A global leader in supplying turnkey systems
Steuler installs many different types of refractory and corrosion protection systems in plants of the cement and lime industry.


Refractory brick masonry

Steuler delivers refractory brick masonry linings for the following parts of a plant:

• Heat exchangers
• Calciners
• Tertiary air ducts
• Rotary kilns (safety zone, transition zone, discharge zone)
• Kiln hood
• Cooler

Steuler supplies all alumina-based linings as well as insulation systems and permanent linings for the entire cement plant, ranging from the heat exchanger to the calciner and tertiary air ducts, also including the safety zone and the upper transition zone. Steuler products are also used in the outlet zone, the furnace head and the cooler.

Andalusite and fireclay bricks are used in the lime industry both for shaft furnaces and for rotary kilns. This is where the abrasion resistance of our high-fired, low-iron fireclay bricks and the excellent chemical resistance of our andalusite bricks are particularly effective.
Therefore, the primary range of applications for these bricks is in the transition and firing zones of these kilns. Special fireclay grades are also available for the charging and cooling zones.


Corrosion protection systems in various parts of a plant

In addition to complete refractory delivery concept, Steuler also offers top-quality industrial corrosion protection for various parts of a plant. The close interface between the business units of Surface Protective Systems, Refractory Systems and Plastics Technology has created a unique range of services for lining technologies and know-how.

Steuler offers linings for equipment, vessels and tanks in the form of resin coatings and rubber linings for the most severe chemical, mechanical and thermal loads, floor toppings in a variety of types and ceramic tile linings, DIBt approved and certified lining systems as well as mechanically anchored thermoplastic linings (Bekaplast) for sewage pipe systems, basins, vessels, shafts and process tanks.
In flue gas scrubbing plants, we use equipment, piping, tanks and individually customised special designs such as spray levels, sieve boxes and linings for flue gas scrubbers made from duroplastics and thermosplastics, but also special highly chemically and thermally resistant materials (Steuler flake) for the channels holding the flue gases.

Flue gas scrubbers

Flue gas scrubbers to clean sulphurous combustion gases are also built in various construction modules and material constellations depending on the scrubbing technology used. Steuler has suitable and reliable materials for every scrubbing process.

Mechanically anchored thermoplastic lining (Bekaplast) for concrete scrubbers

The Bekaplast system Steuler has been using in flue gas scrubbers since 1999 is setting new standards. Steuler also makes use of the advantages offered by polypropylene as mechanically anchored linings in concrete scrubber constructions. Thanks to its outstanding chemical, thermal and mechanical resistance properties as well as its particularly good resistance to abrasion and excellent anti-adhesive properties, polypropylene can also be employed as an ideal mechanically anchored corrosion-protection lining in concrete scrubber constructions.

Steuler uses its special Bekaplast lining system that has been field-proven for more than 30 years, e.g. in the chemical industry. It consists of large-format thermoplastic sheets in thicknesses of 5 to 8 mm. Conical knobs are welded onto the reverse side. These large knobs create a permanent, inseparable mechanical bond between the plastic lining and the concrete structure. The service life of this Bekaplast lining is much superior to such well-known lining materials as rubber and resin coatings. Damage caused by media absorption, the formation of deposits or chemical changes on the surface can be virtually ruled out. Because spray nozzle levels, piping systems, drip separators and sieve boxes are also made of polypropylene, there is only one material in use throughout the entire flue gas scrubber.

Spray nozzle levels, Drop separators, Sieve boxes, Piping systems, Supply tanks

Experience gained over the course of the 25 years during which Steuler has been using a wide variety of corrosion protection materials in flue gas scrubbers has led to the development of a technically advanced and economically viable manufacturing concept. Instead of following the standard and costly practice of protecting spray levels against severe chemical, thermal and mechanical stresses, Steuler today manufactures these large-dimensioned components entirely from polypropylene.
The main advantage of using polypropylene is that this material does not require any further protection. The surface is smooth and pore-free which prevents caked on deposits and incrustations from forming. The service life of the material is virtually unlimited. Damage caused by media absorption, the formation of deposits or chemical changes on the surface can be virtually ruled out. As a result, the structural design of such piping systems, an anticipated service life in excess of 25 years is fully justifiable.
The ease of replacement, the definable assembly times and the standardised construction process meet all the requirements for optimal economic efficiency, freedom from maintenance and a long service life, particularly for retrofit application and scrubber refurbishments.
The excellent properties of the material polypropylene are also used for the manufacturing of circulation piping systems, drip separators, sieve boxes and supply tanks.
In addition to the manufacture, delivery and final assembly of the spray level, the scope of delivery also includes the complete engineering as well as the preparation of all structural and manufacturing drawings. Welding is done in accordance with the guidelines established by the German Association of Welding Engineering (DVS).

Raw gas ducts, raw gas channels and heat exchangers

Steuler can also deal with the extreme requirements found in raw gas ducts and heat exchangers with suitable and reliable materials. Whereas raw gas ducts display conditions similar to those found in scrubber heads – here it is a matter of the diffusion resistance of the lining that plays the decisive role – linings in raw gas ducts and heat exchangers have to deal with high temperatures and be particularly acid resistant. Steuler has linings available that display temperature resistance values up to 220°C combined with good resistance to acids. In extreme areas, such as those found in some heat exchanger systems, Steuler makes use of special film linings on a PFA and MFA base with the highest level of temperature and acid resistance.

Tanks and trenches

For steel tanks and concrete trenches, Steuler can offer suitable rubber linings and coatings that are used as specified by the chemical, thermal or mechanical loads encountered. In concrete trenches, the preference for use is more on thermoplastic, rubber or laminate linings due to their good crack-bridging properties.


Surfaces and chemical storage in conformity with the German Water Management Act (WHG)

The requirement for lining systems with general Building Permits in many areas of power generation facilities is more the rule than the exception.
Steuler presently has eight approved lining systems so that the right solution is available for each requirement and specification. Steuler lining systems with generally approved building permits are subjected to constant third-party inspections and assure the highest and the most uniform quality.

Steuler is your competent partner for everything from planning to material selection right down to final approval to ensure that the project meets all official regulations. Many of Steuler's lining systems with general building permits can also meet such other requirements as those for walking safety and vehicle traffic.