Perillex Bricks PDF

PERILEX® CF - THE FIRST ECO-FRIENDLY PERILEX® BRICK GRADE
WITH IMPROVED PROPERTIES FOR APPLICATION IN CEMENT

ROTARY KILNS
Markus Simon
Refratechnik Cement GmbH, Germany
More than 25 years ago already, the first basic brick, namely PERILEX® 83, was introduced to a rotary
kiln in India. Undoubtedly, a new era was entered at that time by prolonging the kilns’ operation cycle and
stabilizing the overall refractory performance, thus meeting the trend of increasing the kilns’ production
capacity.
Today, one could particularly hardly imagine the world’s cement industries running their kilns without
using basic bricks.
After so many years, the chrome ore containing PERILEX® bricks are still being used successfully in
several rotary kilns worldwide and, of course, in India, which confirms the concept behind this brick -
although the importance of magnesia chromite bricks decreased significantly for ecological reasons.
Thanks to latest developments of raw materials and processes, it is now possible to produce new synthetic
minerals with unique properties. One of these materials, which was developed by Refratechnik, is the so-
called pleonastic spinel (Mg,Fe)(Al,Fe)2O4, which is typically obtained by a fusion process at very high
temperatures.
By applying the established Refratechnik AF Alternative fuel technology, in which sintered magnesia
containing iron oxide and the pleonastic spinel – replacing the chromium oxide – are combined, the
thermomechanically insensitive PERILEX® CF brick grade exhibiting extraordinary physical properties
and outstanding thermal shock resistance could be developed.
Fig.1: Concept of PERILEX® CF, chrome ore-free

PERILEX® CF is primarily suitable for lining the central burning zone also of high thermochemically
loaded kilns and the upper transition zone subjected to normal thermal stresses.
Apart from the advantages of the thermochemically stable pleonaste, which is more resistant to cement
clinker attack than a hercynite, one could benefit from the advantage of a better coatability offered by a
ferrous sintered magnesia compared to that of a low iron natural or synthetic sintered magnesia.
To prove its advantageous properties, PERILEX ® CF was installed in numerous cement kilns with varying
kiln diameters, production capacities as well as process conditions. In addition, its considerable
cost/performance ratio puts the finger on the pulse of many cement manufacturers under cost pressure, in
the process of increasing the profitability.
At the end of 2011, PERILEX® CF was installed in India for the first time in the main burning zone of one
kiln of the Madras Cement group, thanks to their innovative cooperation.
During the first days of operation already, a stable coating was formed on PERILEX® CF confirming the
excellent coating behavior of this magnesia pleonaste brick. Compared to other coating-friendly bricks,
e.g. standard magnesia chromite or standard magnesia hercynite bricks, PERILEX® CF’s elastifier
pleonaste is more stable to cement clinker attack. In addition, PERILEX® CF significantly lowers the
clinker melt infiltration risk due to its low open porosity of about 13-15% and also shows a reduced gas
permeability. This combination of characteristics was highly valued by Madras Cement group when, for
cement market specific reasons, the kiln had to be stopped more frequently. It was then good to find that
the impact of collapsing coating did not result in a wear up to the extent known from standard coating-
friendly bricks with surfaces being saturated by infiltrated clinker melt.
Fig. 2: Performance example of PERILEX® CF
Thanks to the professional operation by Madras Cement group of that particular kiln, fired to a 100% with
high sulphur containing petcoke via the main burner, PERILEX® CF had already been running for 19
months in July 2013. The kiln was stopped then and the brick grade was found to be good enough for
further operation, besides some partial spot wise repairs.
Against the 19 months + X performance of PERILEX ® CF, there could only be reached lifetimes of 13
months with standard magnesia chromite bricks in the same kiln area or even 5 months service life only
with standard 70% high alumina bricks in earlier applications.
In view of the impressive performance of PERILEX® CF achieved in its first application, Madras Cement
group decided to apply this brick grade directly afterwards once again.
By introducing PERILEX® CF “Made in Germany”, Refratechnik has made another substantial

contribution to the progress of lifetime, even in mechanically stressed cement rotary kilns, as well as to
sustainability and environmental protection. PERILEX® CF is budget-friendly and a consistent
supplement to the high-grade AF brick technology.

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PERILEX® CF - THE FIRST ECO-FRIENDLY PERILEX® BRICK GRADE

WITH IMPROVED PROPERTIES FOR APPLICATION IN CEMENT

Fig.1: Concept of PERILEX® CF, chrome ore-free

Fig. 2: Performance example of PERILEX® CF

By introducing PERILEX® CF “Made in Germany”, Refratechnik has made another substantial

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