Client: A large metallurgical enterprise’s lime production line
Goals: Extend lining lifespan, reduce shutdowns from blockages, lower surface temperature
Key Challenges
Burning zone at 1450°C + sulfur corrosion from coke oven gas → refractory lifespan only 9 months;
Preheater blockages (3 tons/day) causing 15+ days annual downtime;
Kiln shell surface temperature reached 210°C (high energy loss & safety risks)
Solutions
Customized Materials:
Burning Zone: Magnesia-alumina spinel bricks (↑30% thermal shock resistance & sulfur resistance);
Preheater: SiC-enhanced castables (↓80% blockage rate);
Kiln Head Seal: Nano-porous lightweight castables + metal anchors (air leakage <8%);
Cooler: Cr₂O₃-alumina castables (↑2x wear resistance).
Smart Services:
Wireless kiln lining thickness/temperature monitoring (±3% accuracy);
Hot repair materials (20-minute rapid application)
Results
| Metric | Before | After | Value |
| Burning Zone Lifespan | 9 months | 16 months | Annual savings: ¥2.8M |
| Preheater Blockages | 3 tons/day | 0.5 tons/day | +11,000 tons annual output |
| Surface Temperature | 210°C | 135°C | Annual energy savings: ¥0.9M |
| Refractory Cost/ton | ¥12.5 | ¥9.8 | ↓21.6% cost/ton |
Client Feedback
“The solution doubled refractory lifespan and shifted us from ‘reactive repairs’ to ‘predictive maintenance’.” – Client Production Director
