Lime Industry

maf-anov-the-lime-industryThe Magnesite factory offers complete refractory lining in lime kilns, in a product range which includes: magnesia-spinel, aluminosilicate, fireclay, insulation, concrete, structural mass and mortar. A detailed proposal covers all types of fittings required to manufacture the most complex elements of refractory kilns. Articles may be further impregnated by vacuum pressure.

 The Magnetise factory implements full designs for lime kiln linings, especially Maerz kilns with standard pillars, pillars of concrete blocks and without pillars with hanging wall.

On request, the Magnesite factory ensure the supervision of buildings and installation of the products supplied. Using specialised software, the Company performs thermal calculations and calculations of the temperature distribution in the machine, constant monitoring of the built-in products and a detailed analysis at the end of their service life.

This allows for continuous improvement and optimisation of refractory linings. The products offered are environmentally friendly because after being subjected to a special process they can be re-used or disposed of.

Awards

We have developed and implemented an innovative construction-material solution for arches between pillars designed for use in Maerz and Gopex kiln type units. It is made from high-quality magnesia-spinel with specially selected grain size and distribution, characterised by high mechanical strength, resistance to abrasion and chemical corrosion.

A novel idea, based on the implementation of a self-locking buckle in the shape of a parabola, allows an improvement in the stability of masonry arches, and thus an extension of the life of the kiln.

The specific and unique design of different shapes (ROP-KSO, ROP-KS1, ROP-KSS, ROP-KSL) enables fast and seamless replacement, as well as use in a variety of layouts for different diameters of kilns. The construction-material solution in the arches of Maerz and Gopex shaft kilns has been awarded:

• Gold Medal at the VIII International Exhibition Industrial Property „Archimedes – 2005” in Moscow.

• Silver Medal at the 53rd World Exhibition of Innovation, Research and New Technologies Brussels – Eureka 2004;

• European Medal for Products – edition 2004;

Special shaped arches

maf-anov-special-shaped-arches

Selected shapes

maf-anov-lime-industry
On request, we are able to manufacture other fittings shapes

Maerz Kiln

A- Heating Zonemaf-anov-maerz-Kiln

B – Firing Zone

C – Wall of the inner cylinder

D – Arches and resistance

E – Standard pillars

E1 – Concrete pillars

F – Cooling Zone

Maerz Kiln – without pillars

The pillar-less Maerz kiln solution is a new design of the liner of the cylindrical wall, it is a self-supporting construction and does not require the construction of pillars.

Thanks to this:

  • it does not create a calcium dust buildup, which facilitates the flow of exhaust gas and consequently does not require duct cleaning and installation of additional equipment.
  • lower cost of kiln linings reduced by the value of the materials needed to manufacture the pillars and inter-pillar arches,
  • reduced energy demand and easier circulation of gas between the shafts.

The new design of reinforced, variable-sized elements of the Maerz Kilnmaf-anov-maerz-kiln-without-pillars monolithic pillar was awarded the Gold Medal at the International Trade Fair for Technological Innovation „Brussels Eureka” In 2011.

A- Firing Zone

B – Hanging Wall

C – The base of the cylindrical wall

Rotary lime kiln

A- Batch Zonemaf-anov-rotary-lime-kiln

B – Heating Zone

C – Firing Zone

D – Cooling Zone

Shaft kiln with burner beams

A – Heating Zone

B – Firing Zone

C – Burner Zone

D – Cooling Zone

maf-anov-shar-kiln-with-burner

Shaft lime kiln

A- Heating Zone

B- Firing Zone

C – Cooling Zone

maf-anov-shaft-lime-kiln

High temperature shaft lime kiln

A – Heating Zone

B – Firing Zone

C – Cooling Zone

maf-anov-high-temp-shat

The lime industry

Qualities GS Chemical analysis [%] SL
mm Al2O3 SiO2 Fe2O3 CaO MgO
Basic refractories Bondmix RG 0-0,1 0,3 0,6 7,6 2,8 87,5 6
Bondmix ZM1S 0-0,1 1 4,8 7,4 2,9 82,3 6
Non-basic refractories Bondmix ZAS 0-1 40 2,7 6
Bondmix ZAL 0-1 47 1,4 6
Bondmix ZAN 0-0,5 60 1,2 6

GS- Grain size
SL – Storage Life

The above given data are typical and may not be treated as conditions of acceptance

We are able to offer an individual choice of refractory materials in consultation with the client.

Our company operates an integrated quality management system in accordance with EN ISO 9001, an environmental management system in accordance with ISO 14001 as well as an industrial safety management system in accordance with PN-N-1800. This integrated system is applied in the areas of design, manufacture and supply of refractory materials.

Qualities Chemical analysis [%] BD AP CCS RUL T 0,5 TE [%] TC [%] Mortars
Al2O3 MgO SiO2 Fe2O3 CaO g/cm3 % MPa °C 300°C 1400°C 700°C 1400°C
Basic refractories Permal A 11,3 87 0,3 0,50 0,9 2,90 17 70 >1700 0,21 1,68 3,40 2,60 Bondmix RG , Bondmix ZM1S
Permal SF5 NSM 5,1 90,9 1,0 1,70 0,5 3,00 13 110 >1680 0,23 1,54 3,86 2,80 Bondmix RG , Bondmix ZM1S
Permal 3 NSM 4,1 91,0 1,3 1,70 0,6 2,92 15 70 >1680 0,27 1,80 3,80 2,60 Bondmix RG , Bondmix ZM1S
Permal 5E 5,5 92,4 0,3 0,50 0,9 2,91 16,5 75 >1700 0,24 1,68 3,58 2,60 Bondmix RG , Bondmix ZM1S
Permal 5E NSM 5,5 92,4 0,3 0,50 0,9 3,00 11 110 >1700 0,24 1,68 3,70 2,70 Bondmix RG , Bondmix ZM1S
Permal 2H NSM 2,4 95,5 0,2 0,50 0,8 3,00 10 110 >1700 0,24 1,68 3,80 1,68 Bondmix RG , Bondmix ZM1S
Permal 5H 5,0 93,2 0,2 0,50 0,8 2,96 15,2 60 >1700 0,25 1,69 3,59 2,70 Bondmix RG , Bondmix ZM1S
Permal 5H NSM 5,0 93,2 0,2 0,50 0,8 3,00 10 110 >1700 0,24 1,68 3,80 2,70 Bondmix RG , Bondmix ZM1S
Permal 2E 2,4 95,5 0,3 0,50 0,9 2,91 16,5 75 >1700 0,24 1,68 3,58 2,80 Bondmix RG , Bondmix ZM1S
Non-basic refractories Almid AL44 44,0 1,80 2,21 18 40 1400 0,40 0,80 1,30 1,40 Bondmix ZAS , Bondmix ZAL
Topan MFF-A60 60,0 37,0 1,00 2,52 16 75 1580 0,30 0,80 1,60 1,50 Bondmix ZAL , Bondmix ZAN
Topan MFF-A60L 60,0 38,5 1,20 2,50 16 60 1570 0,30 0,80 1,60 1,40 Bondmix ZAL , Bondmix ZAN
Topan MFF-A602L 62,0 34,5 1,10 2,48 18 60 1550 0,80 1,50 1,65 Bondmix ZAL , Bondmix ZAN
Topan MFF-A65L 62,0 36,0 1,00 2,52 16 65 1610 0,30 0,80 1,40 1,30 Bondmix ZAL , Bondmix ZAN
Topan MFF-A65 63,5 34,5 0,90 2,54 15 80 1650 0,30 0,80 1,40 1,20 Bondmix ZAL , Bondmix ZAN
Topan MFF – A652L 64,0 32,0 0,94 2,50 16 65 1600 0,70 1,30 1,20 Bondmix ZAL , Bondmix ZAN
Runcast BSNK1 54,0 42,0 0,70 1,9 2,45 12 80 1400 0,15 1,30 1,30
Runcast BSNK2 51,5 43,5 0,90 1,5 2,35 14 100 1320 0,15 1,30 1,30
Runcast BALM/ASM 68,0 Na2O+K2O
0,4
27,0 0,50 2,5 22 2,65 80 1420 0,30 0,90 1,30 1,30
Runcast BKW 97,0 0,8 0,1 0,10 1,5 3,1 14 90 1680 0,35 1,20 1,30 1,30

NSM – Impregnated with salts
BD – Bulk Density
AP – Apparent porosity
CCS – Cold Crushing Strength
RULL T0.5 – Refractoriness under load
TE – Thermal expansion
TC – Thermal conductibity

The above given data are typical and may not be treated as conditions of acceptance

 

Equipment Furnace zone Quality name
Maerz Kiln A Topan MFF-A652L
Topan MFF-A602L
Topan MFFA60
Topan MFF A65
Topan MFF 60L
Topan MFF A65L
Almid AL44
B Permal SF5 NSM
Permal 3 NSM
C Permal 2E
Permal 5E
Permal 5E NSM
D Permal 5E
Permal 5E NSM
Permal 2H NSM
Permal 5H
E Permal SF5NSM
Permal 3NSM
E1 Runcast BSNK1
Runcast BSNK2
F Almid Al44
Topan MFF A60L
Topan MFF A602L
G Runcast BKW
Runcast BALM/ASM

 

Rotary lime kiln A Almid Al 44
B Topan MFFA60
Topan MFFA65
C Permal 5E
Permal 5H
Permal A
D Runcast BKW
Equipment Furnace zone Quality name
Shaft lime kiln A Almid Al 44
Topan MFF A65
Topan MFF A60
B Permal 2E
Permal SF5NSM
Permal 5ENSM
C Almid AL44
High temperature shaft lime kiln A Almid Al 44
Topan MFF A65
Topan MFF A60
B Permal 2E
Permal SF5NSM
Permal 5ENSM
C Almid Al 44
Topan MFF A60
Shaft kiln with burner beams A Almid Al 44
Topan MFF A65
B Permal SF5NSM
Permal 2E
Permal 5ENSM
C Permal 5HNSM
Permal 2E
D Almid Al 44
Topan MFF A60