Incinerators

Power generation and economy is a challenge for any advanced society as demand increases and recourses have to be treated with respect for the sustainability of future generations.

Incinerators are becoming an integral part of the industrial cycle. Demanding conditions are created by the unexpected mix of fuel. Mathios Refractories S.A. has constructed more than 15 new incinerators and has supplied materials for many more. Always taking into consideration the specific conditions that apply for each unique application; hence optimizing cost, performance and sustainability for its clients.

We are able to provide bricks, monolithic, precast sections as well as special parts for the following installations:

  • Incinerator
  • Rotary Kiln Incinerator
  • Grate Fired Boiler Waste Incinerator
  • Reactor Cyclone
  • Reactor
  • Lead Rotary Furnace
  • Used Battery Kettle

Incinerator

Main Combustion Zone After Burner Chamber Ash Hopper
Chimney Burner Insulating Lining
 

Waste incineration for energy production is constantly gaining ground over other sources, such as fossil fuels. The vast variety of waste being eligible for incineration, leads to a plethora of different chemical environments being present. For this reason we have developed, in close co-operation with many incinerator operators, special formulations to overcome the challenges imposed by a range of waste, spanning all the way from animal to municipal and medical.

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

  • IDEAL: Alumina (Al2O3) bricks, with formulations based on calcined fireclay, mullite, andalusite, corundum, silicon carbide and chromium oxide, are used as main combustion zone and after burner chamber linings
  • MAT PLUS: Alumina (Al2O3) low cement castables (LCC), with formulations based on sintered mullite and chromium oxide, are used as ash hopper, chimney and burner linings
  • MAT MICRON: Alumina (Al2O3) ultra-low cement castables (ULCC), with formulations based on sintered mullite, are used as burner linings
  • MAT: Alumina (Al2O3) insulating castables, with formulations based on expanded clay and perlite, for use as insulation linings
  • MAT G: Alumina (Al2O3) insulating gunning materials, with formulations based on expanded clay and perlite, for use as insulation lining

Rotary Kiln Incinerator

Nose Ring Discharge Combustion Zone After Burner Chamber Upper Part
Safety Lining Combustion Zone Insulating Lining
 

As their name implies, rotary kiln incinerators combine immense heat with rotational movement, in order to reduce waste to ash. Gases escaping the kiln are rendered harmless in the after burner chamber and the upper part of the incinerator. The vast variety of waste being eligible for incineration, leads to a plethora of different chemical environments being present. For this reason we have developed, in close co-operation with many incinerator operators, special formulations to overcome the challenges imposed by a range of waste, spanning all the way from animal to municipal and medical.

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

  • IDEAL: Alumina (Al2O3) bricks, with formulations based on calcined fireclay, mullite, andalusite, corundum and chromium oxide, are used as combustion zone, after burner chamber, safety and upper part linings
  • MAT PLUS: Alumina (Al2O3) low cement castables (LCC), with formulations based on chamotte, sintered mullite and chromium oxide, are used as nose ring, after burner chamber and upper part linings
  • MAT LG: Alumina (Al2O3) low cement gunning materials (LCG), with formulations based on mullite, are used as upper part linings
  • MAT GS: Alumina (Al2O3) medium cement gunning materials (MCG), with formulations based on mullite, are used as upper part linings
  • MAT MICRON: Alumina (Al2O3) ultra-low cement castables (ULCC), with formulations based on sintered mullite, are used as upper part linings
  • MAT: Alumina (Al2O3) insulating castables, with formulations based on expanded clay and perlite, for use as insulation linings
  • MAT G: Alumina (Al2O3) insulating gunning materials, with formulations based on expanded clay and perlite, for use as insulation lining

Grate Fired Boiler Waste Incinerator

Chute Slag Hopper First Pass
Boiler Walls Walls Roof
Ash Hopper Rear Roof Wear Area
 

Grate fired waste incinerators not only develop many of the challenges of their rotary and static counterparts, but also present others due to their unique form. Movement of waste on the grate tends to impose high abrasive loads on the boiler walls, while incineration residues cause thermal shocks to the ash hopper. Corrosive environments due to alkali vapors, alkaline earth metals and zinc chlorides are almost always present in grate fired incinerators. For these reason we have developed, in close co-operation with many incinerator operators, special formulations to overcome the challenges imposed by a range of waste, spanning all the way from animal to municipal and medical.

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

  • IDEAL: Alumina (Al2O3) bricks, with formulations based on mullite, are used as chute and wear area linings
  • MAT PLUS: Alumina (Al2O3) low cement castables (LCC), with formulations based on sintered mullite, andalusite, bauxite, silicon carbide and chromium oxide, are used as chute, boiler walls, first pass, roof, slag and ash hopper, rear wall and wear area linings
  • MAT PLUS MC: Alumina (Al2O3) medium cement castables (MCC), with formulations based on chamotte, are used as walls and ash hopper linings
  • MAT LG: Alumina (Al2O3) low cement gunning materials (LCG), with formulations based on mullite, are used as first pass linings
  • MAT GS: Alumina (Al2O3) medium cement gunning materials (MCG), with formulations based on chamotte and sintered mullite, are used as walls, roof and rear roof linings

Reactor Cyclone

Refractory Lining Refractory Lining Safety Lining
Insulating Lining Insulating Lining
 

Reactor cyclones are used to separate the spent catalyst from the cracked product vapors. High abrasion, thermal shocks and corrosive environments are present. Our top of the line materials are specifically developed to combat all the aforementioned needs.

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

  • MAT PLUS: Alumina (Al2O3) low cement castables (LCC), with formulations based on sintered mullite and bauxite, are used as refractory linings
  • MAT PLUS MC: Alumina (Al2O3) medium cement castables (MCC), with formulations based on chamotte, are used as safety linings
  • MAT MICRON: Alumina (Al2O3) ultra-low cement castables (ULCC), with formulations based on chamotte and sintered mullite, are used as refractory and safety linings
  • MAT NANO: Alumina (Al2O3) no cement castables, with formulations based on sintered alumina, are used as refractory linings
  • MAT GS: Alumina (Al2O3) medium cement gunning materials (MCG), with formulations based on chamotte and sintered mullite, are used as refractory and safety linings
  • MAT: Alumina (Al2O3) insulating castables, with formulations based on expanded clay and perlite, for use as insulation linings
  • MAT G: Alumina (Al2O3) insulating gunning materials, with formulations based on expanded clay and perlite, for use as insulation lining

 

Reactor

Refractory Lining Refractory Lining Refractory Lining
Safety Lining Insulating Lining
 

Reactors are mostly prevalent at pyrolitic incinerators. Their purpose is to facilitate the processes of drying, degassing and gasification, all in advance of combustion.

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

  • IDEAL: Alumina (Al2O3) bricks, with formulations based on andalusite and silicon carbide, are used as refractory linings
  • MAT PLUS: Alumina (Al2O3) low cement castables (LCC), with formulations based on sintered mullite, andalusite, bauxite and silicon carbide, are used refractory linings
  • MAT PLUS MC: Alumina (Al2O3) medium cement castables (MCC), with formulations based on chamotte, are used as safety linings
  • MAT MICRON: Alumina (Al2O3) ultra-low cement castables (ULCC), with formulations based on chamotte and sintered mullite, are used as refractory and safety linings
  • MAT NANO: Alumina (Al2O3) no cement castables, with formulations based on sintered alumina, are used as refractory linings
  • MAT GS: Alumina (Al2O3) medium cement gunning materials (MCG), with formulations based on chamotte and sintered mullite, are used as refractory and safety linings
  • MAT: Alumina (Al2O3) insulating castables, with formulations based on expanded clay and perlite, for use as insulation linings
  • MAT G: Alumina (Al2O3) insulating gunning materials, with formulations based on expanded clay and perlite, for use as insulation lining

Lead Rotary Furnace

Burner & Charge Door Safety Lining Rotary Lining
Side Walls Door Insulation Lining
 

Lead recycling is an industrial process with essential benefits to environment conservation and heavy metal poisoning. Refractories must be able to combat thermal shocks, liquid metal infiltration and erosion and corrosion mainly due to fayalithic slags. Alongside our partners, who are leading businesses around the globe when it comes to lead recycling, we continuously update our designs and formulations specifically to tackle the aforementioned challenges.

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

  • IDEAL: Alumina (Al2O3) bricks, with formulations based on calcined fireclay, are used as safety linings
  • MAT PLUS: Alumina (Al2O3) low cement castables (LCC), with formulations based on sintered mullite, are used as burner and charge door linings
  • MAT MICRON: Alumina (Al2O3) ultra-low cement castables (ULCC), with formulations based on sintered mullite, are used as burner linings
  • MAT GS: Alumina (Al2O3) medium cement gunning materials (MCG), with formulations based on mullite, are used as burner and charge door linings
  • MAT G: Alumina (Al2O3) insulating gunning materials, with formulations based on expanded clay and vermiculite, for use as insulation lining
  • IDEAL: Magnesite (MgO) bricks, with formulations based on fused magnesia-chrome grains are used as burner and charge door, side walls and rotary kiln linings

Used Battery Kettle

Burner Lower Walls Insulation Lining Upper Walls