High-Temperature Insulation Project for Rotary Kiln at Russian Cement Plant

Location: Volga River Basin, Russia

Construction Year: 2022

Products Used: SUNTHERM ceramic fibre blanket (1430-grade high-temperature type, partly aluminium-foil-composite type)

Quantity Used: Approximately 35 tonnes

Application Areas: Rotary kiln shell, pre-heater, waste-heat boiler, flue-gas duct system

Project Background

The cement plant’s rotary kiln operates continuously at high temperatures (1350–1400 °C). Traditional refractory bricks suffered from high thermal conductivity, large energy loss, and frequent maintenance. The client sought to adopt a lightweight insulating material to achieve energy savings, reduced maintenance, and improved efficiency.

✨ SUNTHERM Solution

SUNTHERM’s engineering team devised a multi-layer wrapping plus stainless-steel mesh reinforcement approach. They used the 1430-grade high-temperature ceramic fibre blanket, and in areas exposed to severe thermal shock, selected the aluminium-foil-composite version—ensuring both thermal stability and durability.

▶ Engineering Details

• Operation conditions: Kiln temperature extreme, running > 20 h/day continuously, requiring top-grade refractory integrity.

• Installation method: Layered wrapping and zonal reinforcement to prevent thermal bridging due to high-temperature shrinkage.

• Energy data: After installation, system heat loss dropped by ~20%, saving roughly 2,500 tonnes of standard coal per year.

✅ Performance & Benefits

• Exterior shell temperature decreased from 180 °C to 70 °C, significantly improving operational safety.

• Insulation service life extended to 5–6 years, far longer than the typical 2–3 years for refractory brick.

• Annual operating costs dropped; maintenance expenses reduced by approximately 30%.
  
  

★ Project Summary

This project powerfully illustrates the thermal stability, energy-saving potential, and durability of SUNTHERM ceramic fibre blankets in rotary kiln applications. The client highly praised the product’s performance and efficiency—so much so that SUNTHERM was chosen again for subsequent production-line expansions.