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Modular lining for clinker coolers

The exponential increase in kiln capacity, coupled with a corresponding increase in cooler heat recovery efficiency poses a new challenge to refractory linings around the kiln hood and cooler. With it came a sharp increase in secondary air temperature, an increase in alkali and sulphur concentration and an increase in buildup formation. These new conditions are responsible for frequent refractory failures. Pre-cast, fired shapes, the main subject of this paper, are not new to the cement industry. The technical literature refers to preheaters lined with precast moduli as far back as 1983. In the United States, the author's experience with this concept started in 1989, with two cooler linings in New York State. What makes this old concept so attractive today are the increased thermal and chemical stresses posed by high-efficiency clinker coolers and high capacity kilns. This paper compares several cooler lining alternatives to pre-cast, pre-fired shapes.