In the name of Allah, the Beneficent, the Merciful Refractarios Especiales, S.A.

P.I. Poyo de Reva C/ Poniente, 6 1A bajo 46190 Ribarroja del Turia (Valencia), Spain comercial@refracta.net

Refractory Solutions for Critical Areas in Cement Kilns

Content:
I. Introduction II. Products III. Applications IV. Advantages & Savings V. Experience

I. Introduction:
Company: 1940: Foundation of Refractarios Especiales, S.A. - Refracta 1993: Focus on cement industry R&D on special qualities 1997: New generation of qualities obtained 2005: Refracta stops making traditional refractories, to produce only special qualities 2006: Company moves to a new plant

II. Products:
1. Bricks: R-2000 Superior raw material, special manufacturing process Ta > 1600 C Low Porosity 12-14 % Excellent Chemical Attack Resistance Extremely Abrasion resistant High Crushing strength Thermal Shock resistance AF Ready

II. Products:
2. Castable: PF-97-H Ultra Low Cement Castable Superior performance, does not crack Ta > 1600 C High Degree of Chemical Attack Resistance Extremely Abrasion resistant AF Ready

II. Products:

Advantages: Very long service life (2-3x more) Alkali, chemical attack protection Spalling protection Shell corrosion protection: less thickness loss and maintainence Nose ring protection (longer service life of mechanical parts) Solution for Rings, build ups and snowman

II. Products: Alkali attack with a standard alumina brick

Result of: chemical reaction between brick and alkalis Consequences: formation of cracks within the brick and destruction lower lifetime kiln shell corrosion: infiltration of the alkalis penetrates to the kiln shell reacting with H2O to corrosive acids Uneven (spalled) Surface leading to ring formation

II. Products: Alkali attack with magnesia spinel bricks

Result:

infiltration of alkalis through the brick.

Consequences:

cristalisation of salts (up to 30 % more volume!) Cracks on refractory kiln shell corrosion: infiltration of the alkalis goes to the kiln shell and reacts with H2O to create corrosive acids

II. Products: Alkali attack with R2000

Result:

No infiltration of alkalis, no cracks No chemical reaction Consequences: - much longer lifetime - better protection of the kiln shell against corrosion - quick transport of material through the kiln (better process control)

II. Products:
Advantages: No Rings, No Buildups, No Spalling, Long Service Life

UTZ up to kiln inlet

II. Products:
no rings or build ups

No Coating R2000 forms a glassy layer reducing porosity and protecting from infiltration Advantages: No Rings No Buildups No Spalling Long Service Life

II. Products:
No Rings, No Buildups, No Spalling, Long Service Life

II. Products: Alkali attack with PF-97-H

Result:

No infiltration of alkalis No chemical reaction Consequences: - longer lifetime - minimized sticky substance formation

Tests realized under reducing conditions at CSIRO labs, Australia. Result after 96 h.

II. Products: Castable performance:

Holcim Lorca Bullnose - 1 yr result. No cracks PF97H on bottom, competitor on top

II. Products:
Advantages: Smooth Surface, No Infiltration, No Spalling, Long Service Life

III. Applications R2000 Nose ring Outlet zone, retaining ring UTZ up to kiln inlet Grate and planetary cooler Inlet chamber Tertiary air duct/damper area PF97H Nose ring Riser / Calciner Cyclone roofs Inlet chamber / Cone Cooler / Bullnose Tertiary air duct / Damper area Burner (except tip)

III A. Cement Kiln - Grate Cooler:

1. Outlet Zone : 2. UTZ up to kiln inlet: 3. Cooler: 4. Other Areas:

R-2000 and/or PF-97-H R-2000 R-2000 and/or PF-97-H R-2000 and/or PF97-H

1a. Nosering in PF-97H/R-2000:

Extremely good resistance against axial thrust from the other refractories caused by thermal expansion and gravity thrust of bricks

Cemex Pertigalete (Venezuela)

1,5 years later

1b. Nosering in PF-97-H / R2000

Holcim Prahovice

1b. Nosering in PF-97-H / R2000

Holcim Prahovice

1b. Nosering in PF-97-H / R2000

Holcim Prahovice

1b. Nosering in PF-97-H / R2000

Holcim Prahovice

1c. Typical Outlet Profiles

1. Typical

1c. Typical Outlet Profiles

2. With Cone

1c. Typical Outlet Profiles

3. All Bricks

1c. Typical Outlet Profiles

4. FLS Type

1d. Outlet Zone Samples in PF-97-H / R-2000

Italcementi Rezzato

1d. Nosering / Outlet Zone, plant trial

1d. Nosering / Outlet Zone - FLS type

BCSC (Blue Circle Southern Cement) - Sydney / 5.2 m kiln

1d. Holcim Lorca Outlet Zone Installed Jul00

1d. Holcim Lorca Outlet Zone 1 yr result

1d. Holcim Lorca Outlet Zone 1 yr result

1d. Lafarge Villaluenga Installed Jan 01

1d. Lafarge Villaluenga 9 mo. results

1d. Lafarge Villaluenga 1.5 yr results

1d. Lafarge Villaluenga 1.5 yr results

1d. Cementir Spoletto Install

1d. Cementir Spoletto 1 yr result

1e. Lehigh Mason City, USA (Heidelberg)

2. UTZ up to kiln inlet

R2000 areas with chemical attack and kiln shell corrosion OZ LTZ BZ UTZ SZ CZ

30-35 m / 98-115 kiln with grate cooler: R-2000 from 30-35 m - inlet

45-50 m

kiln with satelite cooler: R-2000 from 45-50 m - inlet

2. UTZ up to kiln inlet

Holcim Orizaba Aug. 2003: position 42,6 - 47,8 mts (5,2 mts)

2. UTZ up to kiln inlet

Holcim Orizaba Aug. 2003: position 47,8 - 52,8 mts (5 mts)

2. UTZ up to kiln inlet

Holcim Orizabal 12 months later

2. UTZ up to kiln inlet

Holcim Orizabal 4 years and 3 months later

K1 11/02/2003 4.6m dia, 4800tpd, nsp, 3.3 rpm. 2 Rings in area 40-50 m

Ring 1

Ring 2

K1 08/05/2003

R-2000 in area of Ring 1 only > 3 months

Ring 2

Kiln 1 14/11/2003

R-2000 in area of Ring 1 + 2 > 9months

Kiln 1 08/06/2007

> 4 years and 4 months later

2. UTZ up to kiln inlet

Holcim Mason City Install

2. UTZ up to kiln inlet

Holcim Mason City 1 yr results and extension

2. UTZ up to kiln inlet

Holcim Mason City 1 yr results and extension, no height loss

2. UTZ up to kiln inlet

Holcim Mason City 2 yr results and extension, no height loss

2. UTZ up to kiln inlet

Holcim Mason City 2 yr results and extension, no height loss

3. Grate cooler
Lining with R2000 in combination with castable PF97H: longer lifetime no build ups or snowmen anchored bricks to wall no cut bricks. Fill in with castables

Italcementi Vivo Valentia castable rebuild

Lafarge Villaluenga IKN Castable / Bricks Rebuild

Lafarge Villaluenga IKN Castable / Bricks Rebuild

Lafarge Villaluenga IKN Rebuild

Holcim Apasco Centro rebuild

Holcim Apasco Centro rebuild

IIIB. Cement kiln with planetary coolers:

1. Outlets/discharge ports: 2. Cooling zone: 3. Satellites: 4. Elbows: 5. UTZ up to kiln inlet:

R-2000 and PF-97-H R-2000 R-2000 R-2000 and PF-97-H R-2000

Outlets/discharge ports in R-2000 & PF-97-H

Planetary Cooling zone

Planetary Coolers

Anneliese Ennigerloh

Planetary Coolers
Anneliese Ennigerloh : 3 years later. TOTAL 5 YEARS

4. Other Areas

Lafarge Langkawi Inlet Cone

Inlet Cone 1 yr results

4. Other Areas

Cemex Hidalgo Inlet Slide

Cemex Monterrey Cooler Roof

4. Other areas: Riser / Duct

Real Infiltration resistance, chemical attack protection Very high abrasion and impact resistance Encapsulation installation: insulation and anchor protection Long service life in excellent conditions Easier Cleaning

4. Other Areas

Italcimenti Hood

4. Other Areas

BCSC Sydney Kiln Door

BCSC Sydney Kiln Door Frame

IV. Plant savings and advantages: Lower refractory cost per ton of clinker Less risk of kiln stops due to refractory failures Higher productivity / less & shorter outages Savings on shutdown costs Better process control due to ring elimination Savings on more petcoke replacing coal Savings on shell replacements Capacity optimisation Environmental benefit: less waste and handling

V. Experience: Materials in 52 countries:

Argentina Australia Austria Belgium Benin Canada Check Republic China Croatia Dominican Republic Dubai Ecuador Egypt France Germany Greece India Ireland Italy Korea Latvia Lebanon Luxembourg Malaysia Mexico Morocco Mozambique New Zealand Nigeria Norway Panama Peru Phillippines Polen Portugal Rumania Serbia Slovakia Southafrica Spain Sri Lanka Switzerland Tanzania Tunisia Turkey U.A.E. U.K. U.S.A Venezuela Vietnam Zambia Zimbabwe