Presentation of HASLE Refractories A/S Ceramic Diptube Case Story at a plant in Thailand

The plant has 3 kilns. and capacity is 7.5 million tons per year. Next year we will have kiln no.4, which has capacity 10,000 tons per day and the constructed was about 70 percent. So we will have total capacity over 10 million tons per year in that time. Kiln no.1Kiln no.2 Kiln no.3

Major saving energy has 2 types. 1. Electric energy We have 2 methods. - Improvement air and water in the system and measurement to reduce the unnecessary operation of the machine. - We have power plant. By using, waste heat from preheater and cooler. Today, we have 6 waste heat boilers and 3 turbines. We can make approximate MWH per day, enough for half of all process. 2. Heat energy. We have several of ways such as reduce fault air, using alternative fuel, reduce down time and machine modification for increase efficiency. Today we would like to show one method. That is the heat exchanger efficiency between the hot gas to the material. By separation the most materials from hot gas, in the lower cyclone before entering to higher cyclone. By using high performance dip tube.

If no the dip tube, the cyclone will be has a negative effect in the system. Due to there are more than normal of material, alkaline, sulfur and chloride circulation in the process long time. So, the heat exchanger is not good and the chemical reaction is error. Cause, the percentage free lime of clinker is higher. Must be either increase fuel or decrease feeding to achieve the quality of the clinker. And of course, the heat consumption is higher too. In the lowest stage cyclones effective life time of steel dip tube is often reduce due to high temperature and attack from effects alkaline, sulfur and chloride. Then no long time it will deform and fallen down later. We used HASLE Ceramic Diptube and improved as Mr.Preecha explained. Those problems has not happened, and lifetime is longer than Steel Ditpube.

We have used 2 different castables from HASLE and the ceramic dip tube. (CVF) D52A at Kiln Hood after 12 months D39A at Smoke Chamber after 12 months D52A at Bull Nose after 12 months