Client: A 5000 T/D cement production line in China
Key Issues:
Severe sulfur/alkali corrosion in raw materials
Short refractory lifespan in rotary kiln (8 months)
Frequent wear in grate cooler (6-month replacement cycle
Challenges：
Rotary kiln transition zone with extreme temperature fluctuations (1400-1600°C).
Preheater blockages due to high sulfur/alkali content.
High maintenance costs from frequent shutdowns.
Solutions
Customized Refractories:
Rotary Kiln:
Burning zone: Magnesia-hercynite spinel bricks (excellent thermal shock resistance).
Transition zone: High-alumina SiC composite bricks (low thermal expansion).
Preheater:
Corrosion-resistant zirconia-enhanced castables to reduce buildup.
Grate Cooler:
Steel fiber-reinforced castables (12+ months lifespan).
Technical Support:
Thermal simulation for optimized layout.
Modular construction reduced downtime by 30%
Results：
| Metric | Before | After |
| Rotary Kiln Lifespan | 8 months | 14 months |
| Annual Downtime | 200 hours | 80 hours |
| Grate Cooler Cycle | 6 months | 12 months |
| Energy Consumption | Baseline | ↓3.2% |
Client Feedback：
“The solution significantly reduced maintenance costs, especially in combating sulfur/alkali buildup.” – Client’s Technical Director
