Technical Guidelines
DENSIT® ECONOMY
WITH SEAMLESS AND
FLEXIBLE LININGS
The intrinsic nature of Densit® wear
lining systems means that they are
completely jointless, and can be
formed into any geometry. This flexi-
bility provides the capability for
installing seamlessly graduated
eccentric linings of variable thickness.
In this way the most economical lining
solution is achieved, thicker
protection being applied where wear
is most extreme, and thinner
protection where less wear occurs,
with smooth graduation in between.
This feature is particularly
recommended for lining components
such as pipes, ducts and cyclones,
where wear exposure varies within
the component. For the same reason,
eccentric linings are especially
recommended for pipe bends.
IN-SITU INSTALLATION
Densit® wear protection is applied
by casting, trowelling or spraying,
depending upon the component size
and geometry. Densulate insulated
linings are suitable for high-
temperature applications where
minimising heat loss is critical.
DENSIT® COMPONENTS
Pre-lined Densit® components in
any geometry are also available, for
situations where in-situ lining is
impractical or uneconomical.
Densit a/s · Denmark · Tel. +45 9816 7011 · Fax +45 9933 7788 · E-mail: mail@densit.com · Internet: www.densit.com
The cement industry
General Densit® wear protection in
The lifetime of Densit® Wear rates increase
wear protection exponentially with particle
- ensures continuous operation of critical components
velocity.
increases with reduction
in particle size, slower
Wear rates increase with
particle velocity, and a hardness and angularity of
smaller angle of particle particles, determined by media
impact. mineralogy and physical form.
In particular the heart of the Densit® wear protection systems
process, the kiln, must always is a useful tool in the ongoing
Continuous operation is
essential to maximise run as first priority. Unscheduled battle for continuous
Relation of particle size to angle of incidence
shutdowns must be avoided, improvement and minimum
return on investment in
primarily to avoid production operating costs. Reliable wear
a cement plant. For
loss but also to minimise linings are essential for effective
economical running,
maintenance costs. maintenance planning, and a
maintenance costs must Keeping energy consumption Densit® solution offers both
be minimised through- low is also an important factor in reliability and long life: less
out the plant, requiring running an economical plant, frequent planned maintenance,
engineering skill and affecting many aspects of no unscheduled maintenance
reliable components so process flow and component and no unexpected leaks.
that shutdowns can be selection. Compliance with Densit® wear protection systems
www.bjergs-tegnestue.dk
scheduled. environmental dust control can be designed to minimise
Relation of particle size to air velocity
legislation is an increasing and heat loss in components, ducts
vital priority. and pipes.
WP.02.01.GB/11.2000
 FLOW SHEET
3
3

4
1
6 4
3
4 4

15

Typical process flow 4

in the cement industry, 12
showing components where 14
2
Densit® wear-resistant lining 4 10
7
solutions are installed. 8

10

9 13
1. Rawmill storage. 6. Pre-heater tower. 11. Clinker storage.
2. Raw mill. 7. Kiln. 12. Separator.
3. Filter. 8. Cooler hood. 13. Cement mill.
4. Cyclone. 9. Clinker dedusting. 14. Cement silo 11
5. Raw mill silo. 10. Elevator. 15. Coal mill.
COAL
FIRING SECTOR
QUARRY RAW MEAL MILLING SECTOR KILN SECTOR CEMENT MILLING SECTOR
Areas applicable for DENSIT®
o
0 – 400 C
Shade matches o
(32-750 F)
COMPONENT PROCESS PARAMETERS MEDIA TYPE TYPICAL SERVICE TEMP. RECOMMENDED DENSIT® SOLUTION operating o
KILN CEMENT MILL
temperature: 400 – 1200 C
Pipes, ducts,
Densit® WearFlex/Cast 500 or (750-2190 F)
o
Continuous operation critical. General process parameters
Densit® WearFlex/Cast 2000 depending General process parameters relevant for wear:
bends, valves,
on media type.
conveyors, Transport of process air, Densit® WearFlex 2000 HT for T>400°C. relevant for wear: Cement/slag
flash dryer, ground media, flue gases Raw meal, Up to 450°C dust
Prelined Densit® components. Raw meal and clinker dust, high
riser pipe containing dust in variable clinker or cement. (840°F)
for 1st stage concentrations.
Eccentric or seamlessly graduated linings. temperature, alkali environment. Low temperatures.
Densulate concept where calorie RAW MEAL MILL
preheater
conservatien is required. COMPONENTS COMPONENTS
cyclone
Densit® WearTix 2000/DensiBond concept.
High electricity consumption
operation, therefore operates Riser pipe for 1st stage preheater Grate cooler:
Critical continuous operation most at off-peak electricity rates. cyclone: Duct + bends. Strategic parts.
Recommendation of lining product requires
component (kiln).
Tertiary Environment with variable Clinker. 700°C to 900°C chemical analysis of system. General process parameters First stage preheater cyclone. Dedusting duct:
air duct (900°F to 1650°F) Densulate concept where calorie relevant for wear: Clinker cooler to cyclone.
complex chemistry
dependent upon firing fuel.
conservatien is required. Tertiary air duct: Cyclone to filter (pipe + pipe
Raw meal dust, low temperature. Duct + bends. bends + inlet to filter).
®
Densit WearFlex/Cast 500 or Densit ® COMPONENTS Tertiary air settling chambers. Dedusting cyclone.
Vertical Up to 120°C WearFlex/Cast 2000 depending on media type.
Grinding of media. Raw meal, coal, cement.
mill (250°F) Densit® WearTix 2000/DensiBond concept. Vertical raw meal mill: Vertical cement mill:
Upper housing. COAL FIRING Top part housing.

Separation of fine particles

®
Densit WearFlex/Cast 500 or Densit ®
Raw meal mill separator. Continuous operation critical. High-efficiency separator.
Separator Raw meal, coal, cement. Up to 120°C WearFlex/Cast 2000 depending on media type.
from process air. (250°F) Densit® WearTix 2000/DensiBond concept. Dedusting pipe: General process parameters Dedusting cyclones.
Mill to cyclone/filter (pipe relevant for wear:
Densit® WearFlex/Cast 500 or Densit®
Pipe to cement stock:
bends + inlet to filter). Coal dust, fly ash, low temperature. Separator to filter (pipes +
WearFlex/Cast 2000 depending on media type.
Dedusting Densit® WearFlex/Cast 2000 HT for T>400°C. Dedusting pipe: pipe bends + inlet to filter).
cyclone, Separation of fine particles Raw meal, Up to 500°C COMPONENTS
Seamlessly graduated linings for most Mill to cyclone/silo (pipe + Chain conveyors.
1st preheater from process air or flue gases. clinker, coal, cement. (750°F) exposed sections (inlet, vortex finder, pipe bends).
cyclone Vertical coal mill:
base outlet). Densulate concept. Complete housing.
Densit® WearTix 2000/DensiBond concept. Raw meal dedusting cyclone.
Coal mill separator.
®
Densit WearFlex/Cast 500 or Densit ® Dedusting pipe:
Separation of fine particles Raw meal, Up to 250°C WearFlex/Cast 2000 depending on media type. Cyclone to filter (pipe bends,
Filter from flue gases. clinker, cement. (480°F) inlet to filter).
Lining for inlets and outlets only.
Densit® WearTix 2000/DensiBond concept. Coal burner:
Inlet to coal burner.