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Upgrades, rebuilds and exchange

Pyroprocessing upgrades & rebuilds - extend lifespan & boost efficiency

Enhance performance, increase availability, and improve sustainability with our comprehensive pyroprocessing upgrades and rebuilds, including kiln burner upgrades and calcination upgrades. From waste incineration to steel and fertilizer plants, our tailored solutions help you optimise operations for the long-term.

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What can you achieve with your pyroprocessing upgrade?

  • Reduce energy consumption and emissions

    Optimise heat transfer, gas-solid interaction, and combustion efficiency to lower fuel use and emissions. Enhance thermal efficiency and sustainability with kiln burner upgrades, burner conversions, advanced kiln seals, and more pyrometallurgy upgrades.

  • Extend kiln life and improve reliability

    Targeted mechanical upgrades, including kiln section replacements and hydraulic thrust devices, reduce wear and stress, prolonging the lifespan of your pyroprocessing equipment and minimising downtime. Kiln equipment refurbishments help maintain peak performance over time, while also reducing your costs.

  • Enhance process control and flexibility

    Modern monitoring tools and internal kiln upgrades improve process stability, enable real-time insights, and support fuel flexibility - helping you adapt to changing production and regulatory demands.

Optimize your kiln performance and efficiency

Targeted pyrometallurgy upgrades to boost efficiency, cut emissions, and extend equipment life through strategic rebuilds and enhancements.

  1. 1

    Mechanical audits

    Identify wear, maintenance needs, and structural integrity to determine necessary repairs or replacements.

  2. 2

    Process audits

    Evaluate the entire pyro system to optimise thermal efficiency and gas flow.

  3. 3

    Computational Fluid Dynamics (CFD) studies

    Model and analyse gas and material flow for process improvements.

Seal in efficiency - reduce energy waste and emissions

Is your kiln losing energy? The issue could be your seal. Upgrading to the latest Graphite Kiln Seal prevents false air infiltration, minimises heat loss, and reduces dust emissions. By improving thermal efficiency and lowering fuel consumption, this upgrade cuts costs while delivering a fast return on investment. 

Frequently asked questions

FAQs for pyroprocessing upgrades, rebuilds and exchange

Calcination typically involves rotary kilns, shaft kilns, and fluidised bed reactors. Supporting equipment includes burners, preheaters, coolers, and gas scrubbers to control emissions. 

Pyroprocessing upgrades enhance the efficiency, reliability, and sustainability of high-temperature processing equipment like kilns, coolers, and dryers. These upgrades may include kiln burner conversions, seal improvements, internal modifications, and mechanical refurbishments. 

Yes, kiln bricks can be repaired using patching compounds or replacing damaged sections. However, severe damage may require a full brick lining replacement to restore structural integrity and thermal efficiency. 

The lifespan of a kiln depends on factors like operating conditions, maintenance, and materials used. With proper upkeep, kilns can last 30 – 50 years, though major refurbishments may be needed to extend their operational life.