Applications: rotary kiln lining by zone

For lime, magnesium-metal, zinc-oxide, alumina, incineration and cement kilns. Only product-to-zone correspondences published by Jinxing are listed.

The following is general material-selection guidance; the actual lining design depends on kiln data.

Cement rotary kiln (precalciner) — zone map

Zones are shown from the kiln inlet to the outlet. Select a zone (mouse, or Tab and Enter) to see typical conditions, main wear mechanisms and generic material classes.

Selected zone · Kiln

Upper transition zone

Typical conditions: Approx. 1200–1400 ℃ class; unstable coating, large temperature fluctuation, alkali and sulphur enrichment; high mechanical stress near the tyre
Main wear mechanisms: Thermal-shock spalling, cracking after alkali-salt densification, hot-face loss with falling coating, mechanical stress from shell ovality, hot-spot risk
Generic material classes: Magnesia-alumina spinel bricks (mainstream); silica-mullite or silica-mullite red bricks for small/medium kilns or milder conditions (depending on kiln data); flexible grades in the tyre area

Schematic, not to scale. Zone lengths depend on kiln size, fuel and operation and are set in the lining design. Temperatures are industry-indicative ranges (strongly dependent on kiln type, fuel and operation) used to describe service conditions; they are not measured values for any kiln.

Cement rotary kiln — Zone

Zone	Typical conditions	Main wear mechanisms	Generic material classes
Kiln inlet / inlet chamberKiln	Medium temperature (approx. 800–1100 ℃ class); raw meal and kiln gas enriched in alkalis, sulphur and chlorine; prone to build-up	Alkali-salt infiltration and structural spalling, build-up and blockage, abrasion by raw meal	Anti-build-up (SiC-containing) castables, high-strength alkali-resistant castables, mullite castables; alkali-resistant bricks locally at the inlet
Calcining / preheating zone (safety zone)Kiln	Material approx. 900–1250 ℃ class; carbonate decomposition, alkali-salt condensation, possible ring formation	Alkali attack, thermal shock, abrasion, mechanical damage after ring formation	Silica-mullite bricks, silica-mullite red bricks, anti-spalling high-alumina bricks, alkali-resistant bricks; low-conductivity composite bricks where energy saving is required
Upper transition zoneKiln	Approx. 1200–1400 ℃ class; unstable coating, large temperature fluctuation, alkali and sulphur enrichment; high mechanical stress near the tyre	Thermal-shock spalling, cracking after alkali-salt densification, hot-face loss with falling coating, mechanical stress from shell ovality, hot-spot risk	Magnesia-alumina spinel bricks (mainstream); silica-mullite or silica-mullite red bricks for small/medium kilns or milder conditions (depending on kiln data); flexible grades in the tyre area
Burning zoneKiln	Material approx. 1450 ℃ class, higher flame temperature; a stable coating is normally present	Clinker-melt infiltration, thermal and chemical attack when the coating is unstable, redox fluctuation, mechanical stress	Magnesia-hercynite spinel bricks (mainstream chrome-free solution), magnesia-zirconia or dolomite basic bricks
Lower transition zoneKiln	Approx. 1300–1450 ℃ class, near the outlet; unstable coating, alternating hot/cold secondary air	Thermal shock, coating loss, clinker abrasion, chemical attack	Magnesia-alumina spinel bricks; high-wear silica-mullite bricks in some kilns
Cooling zoneKiln	Approx. 1100–1350 ℃ class; clinker cooling, hot secondary air, no or very thin coating	Clinker abrasion, thermal shock, erosion by hot secondary air	High-wear silica-mullite bricks, corundum-mullite bricks, anti-spalling high-alumina bricks
Kiln outlet / nose ringKiln	Hot clinker discharge, most severe thermal cycling, mechanical impact, nose-casting deformation	Abrasion, thermal shock, clinker erosion, lining loosening from nose-plate deformation	Corundum-mullite, corundum-SiC or mullite-SiC low-cement castables (often with steel fibres); nose-ring precast shapes
Preheater cyclonesExternal system	—	—	Alkali-resistant castables or bricks, anti-build-up castables, lightweight insulation
CalcinerExternal system	—	—	Alkali-resistant castables or bricks, anti-build-up castables, lightweight insulation
Tertiary air ductExternal system	—	—	Alkali-resistant or wear-resistant bricks, castables at bends, calcium-silicate board backing
Kiln hoodExternal system	—	—	Low-cement high-alumina or corundum-mullite castables with anchors
Burner pipeExternal system	—	—	Burner-pipe castable with steel fibres
Grate coolerExternal system	—	—	Hot end: high-strength wear-resistant castables, SiC castables or wear-resistant bricks; side walls, curb walls and bull nose: wear-resistant castables or precast shapes

Lime rotary kiln

Calcining at approx. 1100–1350 ℃ class with practically no protective coating; abrasion, thermal shock, chemical attack (e.g. sulphur) and ring formation dominate.

Zone	Jinxing products
High-temperature / burning zone	Special Corundum-Mullite Composite Brick Corundum–Silica-Mullite Composite Brick (for lime & magnesium rotary kilns) Si-Zr Corundum-Mullite Composite Brick JX-SN Special Corundum Composite Brick Corundum Phosphate-Bonded High-Wear Brick, grade 1550 (subject to kiln conditions) Special Phosphate-Bonded Wear-Resistant Brick, grade 1400 (subject to kiln conditions)
Transition zone	Special Corundum-Mullite Composite Brick Special Phosphate-Bonded Brick, grade 1480
Preheating and cooling zones	Phosphate-Bonded Wear-Resistant Brick, grade 1300

Magnesium-metal (dolomite) rotary kiln

Calcining at approx. 1100–1250 ℃ class; abrasion, thermal shock and dust erosion dominate.

Zone	Jinxing products
High-temperature / burning zone	Special Corundum-Mullite Composite Brick Corundum–Silica-Mullite Composite Brick (for lime & magnesium rotary kilns) Si-Zr Corundum-Mullite Composite Brick JX-SN Special Corundum Composite Brick Corundum Phosphate-Bonded High-Wear Brick, grade 1550 (subject to kiln conditions)
Transition zone	Special Phosphate-Bonded Brick, grade 1480 Special Phosphate-Bonded Wear-Resistant Brick, grade 1400 (lower transition zone)
Preheating and cooling zones	Phosphate-Bonded Wear-Resistant Brick, grade 1300

Zinc-oxide (Waelz) kiln

Approx. 1100–1300 ℃ class under strongly reducing conditions with Zn/Pb vapour, FeO slag and alkali chlorides; chemical attack, ring formation, abrasion and thermal shock combine, and conditions vary widely.

Zone	Jinxing products
Burning / reaction zone	Low-Conductivity Corundum Flexible Slag-Resistant Brick (main recommendation) Corundum Phosphate-Bonded High-Wear Brick, grade 1550 (subject to kiln conditions) Special Phosphate-Bonded Brick, grade 1480 (subject to kiln conditions)
Secondary high-temperature zone	Special Phosphate-Bonded Wear-Resistant Brick, grade 1400
Preheating and cooling zones	Phosphate-Bonded Wear-Resistant Brick, grade 1300

Waste-incineration rotary kiln

Approx. 850–1250 ℃ class with Cl, S, alkalis and molten ash, and frequent thermal cycling; slag attack, chlorine corrosion, thermal shock and impact abrasion combine.

Zone	Jinxing products
High-temperature zone	Corundum Phosphate-Bonded High-Wear Brick, grade 1550 Low-Conductivity Corundum Flexible Slag-Resistant Brick
Secondary high-temperature zone	Special Phosphate-Bonded Brick, grade 1480 Special Phosphate-Bonded Wear-Resistant Brick, grade 1400 (lower transition zone)
Preheating and cooling zones	Phosphate-Bonded Wear-Resistant Brick, grade 1300

Bauxite / alumina rotary kiln

Bauxite calcining kilns and alumina clinker kilns differ: the former run hotter in the high-temperature zone, the latter add alkali (Na₂O) attack.

Zone	Jinxing products
High-temperature and transition zones (bauxite)	Special Corundum-Mullite Composite Brick Si-Zr Corundum-Mullite Composite Brick
Preheating and cooling zones (alumina)	Phosphate-Bonded Wear-Resistant Brick, grade 1300

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