Mathios Refractories S.A.

Refractory lining Turn-Key project for QualiCal Synthesis PFR lime kiln

BMSD, Algeria

Enduring High Temperature and Extreme Pressures

Lime kilns operate under severe internal conditions. The refractory lining protecting the steel shell must not only cope with extreme temperatures, high abrasion figures, thermal shocks and chemical attacks. It must also provide enough insulation to minimize the loss of heat and simultaneously maintain the shell at reasonable temperatures.

During the design process of the refractory lining of the Qualical Synthesis 120 Lime Kiln of SARL BMSD CHAUX in Algeria, we in MATHIOS REFRACTORIES SA had to keep in mind all of the above mentioned conditions, while simultaneously keeping the cost at reasonable levels.

IDEAL Fireclay bricks for each specific zone

The hot face in the preheating and cooling zones, where the conditions are not so arduous, consist of the fireclay bricks IDEAL M382 and IDEAL M310 respectively. In the lower levels of the calcining zone, the high quality magnesia-spinel bricks IDEAL 3 are used as the hot face lining, providing excellent thermal shock and erosion resistance. These are two qualities needed for bricks installed in these
positions. In the upper levels of the calcining zone, where we meet the “burning zone”, conditions reach their most extreme values one can come across in the lime production industry. In order to provide maximum protection to the customer’s investment, the top quality magnesia spinel refractory bricks IDEAL 5E with very low contents of iron oxides able to be operated in variable redox atmospheres, while simultaneously being resistant to high thermal loads as well as corrosion and erosion where selected.
When it comes to the arches, both the main and also the safety ones, and because of their critical role and loads they are expected to bear, no less than the use of the IDEAL 5E can be expected.

Environmental Responsibility

None of the above mentioned magnesite bricks contain chrome. Our company shares the vision of environmental sustainability and preservation and thus does not encourage nor practices the use of chrome containing magnesite bricks.
Behind the hot face, and depending on the exact level, two to four backing layers are present. Their thickness varies, in order to maintain a constant total refractory layer thickness of 515 mm. The first of the backing layers consists of the fireclay brick IDEAL M334, in a large area of the kiln, which acts as a protective layer against possible lime leakage, while also being able to withstand the kiln’s operating temperatures for a limited time in case of the hot face layer being removed. This last attribute gives more time to the user to plan better the kiln’s shut down for repairs.

Every little detail counts

When it comes to turn-key projects, everything has to be studied and planned taking into consideration every little detail and with regards to every single phase. Starting from the engineering and the production to procurement and installation, we in Mathios Refractories S.A., took advantage of our worldwide expertise and our highly experienced departments to successfully bring this project to completion.

Nikolas Mathios Dipl. Civil Engineer

Dimitrios Kotsovos Dipl. Mechanical Engineer