Yongyi Refractory × Qiaojia Baihetan: Forging Rock-Solid Kiln Linings to Safeguard the Construction of a World-Class Mega Dam
Client: Qiaojia Baihetan Cement
Industry: Cement Manufacturing (Specialty/Dam Cement Clinker Production Line)
Services Provided: Comprehensive Supply of High-Stability Refractory Materials and “Zero-Defect” Furnace Masonry Services
Project Background: Located in the heartland of a world-class mega-project—the Baihetan Hydropower Station—Qiaojia Baihetan Cement is a critical supplier for this core water conservancy hub and surrounding major infrastructure. The mass pouring of concrete for mega dams imposes extremely stringent requirements on the quality stability and continuous supply capacity of cement (especially medium-low heat Portland cement). To ensure a continuous, unwavering supply of high-quality clinker during peak construction periods, Qiaojia Baihetan Cement set a “zero-tolerance” standard for unplanned kiln shutdowns due to refractory failure. Ultimately, they chose Yongyi as their core refractory and construction service provider.
Project Challenges: Supplying a national mega-project means the rotary kiln must operate under high-load, continuous extreme conditions for extended periods. Any production halt caused by refractory spalling or a “red kiln” (shell overheating) would result in incalculable losses to the continuous concrete pouring downstream. Furthermore, the calcination of specialty dam cement requires an exceptionally stable thermal regime inside the kiln. This demands a refractory lining that not only possesses superior high-temperature and scour resistance but also exhibits outstanding coating-adherence properties and thermal insulation capabilities to maintain absolute temperature equilibrium within the furnace chamber.
Yongyi’s Solution:
Premium Product Supply (Ultimate Stability and High-Efficiency Thermal Insulation): To conquer the challenge of high-load continuous operation, Yongyi’s technical team equipped the core burning zone of the rotary kiln with top-purity magnesia-alumina spinel bricks. These products boast exceptional thermal shock stability and the ability to rapidly form a robust kiln coating, essentially equipping the furnace with an “iron shield.” In the transition zones and calciner areas, we innovatively introduced low-thermal-conductivity multi-layer composite high-alumina bricks and high-strength nano-insulation materials. While resisting intense material scouring, these materials maximize heat retention within the kiln, ensuring the uniform and constant temperatures required for calcining specialty clinker.
Professional Construction Services (“Zero-Defect” Standard and Panoramic Measurement Masonry): At the Baihetan project site, Yongyi dispatched our highest-grade master furnace masonry team to fully implement a “zero-defect” construction quality management system. Utilizing advanced laser rangefinders and total stations, we conducted high-precision 3D measurement and control of the kiln’s centerline and shell deformation. During masonry, we strictly enforced process disciplines such as “string-line alignment control and double-sided mortar fullness.” This ensured the perfect fit and even stress distribution of tens of thousands of refractory bricks, completely eliminating the risks of stress concentration and brick falling caused by construction tolerances.
Customer Value & Results: Partnering with Yongyi, Qiaojia Baihetan Cement’s rotary kiln system achieved a record-breaking, ultra-long cycle of continuous safe operation (Zero unplanned downtime) during the peak supply period for the hydropower station construction. The furnace lining demonstrated astonishing stability. The surface temperature of the kiln shell remained exceptionally low and uniform, which not only guaranteed the high-quality output of specialty dam cement clinker but also drastically reduced coal consumption per ton of clinker. Through outstanding products and services, Yongyi successfully empowered the client to fulfill their critical supply mission for a national mega-project.
