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Experimental heat losses reduction has been completed by GCE Group


Experiment on cement kilns efficiency advancement by innovative heat insulation material application has been carried out by GCE Group R&D Department, announces GCE Group press service.

External surface of cement kiln was covered by refractory paint during the experiment. Such coating allowed to reduce heat losses and, as a result, fuel consumption. “Kiln lining losses amount to 10% during clinker firing. The data has been proved by results of a dozen energy audits carried out at large cement factories in BRICS countries”, comments GCE Group Director on Energy Efficiency, Vasilii Tarasovskii.

Advantages of insulating paint application are easy operation during maintenance period and possibility for material integrity visual control.

The experiment was carried out in LLC “Cement” (Slantsy, Leningrad region, Russia). Different parts of rotary kiln were plated by refractory paint layers of various thicknesses. Thermal imaging survey showed temperature decrease by 21% from 270 to 214 Co.

GCE Group experts discovered sixty-thousand dollars saving potential for Itambe Cement (Brazil) in case of refractory paint application instead of existing insulation. The payback period for the project investment is less than one year.

It is possible to use insulating paint instead of other conventional materials such as mineral wool, galvanized iron, polyurethane and others in different areas - heating networks, pulp and paper facilities, metallurgical plants. GCE Group expert note that the paint is an innovative product and is not widely used.

Nowadays additional experiments for heat insulation properties, persistency and quality investigation are in the planning stage. «We need to explore the most appropriate thickness of paint layers, coating technology and compare different manufacturers paint quality, - informs Chief Engineer of GCE Group Energy Efficiency Department, Michael Chaika.

GCE Group team has started to develop a new test unit. The unit will allow to proceed with experiments for heat insulation properties upgrading without any negative impact on technological process.

Печь клинкера
Fig.1 (left) – cement kiln surface with refractory paint (thermal imaging)
Fig.2 (right) – cement kiln surface with refractory paint (camera shot)

Reference data:
Raw material mixture (slurry or pellets) is fired in rotary kilns.

Rotary kiln is a hollow cylinder opened from both ends with refractory brick lining. The cylinder, inclined slightly to the horizontal, rotates with 1-1,5 rpm. The speed depends on kiln diameter and capacity. Raw mixture moves from upper “cold end” of the cylinder while air-fuel mixture is supplied permanently from lower “hot end”. Raw mixture moves to the discharge chamber due to cylinder inclination and rotation. Fired clinker is supplied to the fridge through link chamber. Exhaust gas is injected to the atmosphere by dust catchers.

Rotary kiln is divided into six temperature zones according to the clinker firing processes: evaporation and heating are 50—60% of the kiln, calcination and heat generation are 25—30 %, clinker formation is 10—15% and cooling is 2—4%. Rotary kilns are usually equipped with heat exchangers. Clinker is cooled in fridges fixed on the kiln body or installed separately.

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