Effective CO2 Reduction for Rotary Kiln Burning Processes Through Energy‐Efficient Linings

Abstract

CO ₂ reduction targets are a global challenge for all cement and lime manufacturers. Therefore, kiln operation must be energy efficient and avoid kiln stops or dwell times. To achieve that, refractory lining concepts have been developed with a new, finer ceramic microstructure. The resulting porosities of up to 25% reduce heat loss due to their exceptionally low heat transfer characteristics. All other relevant properties are kept at well‐proven values, effective for any kiln purposes, even in aggressive kiln atmospheres. The installation is equivalent to any other standard product. The results of recent installations show a significant drop in kiln shell temperature. The reduction in overall CO2 emission and thermal energy input at the main burner prove the efficiency of the concept as well. In addition, kiln shell heat losses drop by up to 25%, The potential reduction in overall emission is calculated to reach up to 2%. The 10% weight reduction in refractory lining material, adding to improved sustainability and reduced carbon footprint for rotary kiln operator, refractory producer, and environment.