASTABLES

DS Cast 80 NH Low cement Hard

DS Flow 80 NH Self flowing Hard

DS Cast 55 NH 01V-10 Low cement Hard

The smoke chamber is a critical area, where build-ups, frequent use of high pressure water pump which causes thermal shock make it necessary to use special refractories.

The nose ring is also a critical area, requiring specialmonolithic refractory material which has an excellent resistance to:• High Thermal Shock• Mechanical Resistance• Chemical Attack Resistance.Our “DS Cast AS 30”, has been developed by our R&Ddepartment, to ensure the best performance for thiscritical area, along with a very fast installation time.

For the tertiary air duct we suggest abrasion resistant castables for the most stressed areas. For the other areas we suggest to use fireclay bricks.

Smoke chamber

Nose ring

Tertiary air duct

Smoke chamber anchoring.

C

Smoke chamber.

Smoke chamber.Low cement gunning application

Tertiary air duct. Lined with fireclay bricks.

Casting the nose ring.

Smoke chamber. Low cement gunning installation

5.

6.

7.

5

Page 6: in cement industry - dalmiaseven.com€¦ · DALMIA SEVEN is not only a new name, but a new promise: to bring tradition and innovation together for the purpose of serving the Indian

The formed clinker falls from the kiln into the grate cooler.The cooler area is also a problematic zone due to high thermal shock and abrasion. We use high quality raw materials and special binders in our monolithics, which are capable of resisting the severe conditions in the grate cooler.

For this area we suggest refractories with low thermal conductivity, good abrasion resistance and good resistance to chemical attack.

Grate cooler

Kiln hood

Brand name Type of product Operating condition

MONOLITHICS – CASTABLES

DS Cast 50 NM LCC Soft

DS Cast 57 ND LCC Medium

DS Cast 55 NH 01V -10 LCC Hard

DS Cast 50 RD 01 W LCC Hard

DS Cast 30 NC SIC LCC Hard

DS Cast 78 NB LCC Hard

DS Cast 80 NH LCC Hard

DS Flow 80 LCC Hard

DS Cast 135 N Regular Castable

DS Cast 135 S Regular Castable

DS Cast 140 N Regular Castable

DS Cast 140 T Regular Castable

DS Cast 139 N Regular Castable

DS Cast 160 N Regular Castable

MONOLITHICS – GUNNING MIXES

DS Gun 50 RMDS Gun 50 NM

RCGLCG

MediumMedium

DS Gun 32 N SIC M LCG Hard

Brand name Type of product Operating condition

MONOLITHICS – CASTABLES

DS Cast 50 NM LCC Soft

DS Cast 40 NM 01W LCC Soft

DS Cast 59 ND LCC Medium

DS Cast 30 N SIC M LCC Hard

DS Cast 55 NH 01 V -10 LCC Hard

DS Cast 60 NM LCC

DS Cast 70 NM LCC

DS Cast BS 75S SiC based LCC

MONOLITHICS – GUNNING MIXES

DS Gun 50 NM LCG Soft

DS Gun 32 N SIC M LCG Hard

DS Gun 57 RH 01 VC0 RCG Hard

Grate cooler.

Standard DALMIA SEVEN Refractories packaging. 1200 kg pallets in EPAL

Grate cooler.

Kiln hood.

Kiln Hood. Gunning installation

8.

9.

6

Page 7: in cement industry - dalmiaseven.com€¦ · DALMIA SEVEN is not only a new name, but a new promise: to bring tradition and innovation together for the purpose of serving the Indian

Precast Shapes: Grate cooler roof application

Kiln hood.

Pre-cast Shapes

Complementary products

10.

11.

Brand name Type of product Operating condition

MONOLITHICS – CASTABLES

DS Cast 30 NC SIC Precast shapes Medium

DS Cast 50 RD 01 W Precast shapes Hard

DS Cast 59 ND Precast shapes Hard

For critical areas such as the grate cooler roof and bullnose we can produce monolithic precast shapes in orderto provide to our customers quicker start-ups.

The anchoring systems

Our anchoring systems help to improvethe life expectancy of the monolithic areas.We can offer tailor made solutions dependent on the customer’s requirements:- Steel anchors (AISI 304 (1.4301),

AISI 310 S (1.4845), AISI 309 (1.4828) and AVESTA 253 MA.

- Anchor bricks (228 mm, 305 mm and 355 mm) in our quality DS Brick 60 KB.

For the different areas within the cement plant, we suggest a combination of steel and brick anchors be used, to maximise efficiency for the various conditions that are encountered.

Anchor name Sketch Material Available

STEEL ANCHORS

VAISI 304 (1.4301)AISI 310 S (1.4845)AVESTA 253 MA

CVAISI 304 (1.4301)AISI 310 S (1.4845)AVESTA 253 MA

CBHAISI 304 (1.4301)AISI 310 S (1.4845)AVESTA 253 MA

Cast anchorAISI 309 CAST (1.4828 cast)

7

Page 8: in cement industry - dalmiaseven.com€¦ · DALMIA SEVEN is not only a new name, but a new promise: to bring tradition and innovation together for the purpose of serving the Indian

Engineering and technical support12.

DALMIA SEVEN Refractories have the resources able to provide turn-key projects.

• Our engineering department develops new complete projects.

• We are able to supply the Refractory materials along with the necessary engineering for the refractory linings.

• Our supervisors, supervise the complete installation of our products from start to finish on a worldwide basis.

Shot Creting installation. Quality inspection

gunning instAllAt ion

gunning mAchine Assembly

Gunning installationTuning of the gunning machine

Type of productM.O.T(°C)

Chemical composition % Bulk density

(kg/m3)Al2O3 SiO2 CaO(MgO)

INSULATING COMPLEMENTARY PRODUCTS

Light weight insulating slabs 1000 - 45 45 225

Light weight insulating slabs 1100 - 45 47 225

Ceramic fibre boards 1260 45 55 - 300

Ceramic fibre blanket 1260 45 55 - 64,96,128,160

Biosoluble fibre blanket 1200 - 65 29 64,96,128,160

Biosoluble fibre blanket 1300 - 75 22 64,96,128,160

Insulating products

8

Page 9: in cement industry - dalmiaseven.com€¦ · DALMIA SEVEN is not only a new name, but a new promise: to bring tradition and innovation together for the purpose of serving the Indian

LCC= Low cement castableRC = Regular castable

SFC = Self flowing castable

RG = Regular gunning mixLCG = Low cement gunning mix

LCC-S = Low cement castable - Shotcreting

reseArch And sustAinAble development

test ing product ion

green energy

Selection of the raw materials,

dedicated and oriented research,

composition architecture and

on the field technical experts are the

key-points for outstanding efficiency

and reliability of the refractory

linings, excellent control of the

thermal load distribution and low

product variability in time.

11

Page 10: in cement industry - dalmiaseven.com€¦ · DALMIA SEVEN is not only a new name, but a new promise: to bring tradition and innovation together for the purpose of serving the Indian

• Preliminary study and investigation for the project edition

• Design and architecture, bill of materials, thermal calculation

• Full range of products for lining and maintenance

• Regular, low, ultra-low and no-cement castable

• Regular and dense low-cement gunning mix

• Ramming

• Shotcreting

• Grouting, patching and dry vibrating products

services provided

• Supply of mixer, gunning machines, pump, etc.

• Supervision and monitoring by experienced technicians

• Global Research & Development

• Monitoring and targeting of results

• Technical advice from experts

01-2

018

[email protected]

+91 9680774143 | +91 9830525152

Seven Refractories, Karaganda, Kazakhstan

Dalmia Seven Katni, India

indiA Corporate office:Dalmia Seven Refractories Ltd.4, Scindia House, Connaught PlaceNew Delhi 110001Phone: +91 11 23457100

Plant:Plot No. 8 & 13, Phase-III Lamtara Industrial Area Katni – 483501 Phone: +91 7622 266259, 266306

sloveniAPlant:

Seven Refractories d.o.o.Poslovna cona Risnik 40,6215 DivacaTel. +386 5 739 57 60

KAzAKhstAnPlant:LLP Seven Refractories AsiaQuarter 028, block 1655, Bukhar-Zhirau district100408 Doskey, KaragandaTel. +77 212 404 777

Seven Refractories, Divača, Slovenia