SRIC InstallTechnique

8/16/2019 SRIC InstallTechnique

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Refractory InstallationRefractory Installation

For cement Rotary KilnFor cement Rotary Kiln

11THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES


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What did affect to refractory life?What did affect to refractory life?

Quality of Refractor Quality of Refractoryy The Correct InstallationThe Correct Installation


OperationOperation ProcessProcess


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Refractory installation’s RequirementsRefractory installation’s Requirements

1)1) Installed with qualificable acceptance.Installed with qualificable acceptance.

2)2) Optimum time or suitable scheduleOptimum time or suitable schedule

33

. .

THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES


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Refractory Installation forRefractory Installation forRotary KilnRotary Kiln

11)Preparation before shutdown.)Preparation before shutdown.

44

Gap, migration ,Kiln Ovality Check.Gap, migration ,Kiln Ovality Check. Interpret & AnalysisInterpret & Analysis

Mechanical AdjustmentMechanical Adjustment



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Kiln Ovality CheckKiln Ovality Check



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Kiln Shell ReplacementKiln Shell Replacement

in case shell too thinin case shell too thin



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22) Refractory Materials Checking() Refractory Materials Checking(33 months Earlier)months Earlier)-- 33 monthsmonths before shutdown shall check.before shutdown shall check.

Quality of materials, appearance, Package.Quality of materials, appearance, Package.

Quantity of Material, classification, sparedQuantity of Material, classification, spared

refractory.refractory.

77

-- 22--44 weeksweeks before shut down or final check is verybefore shut down or final check is very

important.important.



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Brick Combination.

DiameterDiameter 44..66 mmISO Shaped brickISO Shaped brick 620620 :: 420420

78 : 62 4:3

VDZ Shaped Brick BVDZ Shaped Brick B 620620 : B: B420420


4848 :: 145 1145 1::33

ISO Shaped brick less shortage problem, linedISO Shaped brick less shortage problem, lined

faster & stronger than VDZ Shaped brick.faster & stronger than VDZ Shaped brick.


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Warehouse & Material handling



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33) Machines, tools Equipment checking) Machines, tools Equipment checking-- DeDe--bricking Machine.bricking Machine.

-- materials Transferred Machine.materials Transferred Machine.

-- Bricking Machine.Bricking Machine.-- Pneumatic jack hammer.Pneumatic jack hammer.

-- Concrete mixing machine.Concrete mixing machine.

1010

-- Brick Cutting Machine.Brick Cutting Machine.-- Forklift, lifting hoist, belt conveyer.Forklift, lifting hoist, belt conveyer.

-- Bridge.Bridge.

-- Lighting, welding & Carpenter tools etc.Lighting, welding & Carpenter tools etc.



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44)Man power preparation.)Man power preparation.11 month before shutdown.month before shutdown.

-Training the precaution & safety course.

- Refractory knowledge.

- Refractory installation knowledge.

1111

- Skilful & trained man-powers needs.



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Preliminary work before dePreliminary work before de--bricking.bricking.

Refractory Inspection after kiln cooled down.Refractory Inspection after kiln cooled down.--2424 hours afterward, prepare to inspect physicalhours afterward, prepare to inspect physicalcoating forming, coating thickness, smoothly,coating forming, coating thickness, smoothly,length, Refractory appearancelength, Refractory appearance

--Record, pictureRecord, picture

1212

--Abnormality, damage, worn, samplingAbnormality, damage, worn, sampling11) line of used brick might displaced from before.) line of used brick might displaced from before.

22) Cracking, spalling, Damaged feature.) Cracking, spalling, Damaged feature.

33) Remaining thickness Drilling, UT.) Remaining thickness Drilling, UT.



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Remaining ThicknessRemaining Thickness

UT Tester UT Tester.


Drilling methodDrilling method..


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-Correct all necessary data, analysis and evaluate to

improve refractory life time such as

1) Applied Ceramic Fiber to release stress fromthermal expansion & uneven brick retainer.

2) 2) Mortar Applied at tyre or high mechanical

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3) Select suitable refractory for necessaryapplication

-Resume all data and linkage to operating condition.



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*Plan to locate refractory to be replaced.*Plan to locate refractory to be replaced.

Coating and Brick Dismantling.Coating and Brick Dismantling.

CoatingCoating

--Chipping from kiln outlet to kiln inletChipping from kiln outlet to kiln inletdirection.direction.

SRIC

1515

* De* De--bricking machine.bricking machine.


Coating removing


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BrickBrick

--Chipping from kiln inlet to kiln outlet direction.Chipping from kiln inlet to kiln outlet direction.

* De* De--bricking bricking machine, Temporary brickbricking bricking machine, Temporary brick

stopper in case partial replacement and preventstopper in case partial replacement and preventsliding of existing bricks.sliding of existing bricks.



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BrickBrick

--Removing damage brick and waste from rotary kiln.Removing damage brick and waste from rotary kiln.

•• By Man hole, Rotate and drop to cooler, ManuallyBy Man hole, Rotate and drop to cooler, Manually

removingremoving



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Kiln Shell inspectionKiln Shell inspection

--Deformed Area & Marking with color spray.Deformed Area & Marking with color spray.

--Scaling, rust & acidic coated on shell, sand blasting.Scaling, rust & acidic coated on shell, sand blasting.

--Shell welding joint, another welding spot, kiln mark.Shell welding joint, another welding spot, kiln mark.

1818

Horizontal welding jointHorizontal welding joint

Vertical welding jointVertical welding joint



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Transportation of refractory to kiln.Transportation of refractory to kiln.



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How to correctly carry out theHow to correctly carry out thebricking of cement rotary kiln?bricking of cement rotary kiln?

--Installation methodInstallation method--Kiln rotation Screw jack, gluing, channel method.Kiln rotation Screw jack, gluing, channel method.

2020

--wooden mouldwooden mould

PneumaticPneumatic – –OO--Ring.Ring.



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Bricking with kiln rotationBricking with kiln rotation

Screw jack.Screw jack.

-- Lining achieved by laying a half section longLining achieved by laying a half section long 55--1010 meter and tighten with screw jack.meter and tighten with screw jack.



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Bricking with kiln rotationBricking with kiln rotationchannel methodchannel method

--The method was applied from screw jack method.The method was applied from screw jack method.

Bricks have been laid and tighten with channel andBricks have been laid and tighten with channel andfasten with bolt and nut.fasten with bolt and nut.

2222

Wood wedge Welded nut

Channel steel



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Bricking with kiln rotationBricking with kiln rotation

Gluing method.Gluing method.

-- Lining achieved by applied epoxy resin &Lining achieved by applied epoxy resin &

hardener withhardener with 55 pieces of brick longpieces of brick long 55--1010 meter.meter.

install nextinstall next 55--1010 pieces same length without glue.pieces same length without glue.

2323

onsequence to t e prev ous w en g ue sonsequence to t e prev ous w en g ue salready hard.already hard.



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Bricking without kiln rotation.Bricking without kiln rotation.Formwork method.Formwork method.

11)Formwork or contour )Formwork or contour -- use wooden made arch support, hydraulicuse wooden made arch support, hydraulic

ack and wood wed e for insist brick linin .ack and wood wed e for insist brick linin .

2424



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Bricking without kiln rotation.Bricking without kiln rotation.22) Pneumatic or Mult) Pneumatic or Mult--OO--Ring.Ring.

-- Applied from pneumatic cylinderApplied from pneumatic cylinderindependently with arch support to install aindependently with arch support to install a

2525



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Methodize and it’s comparisons.Methodize and it’s comparisons.

Kiln rotation method.Kiln rotation method.

11) advantage) advantage

-- Simple method regarding to necessary equipment.Simple method regarding to necessary equipment.-- Low investment cost.Low investment cost.

22) Disadvantage) Disadvantage

2626

-- n as o e ro a e ur ng n ng process.n as o e ro a e ur ng n ng process.-- Take risk if bricks are not adequately fastened and slip.Take risk if bricks are not adequately fastened and slip.

-- Ring cannot be tightened prior closing.Ring cannot be tightened prior closing.

-- Kiln diameter larger thanKiln diameter larger than 44 meter might cause screwmeter might cause screw jack slipped & shell distorted. jack slipped & shell distorted.



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Methodize and it’s comparisons.Methodize and it’s comparisons.

Without kiln rotation method.Without kiln rotation method.

11)) advantageadvantage

-- Safe in operation.Safe in operation.

-- Gain accurate brick installed for brick ratio and conform to shell.Gain accurate brick installed for brick ratio and conform to shell.-- Kiln does not to be rotated.Kiln does not to be rotated.

-- Suitable for small and large kiln diameter.Suitable for small and large kiln diameter.

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-- Highest speed up bricking rate.Highest speed up bricking rate.-- Manage and relate in parallel activities.Manage and relate in parallel activities.

22) Disadvantage) Disadvantage

-- Very high cost on an equipment .Very high cost on an equipment .

-- High affordability to assemble an equipments.High affordability to assemble an equipments.



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Installed rate in each methodInstalled rate in each method

Rotation method m2/hour m2/manpower

Screw jack method 1-3.5 0.17-0.25

Gluing method 3-7 0.4-1.2

Channel method less than gluing 0.2-0.5

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Formwork method

Formwork or Contour 1.8-3 0.1-0.2

M-O-R (Clench or dry

mortar) 9.5 0.75

M-O-R (With mortar) 6.5 0.5



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Kiln Rotation and place Man hole atKiln Rotation and place Man hole at 66 OO

oo

ClockClockThe Center line will be checked with accurate tools.The Center line will be checked with accurate tools.

--Aluminum bar dimensionAluminum bar dimension 2525xx5050xx30003000 mm.mm.

--Leveling bar Leveling bar --Plumb bobPlumb bob

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-- ompass.ompass.--Nylon wireNylon wire

--Measuring tape.Measuring tape.

--Chisel ,Steel Hammer ,Color spray.Chisel ,Steel Hammer ,Color spray.



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Center line and Cross section line byCenter line and Cross section line by Kiln RotationKiln Rotation

fixed.fixed.

11) Place an aluminum bar on kiln outlet crossways.) Place an aluminum bar on kiln outlet crossways.



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22) Check aluminum bar and adjust level with leveling) Check aluminum bar and adjust level with levelingbar bar



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33)Place & made Plump bob on level to center of)Place & made Plump bob on level to center of

aluminum bar. (calibrated form QSD)aluminum bar. (calibrated form QSD)44) Gently spot the end of plum to kiln shell.) Gently spot the end of plum to kiln shell.

55) Marking with Chisel and spray the point round) Marking with Chisel and spray the point roundshaped color.shaped color.

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½ L½ L½ L½ L



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66) Every) Every 55 meter check the center points.meter check the center points.

77) Draw string wire from beginning point to last point.) Draw string wire from beginning point to last point.

88) Spray color cover string and remove string off.) Spray color cover string and remove string off.



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33..44 Circumferential lines or radial controlled lines byCircumferential lines or radial controlled lines by

Kiln rotation fixed..Kiln rotation fixed..

--Separated the center line with compass and crossSeparated the center line with compass and cross

exactlyexactly 11 meter along.meter along.

3434

0 1 2 3 4 5 6 7 80 1 2 3 4 5 6 7 8 99 10 11 12 1310 11 12 13 1414



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-- Use pointUse point 11,,33,,55….and point….and point 00,,22,,44,,66…..set for…..set for

crossing With compass radiuscrossing With compass radius 11..88 meter.meter.

3535

0 1 2 3 40 1 2 3 4 5 65 6

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

WORLD CLASS REFRACTORY PRODUCTS AND SERVICES


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3636




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-- Draw more the lateral lines which achieved fromDraw more the lateral lines which achieved from

crossing pattern.crossing pattern.

0 1 2 3 40 1 2 3 4 5 65 6

3737

0 1 2 3 40 1 2 3 4 5 65 6

0 1 2 3 40 1 2 3 4 5 65 6




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--Extended scaffolding and draw higher lateralExtended scaffolding and draw higher lateral lineslines

and cross section line together.and cross section line together.

-- The half upper section will do during bricking.The half upper section will do during bricking.

3838




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Center line and Cross section line byCenter line and Cross section line by Kiln Rotation.Kiln Rotation.

--Check and draw center line then rotate kilnCheck and draw center line then rotate kiln 2020oo

alternately’alternately’

-- Separated the center line in every meter.Separated the center line in every meter.

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0 1 2 3 4 5 6 7 80 1 2 3 4 5 6 7 8 99 10 11 12 1310 11 12 13 1414




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--Rotate kilnRotate kiln 2020oo and check the second center line.and check the second center line.

0 1 2 3 4 5 6 7 80 1 2 3 4 5 6 7 8 99 10 11 12 1310 11 12 13 1414

4040

0 1 2 3 4 5 6 7 80 1 2 3 4 5 6 7 8 99 10 11 12 1310 11 12 13 1414




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--Turning approximatelyTurning approximately 1616 times and draw thetimes and draw the

center lines with cross section lines until completed.center lines with cross section lines until completed.

-- Actually it is very necessary to check center lineActually it is very necessary to check center line

on the last line according to Manon the last line according to Man--hole athole at 66 O’clock.O’clock.--During turning kiln,During turning kiln, cleaning, repairing ,kilncleaning, repairing ,kiln

4141

done at the same time.done at the same time.




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4242

Checking & marking shellChecking & marking shelldeformationdeformation




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Bricking.Bricking.

--Use Channel bar or HUse Channel bar or H--beambeam 100100xx100100xx30003000 mm.mm.placeplace align to the center line.align to the center line.

-- Support the other side of HSupport the other side of H--beam with heavilybeam with heavily

substances such as bricks.substances such as bricks.

4343

4 5 6 7 8 94 5 6 7 8 9 10 11 12 1310 11 12 13 1414



Brick patternBrick pattern


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11)Straight joint pattern.)Straight joint pattern.

Brick patternBrick pattern

4444

. .




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11) Always clean dirt away from kiln shell.) Always clean dirt away from kiln shell.22) Place Channel bar along and aligned to the center) Place Channel bar along and aligned to the center

line.line.

33) Gently install first course of brick from brick) Gently install first course of brick from brick

retainer or existing brick as figure.retainer or existing brick as figure.

4545



Straight joint pattern.Straight joint pattern.


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4646



Stagger joint or Bonded patternStagger joint or Bonded pattern..


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4747




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4848



Kil d f tiKil d f ti


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Kiln deformationKiln deformation

-- Nominated brick ratio by installedNominated brick ratio by installedfrequently larger or smaller size more onfrequently larger or smaller size more on

deformed area.deformed area.

-- 22 oror 33 mm. different in level can adjustmm. different in level can adjustwith mortar.with mortar.

4949

-- DuringDuring 44--88 can threat the deformed shellcan threat the deformed shellwith plastic refractory or fine grain sizewith plastic refractory or fine grain sizecastable.castable.



Convex deformed kiln shellConvex deformed kiln shell


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XX

5050

XXTHE SIAM REFRACTORY INDUSTRY CO.,LTD.




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5151




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Welding Joint

5252



Wrong combinationWrong combination


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Wrong combinationWrong combination

XX XX

5353

Larger brick lined more than ordinaryLarger brick lined more than ordinary

Smaller brick lined more than ordinarySmaller brick lined more than ordinary



Ri h C bi iRi h C bi i


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Right CombinationRight Combination

5454





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Mortar applied here

5555



Concave deformed kiln shellConcave deformed kiln shell

Mortar applied here

Mortar applied at lower and upper section


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Mortar applied at lower and upper section

5656



Prohibit for using


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Prohibit for using

adjustable plates.

XX

5757



XX

Reasons

-Loose lining.

-Interfaced cracking

-- Remove channel bar and wooden spacer off clean allRemove channel bar and wooden spacer off clean all


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Remove channel bar and wooden spacer off, clean allRemove channel bar and wooden spacer off, clean all

dirt, install the adjacent section alongdirt, install the adjacent section along 88--1010 meter thenmeter thenassemble MOR.assemble MOR.

5858



Bricking at brick retainerBricking at brick retainer


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Bricking at brick retainer.Bricking at brick retainer.

1)cutting brick as shape and cover brick retainer

Material flow

5959

.

Low cement castable C-60-A



Bricking at brick retainer.Bricking at brick retainer.


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33) install with brick and castable.) install with brick and castable.

6060



Install brick at tyre area or high mechanical stress areas.Install brick at tyre area or high mechanical stress areas.


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- Motar is being trowelled 1-2 mm. thick at axial& radialbrick sides at tyre area 3-5 meter long.

- Or use the pre mortared brick.

6161



3-5 meters 3-5 meters 3-5 meters

Install brick at tyre area or high mechanical stress areas.Install brick at tyre area or high mechanical stress areas.


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Mortar applied at radial& axial sides.

6262



Pre mortared brick

Brick cutting principle.Brick cutting principle.


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1) The cutting ring shall be remain 2/3 off original length.2) From brick retainer nor existing ring brick at the adjacentmust be original length.

3) Whenever cut more than 1 ring,The cutting ring must beseparated.4) Cutting many rings take long time and high cost, Special

6363

.

L

X

BRICK STOPPER



Brick cutting principle.Brick cutting principle.


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1)1) 22//33 L< X < LL< X < L 11 Ring CutRing Cut

2)2) 11//33 L< X


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Cut Cut

6565



How to install a half upper section.How to install a half upper section.


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pppp

Set up MultSet up Mult--OO--Ring.Ring.

--Assemble platform, support rack.Assemble platform, support rack.

--Connect and adjust arch support.Connect and adjust arch support.--Pneumatic hose, connecting coupling, control valve.Pneumatic hose, connecting coupling, control valve.

6666

--Check all joint, spacer rod, clearance interval kilnCheck all joint, spacer rod, clearance interval kilnshell and rubber plate simultaneously.shell and rubber plate simultaneously.

--Space between brick surface to rubber plates mustSpace between brick surface to rubber plates must

be adjusted tobe adjusted to 100100 mm.mm.



--In case the distance between rubber and brickIn case the distance between rubber and brick


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In case the distance between rubber and brickIn case the distance between rubber and brick

surface is misaligned, adjust the height of platformsurface is misaligned, adjust the height of platformor radial of arch support needed.or radial of arch support needed.

--UnUn--uniform of intervening distance of brickuniform of intervening distance of bricksurface and rubber can cause some brick loosensurface and rubber can cause some brick loosenduring installation proceeding.during installation proceeding.

6767

--Check air pressure, main air requiredCheck air pressure, main air required 55 barbarminimally.minimally.

--Lubrication oil for trapping water condensed inLubrication oil for trapping water condensed in

hose need to be replaced from filter.hose need to be replaced from filter.



Set Up Mult-O-Ring


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6868



--lay up brick in both sides and open cylindrical valve onelay up brick in both sides and open cylindrical valve one


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brick per cylinder.brick per cylinder.--Applied hard surface plastic hammer in each brick duringApplied hard surface plastic hammer in each brick during

install frequently.install frequently.

-- brick ring can be closed by pressing at axial side withbrick ring can be closed by pressing at axial side withpneumatic jackpneumatic jack approximatelyapproximately 28002800--30003000 kg/cmkg/cm22..

6969

-- e ease pressure a pneumat c va ves an removee ease pressure a pneumat c va ves an remove

Arch support to next ring.Arch support to next ring.

-- On the prior ring, utilized the first set of pneumatic set toOn the prior ring, utilized the first set of pneumatic set tosupport prior brick ring and remove pneumatic jack.support prior brick ring and remove pneumatic jack.



--Check the distance from left & right of closing andCheck the distance from left & right of closing and


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calculated or simulate by use installed brick.calculated or simulate by use installed brick.--Follow the precaution, avoiding and try best ratio, minimallyFollow the precaution, avoiding and try best ratio, minimally

key brick, separated when it were being keys. By mean ofkey brick, separated when it were being keys. By mean of

maximum tighten ring without any damage or displacementmaximum tighten ring without any damage or displacementlater.later.

7070

-- --

maximum allowed until ring tighten enough is accepted.maximum allowed until ring tighten enough is accepted.--While ring closing period, the next ring shall be installedWhile ring closing period, the next ring shall be installedbrick up.brick up.



Closing the ringClosing the ring


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--Applied pressureApplied pressure 28002800 kg/cmkg/cm22 safesafeenough for tightening the ring.enough for tightening the ring.

7171



Closing the ringClosing the ring


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Key Bricks

Steel shim 4 pcs, maximum, 2-3mm., thk.

Key Bricks

Steel shim 4 pcs, maximum, 2-3mm. Thk.

7272

X

X



Closing the ringClosing the ring MS-80-AF

620 420 P20 P+20 D d


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620 420 P20 P+20 D d

5 2 1 0 804 741

4 2 0 2 804 741

4 3 1 0 804 738

3 3 0 2 804 738

3 4 1 0 804 734

2 4 0 2 804 7342 5 1 0 804 731

4 2 1 1 794 731

3 2 0 3 794 732

7373



2 3 0 3 794 728

2 4 1 1 794 724

4 2 2 0 784 721

3 2 1 2 784 722

2 2 0 4 784 722

3 3 2 0 784 718

2 3 1 2 784 718

2 4 2 0 784 714

3 2 2 1 774 712


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7474




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7575



Final check and ring tightening


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7676



Steel Anchors With Plastic Cap.Steel Anchors With Plastic Cap.


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Flat bar ShapeFlat bar ShapeFlat barFlat bar – –footing with holder.footing with holder.

7777

Round, rod TypeRound, rod Type Corrugated TypeCorrugated Type Corrugated shape with holder Corrugated shape with holder



Stainless anchor property.Stainless anchor property.


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Stainlesssteelgrade Composition

Scalingtemperature

AISI 253 MA %C


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-Bricking first and casting at kiln outlet & inlet together.

-Casting during center line made.

-Ceramic paper applied for resist brick on the adjacent of nose ring

broken.

7979

- Followed castable user guide whenever castable must be installed.

Ceramic fiber board 10 mm.Thk.

High Alumina Brick

KB-70-PB,BX-80

Low cement castable 60%



Kiln outlet castingKiln outlet casting..


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AnchoringAnchoring

--Welding suitable anchor SUSWelding suitable anchor SUS 310310, SUS, SUS 253253 MA with weldingMA with welding

electrodeelectrode

--AWSAWS 309309,, 310310..

8080

-- Visually checking, Impact test.Visually checking, Impact test.





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Expansion joint

- ply wood 3 ,4 ,5, and 10 mm.

-Ceramic fiber blanket 1260 o C 5 mm and 12.5 mm.thk.

Casting Mould

8181



-Wooden form-Steel mould.



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8282



Ceramic fiber board 10 mm.thk

Some problems might be found while castingSome problems might be found while casting


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Impurity in panImpurity in pan--mixer & Surroundingmixer & Surrounding

Flash Setting or Rapid setting of castableFlash Setting or Rapid setting of castable

8383



1)1) Clean all equipmentClean all equipment

2)2) Use only drinkable water while mixing.Use only drinkable water while mixing.

3)3) Cooled down castable & surroundingCooled down castable & surrounding

mme ate y act onmme ate y act on

Some problems might be found while castingSome problems might be found while casting


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Castable not setting or very long time settingCastable not setting or very long time setting

Immediately actionImmediately action

1) Reduce mixing water.

8484



2) Installed some heater fan & spot light.

3) Add some accelerator.

Documents

SRIC InstallTechnique