CEMENT INDUSTRY - Alfran

CEMENT INDUSTRY

www.alfran.com

INDEXWhat is Alfran?

What we can do

Philosophy

Cyclones, gas ducts, meal pipes

Calciner, riser ducts

Feed shelf / Smoke chamber

Cement rotary kiln

Burner pipe

Tail ring & Nose ring

Tertiary air duct

1

2

3

4

5

7

8

9

6

Kiln hood

Grate cooler

Planetary cooler

Wear resistant linings

Monolithic precast shapes

Demolition

Diagnosis and evaluation of linings

Anchors

Castables

Mortars10

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12

13

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18-19

20-21

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1Cement Industry

alfran® offers refractories, thermal insulation, passive fireproofing and heat treatment

products and services for the industry.

A company committed to continuous development in technology and innovation

in products and services.

Our goal is to achieve the maximum bene�t for our customers;reducing maintenance times, increasing productivity and providing turnkey service.

What is ?

2Cement Industry

What can we doalfran® is part of GRUPO ALDOMER and provides innovative and quality

solutions for the industrial needs.

alfran® provides its customers with integral engineering projects.

Design

We create more value through our innovation strategy, with ambitious targets and measurable results.

R&D+I

Through its technological know-how, alfran® offers solutions for high temperature.

Technology

· Refractory

· Fireproofing

· Thermal insulation

· Heat Treatment

Activities

· Engineering.

· Materials design.

· Lining design.

· Manufacture.

· Demolition.

· Anchor Welding.

· Installation.

· Dry Out.

· On-site Supervision.

· After Sale.

Services

3Cement Industry

MissionBe the reference partner for industrial high temperature.

VisionGrowth, leadership, taylor made products and services, global and continuous transformation creating opportunities for our employees.

ValuesHealth & Safety, improvement, team work, passion, environmental care, cultural diversity.

Philosophy

+550

Direct employees

+500

Guaranteed turnkey

projects

+2k

Recurring

clients

15%-35%

EBITDAin R&D&i

Cyclones, gas ducts, meal pipesThe efficiency of a cement plant, among other factors, will depend on the design of the cyclon system. To correctly define the most suitable refractory linings, we must take into account special conditions such as kinds of atmospheres, an alkaline environment and gas infiltrations in addition to the operational temperature.

alfran® supplies a wide range of materials according to the operating conditions, with high mechanical strength and excellent thermal shock behaviour. Can be applied by vibrocasting, pumpcrete, gunning, high gun or shotcrete-Alfranjet® system.

4Cement Industry

UPPER CYCLONES /GAS DUCTS

LOWER CYCLONES /GAS DUCTS

UPPER & LOWERMEAL PIPES

VIBROCASTING PUMPCRETE SHOTCRETE HIGH GUN GUNNING

TIX 40TIX 60TIX 35 SIC

TIX 60TIX 35 SICABR CLEAN+CLEAN 40 SUPER

TIX 40TIX 60TIX 35 SICCLEAN 40 SUPER

AJ 45 SICAJ 70 SICAJ ABR CLEAN+AJ CLEAN 40 SUPER

HG 70 SICHG ABR CLEAN+CLEAN 85 G

CAST 40CAST 60CAST 35 SIC

CAST 60CAST 35 SIC

AP 45AP 45 SIC

AP ABR CLEAN+AP CLEAN 40 SUPER

AJ 45AJ 45 SIC

HG 40HG 45 SIC

LITE LW 23LITE SLW 26

INSULATING LINING

SEVERE CONDITIONS STANDARD CONDITIONS

AP: Alfranpump AJ: Alfranjet DT: Drytech HG: Highgun

Cement Industry

Calciner, riser ductsIn these areas, the refractory material is exposed to severe thermal, mechanical and chemical conditions due to the high temperature process, especially in “gooseneck” area and burners. The main property of the refractory lining is high resistance to chemical attack.

alfran® recommends low porosity materials with high resistance to chemical attack, also good thermal stability. Available for installation by vibrocasting, pumpcrete, gunning, high gun or shotcrete-Alfranjet® system.

5Cement Industry

GOOSENECK

CALCINER RISERTIX 60TIX 35 SICABR CLEAN+DT CLEAN 55

AP 45AP 70 SICAP ABR CLEAN+AP CLEAN 40 SUPER

AJ 45AJ 70 SICAJ ABR CLEAN+AJ CLEAN 40 SUPER

HG 70 SICHG ABR CLEAN+CLEAN 85GDT CLEAN 40 HG


CAST 60CAST 35 SIC

TIX 60TIX 35 SICABR CLEAN+DT CLEAN 55

AP 45AP 70 SICAP ABR CLEAN+AP CLEAN 40 SUPER

AJ 45AJ 70 SICAJ ABR CLEAN+AJ CLEAN 40 SUPER


CAST 60CAST 35 SIC


INSULATING LINING



Feed shelf / Smoke chamberFeed shelf, feed tile and kiln inlet are critical areas exposed to infiltrations, chemical attack, abrasion, build-ups, etc. which are increased by cleaning with compressed air and pressurized water. To avoid these problems, concretes with special raw materials are needed to provide protection for the refractory lining and anchoring system.

alfran® recommends materials with zircon and silicon carbide content designed to minimize infiltrations and chemical attacks in aggressive alkaline atmospheres (CLEAN and DRYTECH ranges), minimizing builds-up and facilitating the cleaning of these areas. Can be applied by vibrocasting, pumpcrete, gunning, high gun or shotcrete-Alfranjet® system.

6Cement Industry

CAST 60CAST 35 SIC

INLET CHAMBER WALLS

TONGUE


TIX 35 SICCLEAN 40 SUPERABR CLEAN+DT 40 SIC

AJ 70 SICAJ ABR CLEAN+AJ CLEAN 40 SUPER

VIBROCASTING SHOTCRETE HIGH GUN GUNNING

INSULATING LINING


CAST 60CAST 35 SICRAMP & ARCH




CAST 60CAST 35 SIC


PUMPCRETE





AP 70 SICAP ABR CLEAN+AP CLEAN 40 SUPER



Cement rotary kilnIn this area, the highest process temperatures are reached with important physical and chemical transformation. Refractory linings consist of conformed pieces such as bricks with different qualities (basic and aluminious), depending on the zones.

alfran® has also developed a range of advanced technology concretes (ALFRAN MAG 85 HG, DRYTECH CLEAN 40 HG and ALFRANJET MAG 85) increasing brick lining life, through thickness recovery without anchors or demolition work. Can be applied by high gun system or shotcrete-Alfranjet® system.

7Cement IndustryCement Industry

DT CLEAN 40 HG

HIGH GUN

ROTARY KILN

MAG 85 HGROTARY KILN

DT: Drytech

SHOTCRETE

AJ MAG 85

AJ: Alfranjet

Cement Industry 8

Burner pipe

Burner pipe is a critical area with special needs that will depend on the design of the kiln, the fuel used and the raw materials for the process.

alfran® recommends products with high mechanical strength and high resistance to abrasion, designed to minimize chemical attacks due to the use of alternative fuels (CLEAN and DRYTECH ranges). Can be applied by vibrocasting system. DT 95

TIX 98CLEAN 25 BPDT 85 CR

VIBROCASTING

BURNER TIP

FLOW 85TIX 85

DT 85BURNER LANCE


DT: Drytech

Tail ring & Nose ring

Inlet cone is a critical area exposed to infiltration, abrasion, etc. which are increased by the use of alternatives fuels. Concretes with special raw materials are needed to avoid these problems.

The nose ring is also a very critical area that demands materials with high mechanical strength and high resistance to abrasion and thermal shock, as high temperatures.

alfran® recommends materials with high mechanical resistance to abrasion with the addition of silicon carbide and/or zirconium, as well as high resistance to thermal shock. These materials are applied by vibrocasting, pumpcrete, gunning, high gun or shotcrete-Alfranjet® system.

9Cement Industry

INLET CONETIX 35 SICCLEAN 40 SUPERABR CLEAN+DT 40 SIC


VIBROCASTING PUMPCRETE SHOTCRETE HIGH GUN

HG 70 SICHG ABR CLEAN+DT CLEAN 40 HG

NOSE RING

TIX 85CLEAN 40 SUPERDT 85DT 40 SIC



AP 70 SICAP ABR CLEAN+ AP CLEAN 40 SUPER

Tertiary air ductThe tertiary air duct connects the kiln hood with the calciner, transporting the hot air generated in the clinker cooler and recovering the air energy needed for the process. Some clinker particles are suspended and transported by the hot air stream. The main wear suffered by the refractory lining is due to abrasion, mainly generated in the connecting area with the kiln hood, valves and devices for airflow control. In cases where alternative fuels are used, these problems are increased by the effect of the alkaline atmosphere.

alfran® recommends using products with high resistance to abrasion for the most affected areas and resistance to chemical attack when alternative fuel is used. In less demanding areas, different qualities are recommended depending on the temperatures to which the material is exposed. Can be applied by vibrocasting, pumpcrete, gunning and high gun (in less demanding areas) or shotcrete-Alfranjet® system.

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TAD

TAD CONEXTION KILN HOODTIX 85DT 70 SICDT 40 SIC

AP DT 85AP 70 SICAP DT 70 SIC

AJ 70 SICAJ CLEAN 40 SUPERAJ DT 70 SIC

HG 70 SICDT CLEAN 40 HG CAST 35 SIC


TIX 60TIX 35 SICDT 60

AP 45 SICAP 70 SICAP 45 SICAP 70 SIC

AJ 45 SICAJ 70 SICAJ ABR CLEAN+

CAST 60CAST 35 SIC

HG 45 SICHG 70 SICHG ABR CLEAN+CLEAN 85G


INSULATING LINING



Tertiary air ductTertiary air duct

Cement Industry



Kiln hoodIn this area, the transition of the clinker from the rotary kiln to the cooler takes place. In some equipment configuration, the connection with the TAD is located in the kiln hood. Abrasion is the main wear factor in this area due to the particles in suspension, as well as chemical attack in the case of alternative fuels being used. According to the configuration of the installation, this area is sensitive to thermal shock at start-ups because of the injection of cold air hitting the refractory.

alfran® recommends castables with high resistance to abrasion and chemical attack in the case of alternative fuels being used (CLEAN range). Can be applied by vibrocasting, pumpcrete, gunning and high gun or shotcrete-Alfranjet® system.

11Cement Industry

KILN HOOD


TIX 85 TIX 35 SICDT 70DT 85

AP 70 SICAP DT 70AP DT 85 SICAP DT 85

AJ 70 SICAJ DT 70AJ DT 85 SIC

CAST 60CAST 85CAST 35 SIC

HG 70 SICCLEAN 85 GDT CLEAN 40 HG


INSULATING LINING

Cement Industry

Grate coolerIn this area the rapid cooling of the clinker occurs from its exit from the kiln. In grate coolers, the cooling air passes perpendicularly through the clinker bed. Main requirements are thermal shock and severe abrasion, especially in the critical areas of the discharge walls, wear benches and “bull nose”.

alfran® recommends high quality raw materials with high mechanical resistance, thermal shock and alkalis attack resistance. Can be applied by vibrocasting, pumpcrete, gunning and high gun (in less demanding areas) or shotcrete-Alfranjet® system.

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BULL NOSE

COOL SECTION-WALLSAND ROOF

TIX 85DT 70DT 70 SICDT 85

TIX 85DT 70DT 70 SICDT 85

TIX 40TIX 60TIX 35 SICDT 70 SIC

TIX 40TIX 60DT 60

AP 45AP DT 70

AJ 45AJ DT 70





AJ 45 SICAJ DT 70 SIC




HG 40 CAST 60

CAST 85

CAST 85


INSULATING LINING LITE LW 23LITE SLW 26

HOT SECTION-WALLSAND ROOF

TIX 85DT 70DT 70 SICDT 40 SIC

HOT SECTION-LOWER WALLS

COOL SECTION-LOWER WALLS



AP 45 SICAP DT 70 SIC

Cement Industry

alfran® recommends materials with thermal shock and abrasion resistance.

To minimize the problems associated with start-ups and thermal shock, the range of DRYTECH materials was developed, which can be applied by vibrocasting, pumpcrete, gunning and high gun (in less demanding or areas) shotcrete-Alfranjet® system.

Planetary coolerThis area is especially sensitive to start-ups due to high temperature variations that prevent the lining from a propertly drying, mainly when the refractory concrete is new (first drying). Main requirements are thermal shock and severe abrasion, especially in the satellite’s elbows.

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SATELLITE INLET

SATELLITE DUCTS


TIX 35 SICCLEAN 40 SUPERDT 40 SICABR CLEAN+

VIBROCASTING SHOTCRETE HIGH GUN GUNNING

INSULATING LINING

SATELLITE ELBOW

AJ 70 SICAJ CLEAN 40 SUPERAJ DT 85 SIC

HG 70 SICDT CLEAN 40 HG

TIX 35 SICCLEAN 40 SUPERDT 40 SICABR CLEAN+

PUMPCRETE

AJ 70 SICAJ CLEAN 40 SUPER AJ DT 85 SIC

HG 70 SICDT CLEAN 40 HG

CAST 60TIX 40TIX 60DT 60

AJ 45 SICAJ 70 SICAJ DT 70

HG 40HG 45 SICHG 70 SIC

AP 70 SICAP CLEAN 40 SUPER AP DT 85 SIC

AP 70 SICAP CLEAN 40 SUPER AP DT 85 SIC

Wear resistant liningsIn the process of raw meal, coal, clinker or cement, TDZ is used in the following equipments: vertical mills, dedusting cyclones, dedusting ducts and dedusting pipes, and others such as separators, bends, valves, conveyors, filters, etc.

TDZ is a range of hydraulic concretes with excellent wear-resistant characteristics and high mechanical strength at lower temperatures.

These products are designed to be applied by vibrocasting, gunning or plastering system and should be installed on a standard expanded metal mesh, welded to the steel casing. also it is possible to install with metallic fiber.

14Cement IndustryCement Industry

TDZ HS TDZ HSWEAR RESISTANT LINING TDZ V

VIBROCASTING GUNNING TROWELLING

Monolithic precast shapesalfran® designs, manufactures and installs monolithic precast shapes in all grades of castables from our wide range of products, supplied ready to use with controlled drying heat treatment.

We have a unique technology for mass production of these vibrocasted forms which allows us to adapt delivery times to meet the needs of our customers.

Each case is analyzed individually according to the operating and performance conditions. The most widely used pieces have been designed for: cooler walls, blower muffles, ducts, nose ring, TAD clampers, etc.

alfran® has designed shaped products made in metallic-ceramic material with a mixed bonding system designed for high mechanical and thermal performance (STEEL-TECH) ready for installation and startup without dry-out.

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Nose RingCalcinerdesigned for: cooler walls, blower muffles, ducts, nose ring, TAD clampers, etc.

alfranalfranin metallic-ceramic material with a mixed bonding system designed for high mechanical and thermal performance (STEEL-TECH) ready for instalation and startup without dry-out.

Cement Industry

Demolitionalfran® has qualified personnel and high-tech machinery, managed by remote control, for its demolition work in any type of industry, particularly in the cement industry. With this service, we minimize the risks of accidents and provide our clients with shorter execution times than with conventional methods.

This work can be carried out both inside and outside the equipment such as cyclones, smoke chambers, inlet cone, rotary kiln, kiln hood, cooler, etc.

16Cement Industry

Cement Industry 17

Diagnosis and evaluation of liningsOur technical department has the equipment and personnel, specifically trained for diagnosis by thermography in different areas of the clinker production line (preheater, TAD, kiln and cooler).

This analysis is essential for planning preventive maintenance and repair work, without any need to stop the furnace, as it makes it possible to estimate the wear produced on the refractory lining as well as detect defects or anomalies during the operation of the equipment. In addition, it enables a record on the installation to be kept with a view to detecting areas of improvement on the lining.

Cement Industry

Anchorsalfran® has a professional team who can give advice on the most effective anchors according to the area and operational conditions and has a wide range depending on the requirements of our customers:

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Ceramic Anchors CLEANFIXMetallic Anchors

· V,Y (simple and dynamic system),metal mesh, hex metal, single-cell.

· System for Brick Lining.

· Different qualities (AISI 304, 309,310, 314, 316, INCONEL, 253 MA,etc.)

· Anchor system for high temperature. New technological developments with combinations of special ceramic and traditional metallic anchors in order to withstand or minimize attacks on metallic anchor systems in the presence of corrosive atmospheres, resulting from the intensive use of alternative fuels.

Cement Industry 19

alfran® recommends, designs and markets the following support systems, acording to the application area for the cement industry.

Anchors

Cement Industry

LITE LW 23 1300 1,1 3,0 32,0 36,8 18,5 - -

LITE SLW 26 1400 1,5 8,2 38,7 40,0 11,2 - -

CAST 40 1200 1,89 20,0 40,1 45,3 7,3 - -

CAST 60 1500 2,06 10,0 58,9 27,0 8,2 - -

CAST 85 1700 2,73 25,0 81,3 4,6 3,5 - -

CAST 35 SIC 1300 1,98 25,0 40,0 41,0 5,7 10,0 -

TDZ HS 800 2,47 35,0 60,7 10,4 13,7 - 9,6

TIX 40 1400 2,14 50,0 42,8 50,2 2,3 - -

TIX 60 1500 2,25 105,0 56,2 36,7 2,1 - -

TIX 85 1700 2,78 100,0 81,7 11,3 1,8 - -

TIX 98 1800 2,98 115,0 89,7 7,7 2,2 - -

TIX 35 SIC 1450 2,21 50,0 35,1 42,5 1,5 17,6 -

ABR CLEAN+ 1600 2,48 100,0 41,1 35,1 2,0 5,0 14,3

CLEAN 25 BP 1650 2,61 70,0 60,4 12,3 1,5 23,9 1,0 (CR2O3)

CLEAN 40 SUPER 1500 2,55 110,0 32,2 25,9 2,0 38,2 -

DRYTECH 60 1450 2,24 65,0 48,9 46,9 - - -

DRYTECH 70 1650 2,37 70,0 58,7 37,8 - - -

DRYTECH 85 1800 2,74 95,0 82,0 11,3 - - -

DRYTECH 95 1800 2,94 75,0 94,5 4,9 - - -

DRYTECH 35 SIC 1500 2,26 80,0 34,6 40,6 - 21,6 -

DRYTECH 40 SIC 1500 2,43 100,0 34,4 25,6 - 38,0 -

DRYTECH 70 SIC 1500 2,38 65,0 55,7 27,0 - 14,8 -

DRYTECH 85 CR 1700 2,72 65,0 78,0 10,8 - - 5,0 (CR2O3)

DRYTECH CLEAN 55 1600 2,43 70,0 47,0 40,2 - 5,0 4,5

ALFRAN TDZ V 800 2,40 80,0 60,7 10,4 13,7 - 9,6

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CastablesInsulating Castables, Multipurpose

Dense Castables, Multipurpose

Dense Castables, Vibrocasting

Cement Industry 21

Dense Castables, High gun

Dense Castables, Pumpcrete

CastablesHIGH GUN 40 1300 1,91 25,0 38,5 51,9 4,9 - -

HIGH GUN 45 SIC 1400 1,80 15 (800ºC) 37,4 48,5 5,8 3,8 -

HIGH GUN 70 SIC 1400 2,09 30,0 61,8 22,3 6,1 4,4 -

HIGH GUN ABR CLEAN+ 1600 2,16 60,0 51,3 27,9 6,0 4,5 6,0

CLEAN 85 G 1600 2,37 20,0 78,8 9,1 3,2 4,2 -

DRYTECH CLEAN 40 HG 1600 2,08 50,0 40,1 30,8 1,6 24,5 -

MAG 85 HG 1500 2,65 50 (1100ºC) 5,0 5,0 2,0 - 85,0 (MgO)

DRYTECH 70 G 1650 2,28 45,0 68,0 27,9 - - -

ALFRANPUMP 45 1400 2,05 70,0 39,7 54,4 2,3 - -

ALFRANPUMP 45 SIC 1400 2,15 70,0 37,5 52,2 2,0 4,2 -

ALFRANPUMP 70 SIC 1600 2,55 120,0 65,1 23,1 2,6 4,8 -

ALFRANPUMP CLEAN 40 SUPER 1600 2,5 95,0 32,9 25,8 2,3 38,2 -

ALFRANPUMP ABR CLEAN+ 1600 2,5 100,0 53,0 28,9 2,4 4,9 7,2

ALFRANPUMP DT 70 1650 2,45 65,0 67,9 28,1 - - -

ALFRANPUMP DT 70 SIC 1600 2,45 80,0 55,1 27,0 - 14,7 -

ALFRANPUMP DT 85 1650 2,85 90,0 81,3 13,3 - - -

ALFRANPUMP DT 85 SIC 1600 2,81 80,0 72,9 12,67 - 9,8 -

Dense Castables, Alfranjet

ALFRANJET 45 1400 2,08 85,0 39,1 54,7 2,0 - -

ALFRANJET 45 SIC 1500 2,10 110,0 37,5 52,2 2,0 4,2 -

ALFRANJET 70 SIC 1600 2,50 120,0 64,2 24,6 2,3 4,5 -

ALFRANJET CLEAN 40 SUPER 1500 2,5 95,0 32,9 25,8 2,3 38,2 -

ALFRANJET ABR CLEAN + 1600 2,52 110,0 53,0 29,0 2,2 4,9 7,2

ALFRANJET DRYTECH 70 1650 2,47 85,0 68,0 27,9 - - -

ALFRANJET DRYTECH 70 SIC 1600 2,50 100,0 55,0 27,0 - 14,8 -

Cement Industry 22

Mortars

The properties shown on this data sheet represent typical average results generated using standard ISO

test methods (unless otherwise noted) conducted under controlled condition and should not be considered

to be guaranteed specifications. Properties are subject to normal manufacturing statistical standard

deviation ranges, and Refractarios Alfran, S.A., reserves the right to modify the properties and specifications

at any time without prior notice. Refractarios Alfran, S.A. disclaims any express or implied warranties based

on this sheet.

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CastablesT

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KE

Y S

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UT

ION

SAM

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AS-E

UROP

E-M

IDDL

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ST-A

FRIC

A

Cement Industry

alfranpumpHigh speed installation with mirror finish

Low Cement castables with highresistance to corrosion fromalternative fuels

No Cement Castablesfor severe thermal shock resistance

Shotcrete Technologyfor very high speed installation

24Cement Industry

AGENTS / DISTRIBUTORS

ALFRAN MexicoDesarrollo Industrial MonterreyHernán Santos Cantú, # 228 STA.CATARINA C.P. 66350 NuevoLeón – MÉXICOTel & Fax. +52 (81) 14 77 73 [email protected]

ALFRAN-HTRM 41 plot number 69 First floor office N 24, MusaffahAbu Dhabi, United Arab EmiratesTel: +971 56 [email protected]

ALFRAN Headquarters Sevilla Pol. Ind. Hda Dolores. A-92. Km 6. 41500 Alcalá de Guadaíra. Sevilla. Spain.Tel. + 34 955 63 42 00Fax. +34 955 63 11 [email protected]

ALFRAN Saudi ArabiaBuilding 4263, Road 120 Second Industrial Area, Unit 3 JUBAIL-SAUDI ARABIATel. + 966 (0) 13 340 0484 Fax. + 966 (0) 13 340 0343 [email protected]

ALFRAN AlgecirasPol. Ind. Palmones IIC/ Crucero naves 17 y 1911379 Algeciras, SpainTel. +34 663 85 25 [email protected]

ALFRAN USA211 Highland Cross, Suite 210Houston, TX 77073Texas, USAPhone: [email protected]

ALFRAN AsturiasAS-2, nº 3240Pol. Ind. La Vega, Nave 6 33392 Porceyo – Gijón. Spain Tel. +34 985 31 21 51

+34 985 314 071Fax. +34 985 32 76 93 [email protected]

ALFRAN Andino Carrera 28, # 7a - 59Sogamoso, Boyacá, ColombiaTel. +57 [email protected]

ALFRAN AmurrioPol. Ind. Maskuribai, Nave B-13 01470 AmurrioAraba, SpainTel.+34 645 773 [email protected]

ALGET3, Rue Neuf BrisachAngle Bd Rahal El Meskini, 1er Etage20.120 CASABLANCA-MAROC Tel: +212 666 95 49 39 [email protected]

CEMENT INDUSTRY - Alfran

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