Project Background
A domestic steel plant in China adopted a rotary kiln direct reduction process to treat 1.2 million tons of blast furnace dust and converter sludge annually. The previous kiln lining material failed to adapt to the diverse working conditions along the kiln, resulting in frequent unplanned shutdowns (over 7 times/year), low metal recovery efficiency (<83%), and high maintenance costs.
Core Challenges
- Thermal spalling of lining material in high-temperature zones (>1200°C).
- Alkali corrosion and mechanical abrasion in medium- and low-temperature zones (400–900°C).
- Single-material lining could not meet the complex temperature gradient requirements of the entire kiln.
- Need to meet international environmental compliance (Cr-free emission).
JHY Ref Solution：
- Based on thermodynamic simulation and material flow analysis of the kiln, the rotary kiln was divided into: High-temperature reaction zone, Transition zone, Preheating zone.
- Different grades of phosphate-bonded high alumina bricks were applied to each zone to enhanced thermal shock and erosion resistance in the high-temp section
- Improved abrasion resistance and permeability control in mid- to low-temp zones
Optimized Product Performance
JHY Ref’s uniquely engineered phosphate-bonded high alumina bricks feature:High strength、Superior wear resistance、Excellent chemical corrosion resistance. Customized to match real on-site operating conditions, our solution fundamentally addressed the client’s operational bottlenecks.
Project Results
- Extended Service Life: Kiln lining lifespan increased from 6 months to 14 months
- Improved Uptime: Unplanned shutdowns reduced by 80%, additional 180,000 tons of dust processed per year
- Value Enhancement: Metal recovery rate increased to 89.2%, generating over 5 million RMB in extra annual revenue
Client Testimonial
“The phosphate-bonded high alumina bricks provided by JHY Ref adapted perfectly to the complexity of our rotary kiln recycling process. Their high-quality products enabled our equipment to achieve the first-ever full year of trouble-free operation.”
— Mr. Wei, Production Director
