Cement Industry Solutions

Refractory engineering plays a crucial role in the cement industry, as it affects the quality of the final product, the lifespan of combustion systems, energy costs, and emissions. ZHENJIN REFRACTORIES is a leading global supplier of refractory products and lining systems for the cement industry. Our products are designed to meet the latest plant types and environmental regulations while providing innovative solutions. We offer complete services from raw materials to design, development, application, and recycling of used materials with a strong focus on customer satisfaction. Our company operates with structured procedures, rigorous inspections, and effective quality management to ensure the highest possible standards.

1. Preheaters

       The preheater is a component installed upstream of the calciner and the rotary kiln of a clinker/cement plant.
By means of the counterflow principle, the injected raw meal is heated in stages by the upward flow of hot gas, whereby the meal is calcined (deacidified) by up to about 95 %. Depending on the raw mealʻs moisture content and plant capacity, single or dual preheaters with three to five cyclone stages are used.

2. Calciners

       The calciner is installed under the lowest cyclone stage. In this plant section, the raw meal is calcined (deacidified) by up to about 95 %. The energy input required by this stage (about 60 % of the plantʻs overall heating demand) is provided by means of special calciner burners, which can be operated with primary as well as secondary fuels.
The tertiary air duct is connected to the calciner.

3. Rotary kiln

      Slightly angled downwards, the kiln's rotation transports the percalcines raw meal from the inlet to the discharege end (kiln hood), whereby the temperature increases along the kiln's length. Hereby, the required clinker phases are created at material temperatures up to 1450℃.

4. Kiln hoods

      Via the kiln hood, the finished clinker is discharged from the kiln. Simultaneously, the process gases are conducted from the clinker cooler through the hood and into the rotary kiln. In plants with daily clinker outputs up to about 7500 tons, the tertiary air ducts (TAD) are connected mainly to the kiln hood. In larger plants, the TADs are connected behind the kiln hood.

      Therefor, thermochemical resistance has top priority when selecting the most suitable refractory materials for the hood lining. Because of the particularly sensitive behaviour during heat-up, the use of refractory materials that are insensitive to heating up is preferable.

5. Tertiary air ducts

      The combustion air required for the calciner is diverted from the kiln hood by means of the tertiary air duct which bypasses the kiln.
      Various flaps and gate valves are used to control the tertiary airflow. By means of this arrangement – also known as AS (air separate) – dust generation in the kiln is reduced significantly.      

6. Cooler

      The clinker cooler uses air to rapidly cool the hot clinker leaving the kiln, thereby stabilizing the C3S clinker phase and obtaining a high efficiency level. In modern clinker coolers, the cooling air passes through the clinker at right angles, whereby the air absorbs the thermal energy. Via the kiln hood, this recuperated heat is passed to the rotary kiln as secondary air, or as tertiary air via the tertiary air duct.

ZHENJIN REFRACTORIES products

     Periclase-hercynite refractory bricks

     Magnesia—alumina spinel bricks

     GUIMO abrasion resistant bricks

     Spalling resistant high alumina bricks

     HX-35 low thermal conductivity, abrasion resistant bricks

     High-strength alkali-resistant bricks

     Composite structure GUIMO bricks

     Outlet castable

     Refractory castable for burner of cement kiln

     Anti-coating castable castable

     Steel-fiber reinforced castable