Three kinds of attack, all at once
A kiln runs round the clock at material temperatures up to about 1,450 °C in a counter-current process. The lining has to survive chemistry, heat and mechanics together while keeping the shell cool.
Chemical
- ●Alkali vapours: sodium and potassium from raw meal attack the brick.
- ●Sulphur and chlorine: SO₃ and chlorides from fuels infiltrate and spall.
- ●Alternative fuels: raise chlorine and heavy-metal load.
- ●Coating loss: exposes the hot face to direct flame.
Thermal
- ●Thermal shock: start-ups and stops change temperature quickly.
- ●Hot spots: flame impingement overheats the hot face.
- ●Cycling: repeated expansion and contraction fatigues the brick.
- ●Shell temperature: too much heat reaches tyres and drive.
Mechanical
- ●Abrasion: hot meal and clinker erode the hot face.
- ●Ovality: shell deformation crushes and spalls rings.
- ●Tyre loads: concentrated stress at the support sections.
- ●Lining thrust: axial forces push rings towards the outlet.
Which zone gives you the most trouble?
Choose cement or lime, then select any zone on the line to see the operating conditions, what wears the lining, and the Crown grades we specify there.
Kiln outlet & nose ring
The discharge end and nose ring, hit by hot clinker and cooler air.
- ●Thermal shock from secondary air
- ●Clinker abrasion
Start from the symptom
Pick what you see at shutdown or on the shell scanner. We show where it usually starts and how we would line it.
Alkalis and chlorides condense where gas cools, then penetrate open pores in the brick.
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Crown grades along the kiln line
Alumino-silicate bricks, alumina-SiC bricks, castables, insulation and anchors from our Wankaner works, with magnesia-spinel for the hot zones from our group company. One supplier, one quality standard, one point of contact.
| Grade | Type | Cement kiln | Lime kiln | Why it is used |
|---|---|---|---|---|
| CWN-40 | Fireclay brick | |||
| CWN-70.20 | High alumina brick | |||
| CWN-85.15 | High alumina brick | |||
| CWN-MUL-70 | Mullite brick |
Magnesia-spinel for the transition and burning zones
In the hottest part of the kiln we line with magnesia-spinel bricks made by RSR Refractories. Their spinel phase resists thermal shock, and the MgO chemistry holds a stable clinker coating.
Five steps from kiln data to installation
Before, during and after the campaign
Before the shutdown
- ✓Joint kiln audit with your team
- ✓Review of coating, shell temperatures and past campaigns
- ✓Zone-wise proposal with drawings
- ✓Brick and castable quantities, with contingency
During installation
- ✓Crown engineer on site on request
- ✓Checks on ring alignment, shell contact and jacking pressure
- ✓Help when drawings do not match the kiln as built
- ✓Final documentation and sign-off
After the campaign
- ✓Performance review zone by zone
- ✓Laboratory autopsy of used bricks
- ✓Recommendations for the next lining
- ✓Test reports and traceability for every batch
Most early failures start at ring closure
Good bricks fail when rings are over-jacked, keys are clustered or rings run out of square.
If it is on your drawing, we make it
Send your kiln drawing and we match every brick, arch, cone and special from inlet to outlet.
Planning a kiln shutdown?
Send us your kiln diameter, current lining, fuel mix and alternative-fuel rate. Our technical team will come back with a zone-wise lining proposal.
Alumina bricks, monolithics and speciality refractories, manufactured in Wankaner, Gujarat since 1979.
Crown Ceramics
8/A, National Highway, Near Hasanpar Railway Crossing, Wankaner, Dist. Rajkot, Gujarat 363622, India
+91 99746 66341
info@crownceramics.in