The rapid growth of stainless fibre refractory reinforcement (SFRR) in the Cement, Lime and Bauxite industries owes as much to the unique benefits of Fibretech Melt Extract (ME) fibres as to the demand for lower refractory maintenance costs and improved kiln performance. Benefits which, in some applications, have seen refractory performance incrase by more than 100%.

Fibretech's range of fibres has also grown to cope with new kiln applications and demands. For example, the modern use of alternative which generate new kiln atmospheres charged in sulphur and other corrosive elements. Fibretech has developed new, tailor-made alloys to cope with these conditions offering the same lower operating costs and maximum refractory performance.

AZoM - metals, ceramics, polymers and composites : Areas in a cement, lime or bauxite furnace where stainless steel fibre reinforced refractories can be beneficial.

Figure 1. Areas in a cement, lime or bauxite furnace where stainless steel fibre reinforced refractories can be beneficial.
Preheaters and Cyclones

Erosion from dust particles, thermal shock and thermal cycling are all factors leading to the progressive wear of preheater linings. Steel fibres increase refractory toughness to improve performance and provide a long-term solution.

Recommendation: ME 304, ME 430
Riser Ducts

Riser duct refractory deteriorates due to clinker dust penetration and/or impact from high-pressure water or mechanical cleaning (to remove the build up of Sulphates). Steel fibre reinforcement lessens refractory damage and lengthens refractory lifetime, saving maintenance and costs.

Recommendation: ME 310, ME 446
Precalciner

Both calcined kiln feed and high temperature can cause hot face wear of the precalciner refractory. The addition of fibres helps to strengthen the matrix and resist these forces which would otherwise cause cracking and spalling, shortening the refractory's working life.

Recommendation: ME 446
Kiln Inlet Housing/Chamber

The kiln inlet by virtue of its shape, exposure to chemical attack from gases demands a high strength refractory. Fibre addition can improve refractory toughness. The selected steel fibre must be compatible with both temperature and atmosphere.

Recommendation: ME 310, ME 446 , Metalx
Nose Rings

Flexing and thermal shock place particular demands on nose ring refractory. Fibre reinforcement improves flexural strength and reduces cracking avoiding the need for frequent, costly repairs.

Recommendation: ME 310, Metalx
Kiln Outlet

The kiln outlet, positioned inside the kiln hood reaches 1200/1400°c and needs to have good thermal shock and cycling resistance. Fibres ensure the refractory can withstand such conditions, preventing the growth of macro-cracks and delaying failure.