Cement Industry

Linning is the spirit of the cement industry

With over 50 years of experience in the cement industry, Mathios Refractories S.A. has gained an insight to the requirements of a successful cement plant. Being fully capable of providing EPC solutions for all types of cement plants, we strive for the optimum performance of our network. Having forged strategic bonds with the largest cement groups in the world we have developed tailor made solutions for a variety of application around the cement plants. Our experts and R&D teams constantly analyze production information and fuel inputs to reach the most suitable solution for any application. For all ranges of operating conditions – from mild to extreme – Mathios Refractories S.A. will deliver the best and most effective solution. We have been providing our high quality material in all parts of the plants focusing on improving energy efficiency, reduced downtime, shorter repair cycles and enhanced productivity. We are able to provide bricks, monolithic, precast sections as well as special parts for the following products:
  • Cyclone
  • Calcinator
  • Riser Duct / Inlet Zone
  • Cement Rotary Kiln
  • Grate Cooler / Bull Nose / Tertiary Air / Burner

Upper Cyclone

Cyclone Lining Insulating Lining

Cyclones are the vital part of the preheater in a cement plant. Upper cyclone refractories are subject to relatively low thermal and abrasive loads, for this reason more mundane and hence economical solutions are proposed.

The refractory materials offered by MATHIOS REFRACTORIES are vastly tested and proven by the industry.

Products from the following lines are recommended by our experts:

  • IDEAL: Alumina (Al2O3) bricks, with formulations based on calcined fireclay and silicon carbide, are used as hot face linings
  • MAT PLUS: Alumina (Al2O3) low cement castables (LCC), with formulations based on chamotte, are used as hot face linings
  • MAT PLUS MC: Alumina (Al2O3) medium cement castables (MCC), with formulations based on chamotte, are used as hot face linings
  • MAT G: Alumina (Al2O3) conventional gunning materials, with formulations based on chamotte, are used as hot face linings
  • MAT GS: Alumina (Al2O3) medium cement gunning materials (MCG), with formulations based on chamotte, are used as hot face linings
  • MAT: Alumina (Al2O3) insulating castables, with formulations based on vermiculite, for use as insulation linings
  • MAT G: Alumina (Al2O3) insulating gunning materials, with formulations based on vermiculite, for use as insulation linings

Lower Cyclone

Cyclone Lining Raw Mill Duct Insulating Lining

Cyclones are the vital part of the preheater in a cement plant. Lower cyclones, in contrast to their upper counterparts, refractories are subject to significantly higher thermal and abrasive loads. For this reason materials with special additives such as zirconium dioxide (ZrO2), silicon carbide and other ultra-high strength materials are proposed.

The refractory materials offered by MATHIOS REFRACTORIES are vastly tested and proven by the industry.

Products from the following lines are recommended by our experts:

  • IDEAL: Alumina (Al2O3) bricks, with formulations based on calcined fireclay and silicon carbide, are used as hot face linings
  • MAT PLUS: Alumina (Al2O3) low cement castables (LCC), with formulations based on chamotte, sintered mullite, bauxite, synthetic raw materials, zirconia and silicon carbide, are used as cyclone and raw meal duct hot face linings
  • MAT PLUS MC: Alumina (Al2O3) medium cement castables (MCC), with formulations based on chamotte, are used as hot face linings
  • MAT G: Alumina (Al2O3) conventional gunning materials, with formulations based on chamotte and zirconia, are used as cyclone and raw meal duct hot face linings
  • MAT GS: Alumina (Al2O3) medium cement gunning materials (MCG), with formulations based on chamotte and synthetic raw materials, are used as hot face linings
  • MAT: Alumina (Al2O3) insulating castables, with formulations based on vermiculite, for use as insulation linings
  • MAT G: Alumina (Al2O3) insulating gunning materials, with formulations based on vermiculite, for use as insulation linings

Calcinator

Refractory Lining Insulating Lining

The calcinator, as its name implies, is responsible for the raw meal calcination process . Calcinator, much like lower cyclone, refractories are subject to significant thermal and abrasive loads. For this reason materials with silicon carbide addition and other ultra-high strength materials are proposed.

The refractory materials offered by MATHIOS REFRACTORIES are vastly tested and proven by the industry.

Products from the following lines are recommended by our experts:

  • IDEAL: Alumina (Al2O3) bricks, with formulations based on calcined fireclay , mullite and silicon carbide, are used as hot face linings
  • MAT PLUS: Alumina (Al2O3) low cement castables (LCC), with formulations based on sintered mullite, bauxite and silicon carbide, are used as hot face linings
  • MAT LG: Alumina (Al2O3) low cement gunning materials (LCG), with formulations based on sintered mullite and silicon carbide, are used as hot face linings
  • MAT G: Alumina (Al2O3) conventional gunning materials, with formulations based on high alumina raw materials, are used as hot face linings
  • MAT GS: Alumina (Al2O3) medium cement gunning materials (MCG), with formulations based on sintered mullite and silicon carbide, are used as hot face linings
  • MAT: Alumina (Al2O3) insulating castables, with formulations based on vermiculite, for use as insulation linings
  • MAT G: Alumina (Al2O3) insulating gunning materials, with formulations based on vermiculite, for use as insulation linings

Riser Duct / Inlet Zone

Riser Duct Inlet Chamber Insulating Lining

The riser duct / inlet zone is the link between the calcinatory and the rotary kiln. Riser duct / inlet zone refractories are subject to significant thermal and mechanical loads. For this reason materials with special additives such as zirconium dioxide (ZrO2), silicon carbide and other ultra-high strength materials are proposed.

The refractory materials offered by MATHIOS REFRACTORIES are vastly tested and proven by the industry.

Products from the following lines are recommended by our experts:

  • MAT PLUS: Alumina (Al2O3) low cement castables (LCC), with formulations based on chamotte, sintered mullite, bauxite, synthetic raw materials, zirconia and silicon carbide, are used as riser duct and inlet chamber linings
  • MAT PLUS MC: Alumina (Al2O3) medium cement castables (MCC), with formulations based on mullite and bauxite, are used as riser duct and inlet chamber linings
  • MAT MICRON: Alumina (Al2O3) ultra-low cement castables (ULCC), with formulations based on sintered mullite for use as riser duct and inlet chamber linings
  • MAT LG: Alumina (Al2O3) low cement gunning materials (LCG), with formulations based on sintered mullite and silicon carbide, are used as riser duct linings
  • MAT GS: Alumina (Al2O3) medium cement gunning materials (MCG), with formulations based on synthetic mullite, silicon carbide and zirconia, are used as riser duct linings
  • MAT: Alumina (Al2O3) insulating castables, with formulations based on vermiculite, for use as insulation linings
  • MAT G: Alumina (Al2O3) insulating gunning materials, with formulations based on vermiculite, for use as insulation linings

Cement Rotary Kiln

Nose Ring Outlet Zone Lower Transition Zone
Burning Zone Upper Transition Zone Safety Zone
Calcination Zone Preheating Zone Burner

The rotary kiln is the fiery heart of the cement plant. Raw meal is fed into one side and superheated clinker comes out on the other. The rotary kiln is comprised of many zones, with each one imposing different requirements and challenges on the refractory lining. Extremely high temperatures, chemical attack and mechanical stresses arising not only from the movement of the fed material inside the kiln, but also due to its rotation and shell ovalities created over time by wear and tear, are the main issues that need be overcome.

The refractory materials offered by MATHIOS REFRACTORIES are vastly tested and proven by the cement industry around the world. Especially our trademark MAT MICRON ULCC has been in service at some of the largest plants in the world, with unprecedented results and service life. The same applies for the IDEAL A-63 which produces astonishing results at the kiln supports and the MAT PLUS 60-A which has been developed specifically for kiln nose rings in conjunction with some of the major players in the cement industry and has yielded spectacular results.

Products from the following lines are recommended by our experts:

  • IDEAL: Alumina (Al2O3) bricks, with formulations based on calcined fireclay, mullite, andalusite, bauxite and silicon carbide, are used as nose ring, safety, calcination and preheating zone linings
  • MAT PLUS: Alumina (Al2O3) low cement castables (LCC), with formulations based on sintered mullite, andalusite and silicon carbide, are used as nose ring, preheating zone and burner linings
  • MAT MICRON: Alumina (Al2O3) ultra-low cement castables (ULCC), with formulations based on sintered mullite and silicon carbide, are used as nose ring and burner linings
  • MAT NANO: Alumina (Al2O3) no cement castables, with formulations based on sintered mullite, are used as nose ring and burner linings
  • IDEAL: Magnesite (MgO) bricks, with formulations based on magnesia spinel, are used as outlet, lower and upper transition and burning zone linings

Grate Cooler & Kiln Hood

Bull Nose Kiln Hood Cooler-Hot Section
Cooler-Cool Section Horseshoe Lower Tertiary Air Duct
Upper Tertiary Air Duct Insulating Lining

After exiting the kiln, the superheated clinker is lead to the grate cooler. The cooler’s hot section is covered by the kiln hood and includes the Horseshoe and Bull Nose, which are critical parts and as such deserve the best materials. Our trademark MAT PLUS 10 SiC M has been in service at both aforementioned parts, while the MAT MICRON 10 SiC M at the Horseshoe, of some of the largest plants in the world with unprecedented results and service life.

Another part connected either to the kiln hood or cooler is the Tertiary air duct, which feeds the calciner with hot gases. Some zones are under high abrasion, due to concentration of dust in the stream. For these zones, materials containing Zirconia or Silicone Carbide are proposed.

The refractory materials offered by MATHIOS REFRACTORIES are vastly tested and proven by the cement industry around the world. Products from the following lines are recommended by our experts:

  • IDEAL: Alumina (Al2O3) bricks, with formulations based on calcined fireclay and mullite, are used as kiln hood, cooler hot and cold sections and tertiary air duct linings
  • MAT PLUS: Alumina (Al2O3) low cement castables (LCC), with formulations based on chamotte, sintered mullite, bauxite and silicon carbide, are used as bull nose, kiln hood, cooler hot and cold sections, horseshoe and tertiary air duct linings
  • MAT PLUS MC: Alumina (Al2O3 medium cement castables (MCC), with formulations based on fireclay, mullite and bauxite, are used as bull nose, kiln hood, cooler hot and cold sections and tertiary air duct linings
  • MAT MICRON: Alumina (Al2O3) ultra-low cement castables (ULCC), with formulations based on chamotte, sintered mullite and silicon carbide, are used as bull nose, kiln hood, cooler hot and cold sections and horseshoe linings
  • MAT LG: Alumina (Al2O3) low cement gunning materials (LCG), with formulations based on sintered mullite and silicon carbide, are used as kiln hood and tertiary air duct linings
  • MAT GS: Alumina (Al2O3) medium cement gunning materials (MCG), with formulations based on chamotte, bauxite, silicon carbide and zirconia, are used as kiln hood, cooler – cool section and tertiary air duct linings
  • MAT: Alumina (Al2O3) insulating castables, with formulations based on expanded clay and vermiculite, for use as insulation linings
  • MAT G: Alumina (Al2O3) insulating gunning materials, with formulations based on expanded clay and vermiculite, for use as insulation linings