THERMAL INSULATION

owering energy consumption and heat

loss in cement plants has gained in

importance due to economic, legislative

Figure 1: wet corrosion of steel shell by temperatures below dewpoint for different insulation concepts

and sustainability factors. Reducing

160

a plant's carbon footprint and the

implementation of energy management

regular insulation thickness

140

systems, together with mitigating

greenhouse gas emissions have been
milestones in this development process.
Thermal insulation reduces heat loss of
refractories with low thermal conductivity
while, at the same time, allowing the
cement manufacturing process to continue
smoothly without affecting the properties

120

.a

100

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optimized area
low heat losses
low risk df corrosion

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60

or quality of the cement being produced .

Although the production of cement

40 area of wet corrosion

demands a theoretical energy of 16501800kJ/kg clinker,l.l the real values are

20

higher. They range from 3000kJ/kg clinker

over an average of -3500kJ/kg clinker
up to 8000kJ/kg/clinker for plants with
low thermal efficiency. Reducing energy
input is based on the optimisation of plant
technology and increasing the thermal
insulation capability of the refractories.
Insulation is possible in the kiln and
in static units, mainly the pre heater.
In addition to the essential insulating

--.. ~----.....-

below dew point

10

20

30

40

50

60

70

BO

90

100

insulation thickness [mm]

refractory lining example

wear lining: 114 mm fireclay brick
insulation: e lightweight
expanded clay
fireclay gunnable gunnable

0 vermiculite

e calcium silicate plates

gunnable

- T[inside] = 500 C, T[ambient] = 20 C, no wind

which has an application limit of 950 C, is

gaining more attention due to its thermal

its temperature is below the dewpoint of

water of about 60 C (see Figure 1).

properties, materials have to enable an

uninterrupted cement production process.

stability and chemical resistance. This is of

particular importance given the increasing
use of alternative fuels.

In the presence of chlorides, electrolytic

reaction reduces the strength of the

Demands on thermal insulation

Typical requirements for insulating

materials are:

As air is the best thermal insulator (aside

from a vacuum), insulating refractory
products are characterised by high
porosity. However, increased porosity
means that the strength, refractoriness
and corrosion resistance of refractory
linings decreases.
The correct selection of materials can
counter these challenges to some extent.
The most commonly-used materials for
insulating refractories include calcium
silicate (thermal application limit: 1100 C),
expanded clay (1200 C) and fireclay
(1300 C). 4 Additionally, vermiculite,

low thermal conductivity

thermal resistance
chemical resistance
mechanical strength
volume stability.

Corrosion mechanisms
in preheaters
Corrosion reactions at low and high
temperatures
In the upper cyclone stages with a gas
temperature of 180-500 C, corrosion of
the steel shell is a wet process (rusting), as

metallic anchors of a monolithic lining

and of the steel shell and thus the stability
of the construction. If the dewpoint of
sulphuric acid (-70-140 C) is reached ,
wet corrosion is accelerated. Although the
reaction mechanism is different, the result
is similar but is reached much earlier, so
the deiA!point must be avoided.
In the lower cyclone stages, hot gas
corrosion may take place, especially in the
presence of hydrochloric acid. Reaction
with sulphatic compounds, which in the
presence of oxygen and chlorides will
cause corrosion of the metallic shell, are
possible (see Figure 2).
Therefore, in all preheater stages

THERMAL INSULATION

Figure 2: hot gas corrosion by increased chloride concentration

(~bove 900 O
CJ

insulating
concretes ore superior to
calcium silicate plates)
because they maintain
their dimensional
stability))

deposits

oxide

properties and oxidation resistance is

therefore possible. Anchors exhibiting the
metal

sigma phase are very brittle and break

easily under mechanical loads. A dropping
of anchored concrete fields may occur.

Source: German Association of Material Science

parameters be observed but also the

Sigma-phase embrittlement of
metallic anchors

Lining concepts for insulation

Calcium silicate boards
A worldwide accepted lining design is the
installation of calcium silicate boards.

not only must the cement production

process parameters for secondary

Sigma phase is an intermetallic chrome-

compounds, temperatures and

atmospheres to prevent the formation of

iron phase that occurs between 700900 C in heat-resistant steel alloys

deleterious substances.

with chromium contents of>17 per

In addition, hot gas corrosion of

chromium-containing anchors has to be

cent. Continuously exposed to these

prevented as the formation of hexavalent

temperatures, the steel embrittles

because of the sigma phase formation

chromates is possible. This must be

avoided for structural stability and

(see Figure 3). A reduction in resistance to

corrosion mechanisms (like the depletion

environmental reasons.

of chromium), plus a loss of refractory

These should be installed carefully so

that hot gases cannot reach the kiln shell
through gaps and joints (see Figure 4).
Apart from the environmental benefits,
proper installation reduces energy loss and
increases the lifetime of the lining.
A drawback of this concept is thermallyinduced shrinkage when calcium silicate

Figure 3: sigma phase embrittlement of metallic anchors with

chromium contents> 17%

Independent welding in the oil & gas industry has

become reality with UTPperform.

voestalpine Bohler Welding

www.voestalpine.com/welding

voestalpine

((Installation of insulating
concretes on the basis
of flrecla~ expanded
clay or vermiculite give
considerable advantages
regarding thermal
stability and emergency
properties over the timeconsuming installation of
calcium silicate plates.''
Fo.- ex a.wJrle, ,YJ ~r'r~r W~o.Y!
cyclone stage, a one-layer lining with high
strength and optimised insulation using
a lightweight fireclay concrete has been
installed.
plates are exposed to higher temperatures

Figure 5: thermal stability of calcium silicates and an expanded clay insulation castable

(see Figure 5). This will generate thermal

bridges in the lining from the hot calciner
atmosphere to the shell. Kiln gases then
diffuse more easily through the gaps
between the calcium silicate and the

700 oc

1000 oc

1200 oc

working lining. Consequently, acids and

alkalis can condense on the anchors or
on the steel shell, causing subsequent
corrosion and damage to the lining.
If calcium silicate materials are used

calcium
silicate
plates

expanded clay gunnable

as insulation in statically-stressed plant

units, shrinkage can endanger the entire
system. In the statically-defined system a
closed ring can lose its locking force so that
it opens in the keying section, which may
lead to the collapse of the entire lining.

Insulating castable lining

As an alternative to calcium silicate plates,
various lightweight refractory concretes
are available (see Table 1). These can be
installed by rodding, trowelling, casting or

Figure 6: relationship between porosity and conductivity

gunning. The most advantageous of these

three processes is gunning as it offers the
quickest installation time and high lining
quality. Gunning mixes also have the
following benefits:
selection in terms of heat transfer and
insulation thickness
improved homogeneity of the
insulation layer
good enclosure of the anchors for a
homogeneous lining
castables with improved
refractoriness. The emergency running
properties are sufficient to continue
production temporarily without fatal
failure.
For example, in the uppermost

temperature I C
100

100

7Q0

800

900

10,00

11,00

12,00

13,00

-----------~---------

90
80

70

60

i!"
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0.14

0..

c:

50
40

95% apparent porosity

0.23 W/mK

0.25
0.30 W/mK
65 % apparent porosity

a
-

0.18 W/mK

0.17
0.20
85 %apparent porosity

0.40
0.50 W/mK
40 % apparent porosity

30

+ calcium silicate plates

vermiculite + expanded clay + lightweight clay

gunnable
gunnable
gunnable

THERMAL INSULATION

As Figure 6 shows, a vermiculitebased concrete comes very close to the

cyclone that was installed on the central

calcium silicate plates in terms of thermal

conductivity. Above 900 C insulating

Comparison ofthe lining with calcium

silicate plates in one cyclone and a
vermiculite

concretes are superior to calcium silicate

air outlet of a cement cooler.

plates because they maintain their

dimensional stability. A homogeneous

concrete lining

concrete lining can be applied in

thicknesses starting from about 35mm

is possible,
covering the
installation and

and meets demands in terms of calculated

and expected shell temperatures. An
optimum balance between heat loss and a
shell temperature that provides corrosion

the resulting
outside
temperatures.
The vermiculite
lining was

with insulating vermiculite concrete. The

areas down to the lowest cyclone stage
should still be lined with materials based

gunned for
insulation of the
areas shaded in

on expanded clay and lightweight fireclay,

given their higher refractoriness.
Following the loss of the wear lining, an

grey, while all

other areas were

obtain some additional service life after

loss of the wear lining, enabling repair at a
later stage.

Practical application of an
insulating concrete
A direct comparison of the different
systems used in a plant is demonstrated
using a 'satellite cut' (see Figure 8). This
involves the lining of a double dedusting

kept the lining away from the dewpoint of

acidic compounds.

in the other

protection can be ensured .

Figure 7 shows vessels that can be lined

insulating concrete that remains in place

is the better option. Production usually
has to stop in this case, as calcium silicate
plates are less resistant to kiln gases and
kiln feed dusts. Therefore, it is possible to

shell temperatures but gave more security

regarding emergency properties and also

insulated with
calcium silicate
plates.
The concrete

UTPperform is a unique welding system that allows

lining was
installed at
twice the rate
of the calcium
silicate plate.
According to
measurements,

supply- anytime and everywhere. A machine

the gunnable
vermiculite
lining concept
showed only
slightly higher

you to weld independently of any stationary power

designed for the demands of independent people
who go for individual welding performance. Welding
filler metals designed for the special welding
requirements even under toughest conditions.
Together it is UTPperform- the independent welding
system that allows you to perform your own way!
Check out your live independent welding demo at:
www. utp-maintenance.com/perform
voestalpine Bohler Welding
www.voestalpine.com/ welding

voestalpine
ONE STEP AHEAD

THERMAL INSULATION

The importance of good

insulation and corrosion
prevention
To reduce heat loss in a cement kiln good
insulation and corrosion prevention
are essential. This includes considering

Industry. Third edition. Wiesbaden / Berlin,

Germany: Bauverlag.

Proceedings Refratechnik Symposium , Berlin

2012, p199-208.

THOMAS SAND BEIMDIEK K (2012)'REFRALITE

20 G- the innovative supplement to
Refratechnik's insulating concrete concept.'

ROUTSCHKA, G AND WUTHNOW, H (2011)

Praxishandbuch Feuerfeste Werkstoffe, 5.
Auf/age. Essen, Germany: Vulkan Verlag.

Figure 7: fields of application of a vermiculite concrete as two-layer lining

the metallic corrosion of vessel shells

and anchors so that the possibility of
acidic reaction as well as sigma-phase
embrittlement is reduced- or even
prevented.
Installation of insulating concretes
on the basis of fireclay, expanded clay
or vermiculite provide considerable
advantages in terms of thermal stability
and emergency properties over the timeconsuming installation of calcium silicate
plates. This ensures a long-term and
satisfactory service life of the refractory
lining and a prolonged lifetime of the steel

inside temperature
:5

850 oc

peak temperature

1150 oc

structures, thereby improving performance

of the entire cement plant.

REFERENCES
1

CEMENT SUSTAINABILITY INITIATIVE (CSI)

(2009) Development of the State of the ArtTechniques in Cement Manufacturing. CSI/
ECRA Technology Papers. Geneva, Switzerland/
Dusseldorf, Germany.

2
DUDA WH (1985) Cement Data Book. Volume 1:
International Process Engineering in the Cement

Figure 8: installation of a gunnable vermiculite concrete compared to calcium silicate plates

outside temperature: 5 C I wind velocity: approx. 2.5 mls

temperature of central air before entering double cyclone:
measuring plane 1: 469 C I measuring plane 2: 447 C

D vermiculite gunnable D calcium silicate plates

measuring points:

e vermiculite gunnable (right side) e calcium silicate plates (left side)