“Innovative Refractory Solutions for Lime Sludge Recovery Kilns to Achieve Sustainable Energy Savings“

ABSTRACT
Energy savings are of critical importance in lime sludge kilns, as this directly translates into reduced shell
temperatures on the rotary kiln, with the potential added benefits of reduced fuel consumption and
therefore reduced CO2 footprint. Historically, lime sludge rotary kilns have used dual layer linings as an
effective means to provide reduced heat transfer through the refractory lining resulting in lower kiln shell
temperatures.
However – the limitation has been that the insulating refractory component inherently does not possess
high strengths, thus making it susceptible to disintegration and premature failure under the mechanical
forces present in all rotary kilns.
This paper will review the chronological development of substantially improved refractory designs for dual
layer linings which provide significantly greater mechanical strengths and lining stability.
Additionally – the concurrent development of a reduced thermal conductivity refractory composition for
the working lining component has allowed the consideration of single-layer linings as replacement for dual
layer linings. With the tangible benefits of using a reduced thermal conductivity single-layer lining being
lower upfront material costs as well as faster installation time while eliminating the risk of degradation of
the insulation lining.
The initial development of a reduced thermal conductivity refractory brick was achieved on a MgO-Al2O3
Spinel composition, which is now being used successfully worldwide. Subsequent to that – an Andalusitebased
refractory composition with reduced thermal conductivity has been developed for use.
Both products are now being used in Lime Sludge Recovery Kilns and Pebble Lime kilns to achieve
reduced kiln shell temperatures and lower heat loss. 

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