Alternative Fuels and Refractories: Managing Risks, Impacts and Solutions in Cement Plants

Understanding how alternative fuels affect refractory performance is therefore essential for maintaining kiln reliability, extending lining service life, and supporting stable cement production.

To explore these challenges and the solutions available to cement producers, Calderys will be hosting a dedicated technical webinar on the 20^th of August for the cement and lime community in Australia and New Zealand.

Why alternative fuels are changing refractory requirements

The use of alternative fuels is becoming increasingly important in the cement industry. Refuse-derived fuel (RDF) and other alternative fuel sources can help cement plants reduce their reliance on conventional fossil fuels and support broader energy transition objectives.

However, alternative fuels can also introduce greater variability into the combustion process. Differences in fuel composition, moisture content, ash chemistry, and calorific value can influence operating conditions throughout the kiln system.

For refractory linings, this can result in:

• Higher or more variable operating temperatures
• Increased exposure to chemical attack
• Changes in the formation of deposits and build-ups
• Greater thermal and mechanical stresses
• More demanding conditions for refractory materials and lining systems

These factors can affect refractory performance and may contribute to premature wear if the lining system is not designed and selected according to the specific operating conditions of the plant.

From alternative fuel challenges to practical refractory solutions

The webinar will bring together two Calderys experts to explore how alternative fuels affect refractory systems and the technologies that can help cement plants address these challenges, combining scientific expertise with practical engineering insights.

Dr. Indra Nath Chakraborty: Decades of expertise in refractory science

Dr. Indra Nath Chakraborty is a refractory scientist and calcium aluminate cement specialist with more than 40 years of experience in refractory and cement technology; he will be sharing his perspective on the technical challenges created by alternative fuel use and the role of refractory materials and calcium aluminate cement technologies in supporting reliable plant operations.

Rudraksh Kulkarni: Engineering refractory solutions for complex applications

Rudraksh Kulkarni brings nearly 20 years of experience in refractory design engineering and project execution across industries including cement, power, steel and petrochemicals. His contribution to the webinar will be focused on the practical engineering aspects of refractory solutions, including how precast technologies can help address complex installation and performance requirements.

Building knowledge around alternative fuels and refractories

The webinar is part of Calderys' commitment to supporting customers as the cement industry continues to evolve. Through technical expertise, refractory engineering and application knowledge, Calderys works with customers to develop solutions adapted to the specific requirements of their processes.

Want to learn more about refractory solutions for cement plants using alternative fuels? Contact Calderys to discuss your application and refractory requirements.

Key takeaways

• Alternative fuels such as RDF can create more variable and demanding conditions for refractory linings. 
• Changes in temperature, fuel chemistry and chemical attack can affect refractory performance. 
• Refractory selection should be based on the specific operating conditions of each cement plant. 
• Precast refractory technologies can provide customized solutions for complex industrial applications. 
• Technical expertise and application-specific engineering are essential when transitioning to alternative fuels.