3-fløjet GB 0406.

qxd 28/04/06 8:27 Side 3

HASLE REFRACTORIES A/S

Photograph with kind permission from Aalborg Portland

Unique low-cement castables and precast solutions

- specially developed for the cement industry

HASLE low-cement castables have been developed to obtain the best combination of strength
and resistance to chemical attack, thermal shock and abrasion.

www.hasle-refractories.com
3-fløjet GB 0406.qxd 28/04/06 8:27 Side 4

Refractory products for cement and lime kilns

Special materials for special problems

HASLE Refractories have been manufacturing refractory products for more

than 100 years, and since 1980 specialized in producing materials for cement
and lime kilns. Alkali resistant low-cement castables and a new generation of
shaped ”HASLE LCC Precast Linings” are developed to solve the limitations of
traditional linings.

The development continues with improved castables and new designs.

Troubleshooting

1. Coating/build-up in smoke chamber, riser duct and cyclones:

HASLE Precast Modular Lining made from our coating repellant castables

2. Buckling and corrosion of centre pipe (dip tube):

HASLE Ceramic Vortex Finder

3. Short refractory life of kiln outlet (nose ring), burner pipe,

kiln hood, grate cooler, planetary cooler elbows and outlets:
HASLE LCC products are highly resistant to abrasion, thermal shock,
impact and chemical attack.

4. Abrasion in T.A. Duct, take-off and damper:

The exceptional abrasion resistance of HASLE LCC products

5. High clinker temperature in planetary cooler outlets:

HASLE Precast Cooler Cam Lining

6. Poor heat exchange in long wet kilns:

HASLE Precast Tumbler Lining

Exceptional resistance to chemical attack

Two low-cement castables subjected to alkali test (DIN 51069, Page 2)

Left: Chemically resistant HASLE LCC castable D39A.
Right: Ordinary LCC castable.
3-fløjet GB 0406.qxd 28/04/06 8:27 Side 5

Troubleshooting in cyclones, riser duct and inlet (smoke) chamber

Coating/build-up: The increased usage of alternative fuels (petcoke, lignite, tyres etc.) often leads to more
coating/build-up inside the lower stage cyclones, riser duct or inlet chamber.

Precast modular lining system in HASLE alkali resistant LCC castables

• reduces/eliminates coating problems (build-up)

• reduces maintenance
• improves insulation
• increases cross-sectional area
of riser duct/feed pipe (with thinner lining)
• reduces installation time (downtime)

Thickness P39A BS1200 Calcium Heat flow

(total) silicate

180 mm 70 mm 60 mm 50 mm 1,294 W/m2

200 mm 70 mm 80 mm 50 mm 1,230 W/m2
230 mm 70 mm 110 mm 50 mm 1,144 W/m2
250 mm 70 mm 130 mm 50 mm 1,093 W/m2

NOTE:
Heat flow is calculated for vertical walls and unforced
air circulation.
Kiln temperature 1,000°C
Outside temperature 20°C
In order to achieve the longest possible life of the Refractories in the most
critical areas, HASLE recommends a precast modular lining. HASLE offers all
castables as precast solutions, and for many years type D39A has been the
most popular. As precast this castable is designated P39A today.
With more and more extensive use of alternative fuels and the subsequent cleaning with water, HASLE has
developed a new generation of castables with the newly developed D20SC. Both having unique resistance to
chemical attack and a very good resistance to thermal shock and abrasion which is important when water
spray is used.
All precast elements are manufactured under strictly controlled conditions in our factory, and after casting
and setting all elements are heated up to 1,050˚C in order to secure that all chemically bound water is remo-
ved so that the element achieves the best possible strength.
By choosing a HASLE precast solution, it is unnecessary to dry out the lining. The kiln can be heated up to
operation temperature right away, which along with the quick installation time will reduce the downtime
significantly - often by 50% or more. Time which instead will be spent in the production of klinker.
By choosing a HASLE precast solution the cross-sectional area can also be increased as the present solution is
thinner than a traditional cast solution, and by this more space will increase production capacity.

Precast Modular Lining Precast Conical and Cylindrical Lining Precast special tailored solution
For flat walls and roofs. Very fast installation.
No anchors required.
3-fløjet GB 0406.qxd 28/04/06 8:27 Side 6

Troubleshooting on kiln outlet (nose ring), burner pipe and grate cooler
Problem: Short refractory life: abrasion, thermal Solution: HASLE LCC castables: highly resistant to
shock, impact and chemical attack contribute to short abrasion, thermal shock, impact and chemical attack.
life of traditional refractory castables and high alumi-
na castables in these areas.

Nose ring - newly cast in sections. Burner pipe - preparation for casting.

A fully precast roof lining. Bull's nose – cast in D52A.

D20SC is a newly developed castable based on

D39A with 17% SiC. It has the same resistance to
chemical attack and build-up as D39A, but much
improved resistance to thermal shock and abra-
sion - advisable where water cleaning is used.
D52A: A tough castable. Exceptional resistance
to chemical attack and abrasion. Used on burner
pipe, nose ring, grate cooler roof, walls and bul-
l's nose, kiln outlets, elbows and precast cam
lining.
D59A: Very strong with exceptional resistance to
thermal shock. Used on burner pipe, nose ring,

Grate cooler

Precast modular roof elements hang from the steel

channels in the roof of the grate cooler. Insulating
castable is cast on top of the elements.
3-fløjet GB 0406.qxd 28/04/06 8:27 Side 1

Dense Low - Cement Castables Back-up Castables

HASLE HASLE HASLE HASLE HASLE HASLE HASLE HASLE HASLE HASLE HASLE
Chemical analysis: D20SC D39 A D52A D57SC D59A D60WC D66 D1700A D1600SC BS1200 BHI1200
AI2O3 % 32 39 50 52 62 56 66 58 26 42 37
TiO2 % 1.1 1.1 1.4 1.1 1.4 1.1 1.1 1.3 0.2 1.3 1.2
SiO2 % 47 56 45 27 33 23 29 35 18 46 37
Fe2O3 % 1.2 1,4 1,1 1.1 1.1 1.2 1.4 1.3 0.6 4 7
CaO % 1.6 1,6 1,6 1.4 1.4 1.6 1.6 2.6 2.2 6 14
SiC % 17 - - 17 - 17 - - 53 - -
Physical data:
Refratoriness PCE 33 33 34 35 36 35 35 36 35 10 10
Max. service temperature °C 1500 1500 1550 1600 1650 1500 1500 1700 1600 1200 1200
Bulk density kg/m3 2300 2200 2350 2550 2450 2558 2550 2500 2600 2000 850
Max grain size mm 10 10 10 10 10 5 5 5 6 10 3
Modulus of rupture
after heating to: .110°C MPa 15 16 16 15 18 15 15 15 15 7 2
.500°C MPa 15 16 18 18 18 20 20 15 15 4 1,5
1.000°C MPa 15 18 17 18 18 20 21 14 18 3 1
1.500°C MPa 15 16 20 18 20 20 22 20 20 - -
Cold crusing strength
after heating to: .110°C MPa 115 115 125 115 130 130 130 130 100 35 3.5
.500°C MPa 115 120 140 120 140 140 150 145 120 25 3
1.000°C MPa 115 130 155 125 155 150 170 130 120 25 2.5
1.500°C MPa 115 150 160 120 185 130 190 180 100 - -
Drying shrinkage: 110°C % 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.2 0.3
Linear shrinkage excl. drying
skrinkage after .500°C % 0.0 0 0 0,0 0 0,0 0 0 0 - 0
heating to: 1.000°C % 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.1 0.1 0 0.5
1.500°C % 0.2 0.2 0.2 0.2 -0.3 -0.3 -0.2 -0.3 -0.1 - -
Thermal conductivity: .400°C W/mK 2.3 1.16 1.28 2.7 1.4 2.7 1.42 1.38 5.8 0.6 0.23
800°C W/mK 2.5 1.28 1,4 2.9 1.51 2.9 1.54 1.49 6 0.7 0.26
1.200°C W/mK 2.7 1.51 1.57 3.1 1.63 3.1 1.65 1.6 6.2 0.8 0.28
Alkali test (scala 0-10 mm) 0 0 1 1 1 1 2 2 2 9 -
Resistance to abrasion g/cm 2
0.08 0.3 0.15 0.06 0.15 0.04 0.04 0.1 0.04 0.6 -
Resistance to thermal shock high good high extra high extra high extra high good extra high extra high low -
Reversible linear expansion:
1000°C % 0.45 0.45 0.5 0.5 0.5 0.5 0.55 0.55 0.55 0.5 -
Average water addition % 5.6 5.2 5.2 4.5 4.8 4.5 4.4 4.8 5.6 10 50

The HASLE low-cement castables - specially developed for the cement kilns
The HASLE low-cement castables have been develop- D59A: Very strong with exceptional resistance to ther-
ed to obtain the best combination of strength and mal shock. Used on burner pipe, nose ring, kiln out-
resistance to chemical attack, thermal shock and abra- lets, grate cooler roof, walls and bull's nose.
sion.
D60WC: Developed from D66 with 17% SiC. Much
All HASLE castables designated with the letter “A”
improved resistance to themal shock and chemical
have an exceptional resistance to chemical attack, and
attack.
thereby highly resistant to build-up (coating).
D1700A: As D59A but with extra high resistance to
D20SC: As D39A, but also very high resistance against
abrasion. Used on burner pipe, nose ring, kiln outlets.
thermal chock and abrasion.
D66: Exceptional resistance to abrasion. Used in terti-
D39A: The absolute best regarding resistance to che-
ary air duct, chain zone and other areas of high abra-
mical attack. Used in smoke chamber, riser duct, pre-
sion.
calciner and cyclones.
D1600SC: Contains 53% silicon carbide. Highly resis-
D52A: As D39A but even stronger. Extra high resistan-
tant to abrasion and thermal shock. Used in areas sub-
ce to abrasion. Used on burner pipe, grate cooler-
ject to extreme wear and thermal shock, or where
roof, walls and bull's nose, kiln outlet, elbows and
high thermal conductivity is desired.
precast cam lining.
D57SC: An exceptional castable. Based on D59A with
17% SiC. Exceptional resistance to thermal shock, che-
mical attack and abrasion. Used on nosering burner
pipe, grate cooler and elbows.
3-fløjet GB 0406.qxd 28/04/06 8:27 Side 2

Troubleshooting on vortex finder (centre pipe, dip tube) in lowest stage cyclone

Problem: Buckling and corrosion
In the lowest stage cyclones the effective lifetime of
steel centre pipes is often reduced due to high tem-
perature, buckling, and/or the aggressive effects of
sulphur and chlorine. Furthermore build-up on steel
centre pipes reduces efficiency and requires cleaning.
Solution: HASLE Precast Ceramic Vortex Finder
• cannot buckle or burn
• exceptional resistance to chemical attack
• exceptional resistance against coating (build-up)
• quick and easy installation

Troubleshooting in planetary coolers Troubleshooting in long wet kilns

Problem: Inefficient cooling of the clinker Problem: Poor heat exchange

Solution: HASLE Precast Cooler Cam Lining Solution: HASLE Precast Tumbler Lining
• no sliding - clinker rolls on clinker • improved quality due to better mixing
• cools clinker more rapidly • efficient heat transfer
• increases the temperature of the secondary air • no sliding - reduces abrasion
• greatly improves the life of the steel lifters • does not create dust
• (due to lower clinker temperature)

HASLE agent network - the HASLE solutions are widely HASLE Brochures - specific brochures are available for all
appreciated and sold all over the world, either directly or HASLE specialist products either from our headoffice or from
through our international agent network. Please refer to our agents.
our website www.hasle-refractories.com

Our Mission: It is the objective of HASLE Refractories A/S to HASLE REFRACTORIES A/S
develop, manufacture and globally supply refractory cast- Almindingsvej 76
ables, precast elements and special unique products based DK-3700 Roenne
on the best know-how and of the highest quality. In connec-
tion with the products, extensive technical advice is offered,
Phone: +45 56 95 18 00
and the characteristics of HASLE Refractories are: quality, Fax: +45 56 95 31 81
flexibility and quick reaction time. hasle@hasle-refractories.dk
www.hasle-refractories.com