Cement Industry

maf-anov-cement-indChallenged by industry requirements, in the beginning of the eighties we were the first company to produce magnesiaspinel bricks, replacing the magnesia chrome bricks commonly used in the past.

Another important product line development from the nineties is our manufacturing technology for magnesia-spinel bricks with zirconia, the so called third generation refractories. These products were developed in cooperation with the Institute of Refractory Materials from Gliwice and the Committee of Scientific Research from Warsaw. Those materials perform very well in harsh clinker burning conditions when secondary fuels are used.

On our own initiative we investigated the resistance of our materials against the destructive influence of different clinkers from most foreign cement plants. Based on the results of those investigations, we have prepared custom designed solutions to our customers.

Thanks to our close cooperation with cement and lime plants, we introduced new solutions for kiln linings, which resulted in lower brick specific consumption and reduced installation time.

Supported by our Research, Design and Engineering teams, we were able to meet specific customer requirements throughout the years.

In our company functions the integrated system of quality management according to EN ISO 9001, environment management according 14001 and industrial safety according to PN-N-1800. This system is applied as far as preparing project, production and delivering of the offered refractory materials are concerned.

K-5 shapes: a lining concept for conical section of rotary kilns

K-5 shapes: a lining concept for conical section of rotary kilns.maf-anov-cement-indus

  • no gaps between shapes -no need to cut the first and last ring
  • faster and safer installation
  • longer lining life -no straight radial joints
  • no need to cut key bricks thanks to our special closing system

Product labeling and packaging

We understand that clear and visible marking is an important factor for refractory installation especially in a low luminosity environment. Besides the traditional groove we have applied clear marking identification of brand and shape, as well as a colour code to better identify the different shapes. As a result the installation ratio and the position of key bricks can be easily identified.

Packing is an important component of the final product as it protects the integrity of the refractories during transport and storage. We have developed two standards of packing depending on the type of transport used, transit time and storage time. Both standards include the necessary wood pallet quality, plastic foils, corner protection and adequate tightening of the bricks, creating a sturdy pallet adequate for transport, handling and storage in different conditions. The labelling of the pallets is also done on four faces, in order to make identification of Brand/Shape easier. A special code attached to each individual pallet accounts for its traceability according to EN ISO 9001:2008.

YELLOW B216 B218 B220 B222 B218L* B222L* 214 218 220 222 225 214L* 225L*
RED B318 B320 B322 B325 B318L* B325L* 314 318 320 322 325 330 314L* 330L*
BLACK B416 B418 B420 B422 B425 B416L* B425L* 418 420 422 425 430 418L* 430L*
PURPLE B518 B520 B522 B525 B518L* B525L*
WHITE B618 B620 B622 B625 B618L* B625L* 618 622 625 618L* 625L*
WHITE B722 B725 B722L* B725L* 722 725 722L* 725L*
GREEN Key Bricks KB22L KBL22L* 22B 22BL*
BLUE Key Bricks KB22S KB22S* 22A 22AL*

Arches for rotary kilns

Dimensions of π/3 shapes according to ISO 54017-1986
Shape Dimensions (mm) Volume Kiln Diameter
a b h i dm3 mm
218 103 84,0 180 198 3,33 1952
318 103 90,5 180 198 3,45 2966
418 103 93,5 180 198 3,50 3903
518 103 95,5 180 198 3,54 4944
618 103 97,0 180 198 3,56 6180
718 103 97,7 180 198 3,58 6996
220 103 82,0 200 198 3,66 1962
320 103 89,0 200 198 3,80 2943
420 103 92,5 200 198 3,87 3924
520 103 94,7 200 198 3,91 4964
620 103 96,2 200 198 3,94 6059
720 103 97,0 200 198 3,96 6867
820 103 97,8 200 198 3,98 7923
322 103 88,0 220 198 4,16 3021
422 103 91,5 220 198 4,24 3941
522 103 94,0 220 198 4,29 5036
622 103 95,5 220 198 4,32 6043
722 103 96,5 220 198 4,35 6972
822 103 97,3 220 198 4,36 7951
425 103 90,0 250 198 4,78 3962
525 103 92,7 250 198 4,84 5000
625 103 94,5 250 198 4,89 6059
725 103 95,5 250 198 4,91 6867
825 103 96,5 250 198 4,94 7923
Dimensions of VDZ shapes according to ISO 54017-1986
Shape Dimensions (mm) Volume Kiln Diameter
a b h i dm3 mm
B216 78,0 65,0 160 198 2,77 1920
B416 75,0 68,0 160 198 2,27 3429
B218 78,0 65,0 180 198 2,55 2160
B318 76,5 66,5 180 198 2,55 2754
B418 75,0 68,0 180 198 2,55 3857
B518 74,5 68,5 180 198 2,55 4470
B618 74,0 69,0 180 198 2,55 5328
B220 78,0 65,0 200 198 2,83 2400
B320 76,5 66,5 200 198 2,83 3060
B420 75,0 68,0 200 198 2,83 4286
B520 74,5 68,5 200 198 2,83 4967
B620 74,0 69,0 200 198 2,83 5920
B222 78,0 65,0 220 198 3,11 2640
B322 76,5 66,5 220 198 3,11 3366
B422 75,0 68,0 220 198 3,11 4714
B522 74,5 68,5 220 198 3,11 5463
B622 74,0 69,0 220 198 3,11 6512
B325 78,0 65,0 250 198 3,54 3000
B425 76,5 66,5 250 198 3,54 3825
B525 75,0 68,0 250 198 3,54 5357
B625 74,5 68,5 250 198 3,54 6208
B725 74,0 69,0 250 198 3,54 7400
B322L 76,5 66,5 250 300 4,72 2926
B622L 74,0 69,0 250 300 4,72 6072
B325L 78,0 65,0 250 300 5,36 2500
B625L 74,5 68,5 250 300 5,36 5708

Cement Rotary Kilns

Quality Chemical analysis [%] OP BD CCS RUL T0,5 TS TE [%] TC [W/mK ]
MgO Al2O3 SiO2 CaO Fe2O3 % g/cm3 MPa °C 950°C 300°C 1400°C 400°C 800°C 1200°C
Magnesia-spinel bricks
Permal AZ ZrO2+HfO2=2,7 82,7 12,0 0,30 0,80 0,50 16,5 2,94 65 >1700 100 0,21 1,74 3,90 3,30 2,80
Permal 12 84,1 11,8 1,20 0,50 1,70 19,0 2,85 60 1680 > 100 0,25 1,54 3,70 2,80 2,50
Permal SF12 85,1 11,2 1,00 0,60 1,50 18,0 2,90 65 1680 > 100 0,25 1,54 3,80 3,00 2,70
Permal A 87,0 11,3 0,30 0,90 0,50 17,0 2,90 70 >1700 > 100 0,21 1,68 1,68 3,30 2,80
Permal AP 86,0 11,3 0,55 1,15 0,75 16,0 2,92 70 >1700 100 0,21 1,68 1,68 3,30 2,80
Permal 7 87,3 8,00 1,30 0,50 2,00 19,0 2,85 70 1680 > 100 0,25 1,54 3,80 2,80 2,50
Permal ANG 87,5 11,0 0,20 0,80 0,50 15,5 2,98 62 >1700 > 100 0,20 1,68 4,00 3,40 2,90
Permal 11H 87,5 10,7 0,20 0,80 0,50 16,0 2,95 60 >1700 100 0,21 1,68 4,00 3,40 2,90
Permal HF 88,0 10,5 0,20 0,80 0,50 15,5 2,96 65 >1700 100 0,21 1,68 4,00 3,40 2,90
Permal SF7 88,5 7,70 1,00 0,70 1,40 18,5 2,86 75 1680 > 100 0,22 1,53 3,80 3,00 2,70
Permal 8E 89,0 8,50 0,30 0,90 0,50 17,0 2,91 60 >1700 > 100 0,21 1,68 4,00 3,30 2,80
Permal 8P 89,0 9,00 0,50 1,15 0,75 16,0 2,92 70 >1700 100 0,21 1,68 4,00 3,30 2,80
Permal 8NG 90,0 8,50 0,20 0,80 0,50 14,5 3,00 62 >1700 100 0,20 1,65 4,10 3,40 2,90
Permal 8H 90,5 8,50 0,20 0,80 0,50 15,5 2,95 70 >1700 > 100 0,21 1,68 4,10 3,40 2,90
Permal 5P 91,0 6,00 0,55 1,15 0,75 16,0 2,92 70 >1700 100 0,21 1,68 4,10 3,40 2,90
Permal 5E 92,4 5,50 0,30 0,90 0,50 16,5 2,91 75 >1700 > 100 0,21 1,68 4,10 3,30 2,90
Permal 5NG 93,0 5,50 0,20 0,80 0,50 15,0 2,98 65 >1700 100 0,20 1,68 4,10 3,30 2,80
Permal 5H 93,2 5,00 0,20 0,80 0,50 15,2 2,96 60 >1700 > 100 0,21 1,68 4,20 3,40 2,90

OP – Open porosity
BD – Bulk density
CCS – Cold crushing strength
RUL T0,5 – Refractoriness under load
TS – Thermal shock resistance
TE – Thermal expansion TC – Thermal conductivity

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

Quality Chemical analysis [%] OP BD CCS RUL T0,5 TS TE [%] TC [W/mK ]
MgO Al2O3 SiO2 CaO Fe2O3 Cr2O3 % g/cm3 MPa °C 950°C 300°C 1400°C 1200°C 400°C 800°C 1200°C
Magnesia – chrome bricks
Perkrom MC3 76,8 3,7 2,5 1,4 6,2 8,6 19 2,9 35 1580 80 0,50 1,00 1,50 4,90 3,70 3,00
Perkrom MC6 83,0 3,0 2,1 0,5 3,8 6,0 19 2,9 60 1680 80 0,50 1,00 1,60 5,10 3,70 3,00
High alumina bricks
Topan MFF-A65 63,5 34,5 0,9 15,0 2,54 80 1650 >30 0,16 0,42 0,67 1,80 1,44 1,43
Topan MFF-A60 60,0 37,0 1,0 16,0 2,52 75 1580 >30 0,13 0,39 0,64 1,70 1,34 1,33
Topan MFF-B85 0,3 85,0 8,50 1,4 TiO2 – 2,9 17,0 2,82 95 1500 >30 0,19 0,55 0,92 1,70 1,80 1,80
Topan MFF-B80 0,3 82,0 11,5 1,7 TiO2 – 3,2 20,5 2,75 70 1450 >25 0,19 0,55 0,92 1,70 1,80 1,80
Other bricks
1000°C 1000°C
Alsik CP 45,0 26,0 SiC – 25 1,0 C – 6,5 15,5 2,55 70 1550 95 0,20 0,40 0,60 4,70 3,60 3,30
Alsik CP17 49,7 32,7 SiC – 17 0,9 15,5 2,55 70 1550 95 0,20 0,40 0,60 3,80 2,90 2,70

OP – Open porosity
BD – Bulk density
CCS – Cold crushing strength
RUL T0,5 – Refractoriness under load
TS – Thermal shock resistance
TE – Thermal expansion TC – Thermal conductivity

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

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.

Quality Chemical analysis [%] OP BD TS GS
MgO Al2O3 SiO2 CaO Fe2O3 SiC % g/cm3 950°C >mm
Mixes and low-cement prefabricated castables
Runcast BWAC3M 64 7 1,3 0,6 25 19* 2,77* > 45 0 – 60
Runcast BWA1M 73,5 24,6 0,6 0,45 15* 2,77* > 45 0 – 60
Runcast BALM/ACM 49,5 17 1,5 0,4 30 13* 2,78* > 30 0 – 6,3
Magnesia mortars
Bondmix ZMX90 87,0 0,6 1,6 2,9 7,7 0 – 0,1
Bondmix ZM1S 82,3 1,0 4,8 2,9 7,4 0 – 0,1
Magnesia–chrome mortar
Bondmix ZMCK 72,0 3,5 5,8 1,0 8,2 Cr2O3 – 7,3 0 – 0,1
High-alumina mortar
Bondmix ZAK 58,0 34,3 1,0 Na2O+K2O – 2,3 0 – 0,1

* – Properties after firing at 1500°C
OP – Open porosity
BD – Bulk density
TS – Thermal shock resistance
GS – Grain size | Uziarnienie

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

Klin outlet Lower transition zone Central burning zone Upper transition zone Safety zone Calcinating zone Burner
A B C D E F G
Runcast BWAC3M Permal 5NG Permal 11H Permal 5NG Permal SF7 Topan MFF-A65 Runcast BWAC3M
Runcast BWA1M Permal 8NG Permal 8H Permal 8NG Permal 7 Topan MFF-A60 Runcast BWA1M
Runcast BALM/ACM Permal ANG Permal A Permal ANG Topan MFF-B85 Runcast BALM/ACM
Permal 5E Permal HF Permal 8E Permal 8H Topan MFF-B80
Permal AZ Permal 8H Permal AP Permal 5E Permal 5NG
Permal A Permal 5H Permal 8P Permal 8E
Alsic CP Permal AZ Permal SF12 Permal 8P
Alsick CP17 Permal 8E Permal SF7 Permal 5P
Permal 5E Permal 12 Permal SF7
Permal 8P Permal 7 Permal 7
Permal 5P
Permal SF7
Permal 7

 

Troubleshooters
Permal HF Tire area kilns with deformed shell
Permal 5NG Protects against build-ups and rings formation

There is a possibility to choose refractories individually, according to the settlements with the customer.