Yongyi Refractory × Huaning Yuzhu: Overcoming Complex Erosion to Empower Long-Cycle, Low-Consumption Operation for a Southwest Cement Pearl
Client: Huaning Yuzhu Cement
Industry: Cement Manufacturing (Dry Process Cement Clinker Production Line)
Services Provided: Supply of Thermal Shock/Erosion-Resistant Specialty Refractories and High-Standard Full-Kiln Construction Services
Project Background: As a crucial supplier of high-quality cement in Southwest China, Huaning Yuzhu Cement is committed to achieving green and highly efficient production through continuous technological upgrades. With rising industry environmental standards and increasingly complex raw material and fuel structures (such as the use of low-calorific-value coal and alternative fuels), chemical erosion inside the rotary kiln has intensified. This led to accelerated wear of the original refractory lining and shortened kiln operational cycles. To break through this production bottleneck and achieve longer, safer campaign lives, Huaning Yuzhu brought in Yongyi as their comprehensive refractory solution provider for their core kiln overhaul project.
Project Challenges: The combustion of complex raw materials and fuels generates large volumes of harmful gases rich in alkalis, chlorine, and sulfur. These gases continuously circulate and enrich in the preheater, calciner, and the transition zone of the rotary kiln. They easily penetrate the interior of the refractories, triggering chemical reactions that cause severe “alkali cracking” and structural spalling. Simultaneously, the burning zone faces more intense thermal shock fluctuations and liquid-phase scouring. The client required specialty refractories capable of robustly resisting complex chemical attacks, coupled with precision masonry to eliminate any risk of corrosive gases penetrating through the brick joints.
Yongyi’s Solution:
Premium Product Supply (Customized Anti-Erosion and Structural Reinforcement): Yongyi’s technical experts conducted an in-depth analysis of the alkali-sulfur-chlorine erosion mechanisms within the Huaning Yuzhu kiln to develop a targeted anti-erosion strategy. For the most severely damaged upper and lower transition zones, we utilized premium Silica-Mullite bricks (incorporating Silicon Carbide composite materials). These bricks feature extremely low porosity and excellent thermal shock resistance, forming a dense protective layer on the surface that effectively blocks the penetration pathways of alkaline gases. For the burning zone, we deployed the new-generation magnesia-iron-alumina spinel bricks, which facilitate rapid coating formation and resist high-temperature melt scouring. Furthermore, for the preheater system, we comprehensively upgraded to high-strength, alkali-resistant, and anti-explosive castables, ensuring volume stability under complex working conditions.
Professional Construction Services (Micro-Joint Masonry and Stress Release Management): Yongyi dispatched an elite construction team experienced in handling complex furnace conditions. During the masonry of the rotary kiln shell, we strictly implemented a “micro-joint masonry” process. Using high-purity customized fire mud, we controlled the brick joints to extreme millimeter-level tolerances, physically sealing off penetration channels for harmful gases. Simultaneously, based on the thermal expansion coefficients of materials in different temperature zones, our construction experts precisely reserved and filled expansion joints with high-quality materials. This perfectly released internal stress during high-temperature operation, avoiding the risk of bricks being squeezed out.
Customer Value & Results: Following the application of Yongyi’s specialty refractories and high-standard construction, the Huaning Yuzhu cement production line successfully re-ignited and resumed production. After a long period of operational testing, the rotary kiln has demonstrated exceptional adaptability to complex raw material and fuel conditions. The anti-erosion and anti-spalling performance of the refractories in the transition and burning zones has significantly improved. The surface temperature of the kiln shell has noticeably decreased and remains uniform, leading to a substantial reduction in heat loss. This collaboration has not only drastically extended the continuous campaign life of the Huaning Yuzhu cement kiln but also provided a solid backbone for the client in achieving energy savings and handling complex operational conditions.
