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Refractory installation in the cement rotary kiln

2019-06-14 11:14:32

The annual global refractory consumption of cement production is estimated to exceed 5 million metric tons, accounting for 12% of the world's total refractory market, and is still growing. The overall refractory material accounts for a large part of the market, up to 40%, which is a matter of course. It is faster and easier to install than refractory bricks, which is why up to 2.3 million tons of monolithic refractories are used each year. Due to equipment improvements and material innovations - such as cement-free, colloidal silica, which provides optimum alkali resistance and adhesion - the contractor is installing integral refractory materials in the cement kiln area and has been used in brick refractories. This includes the nose ring and the tail ring, also known as the inlet cone. These improvements and innovations also make brick refractory contractors easier and more cost effective.

Refractory in the Cement Rotary Kiln


Execution of the brickwork:

The implementation of the refractory lining can be achieved in two different ways: with or without the need for a rotary kiln. In fact, when using a screw jack or lining with a glue method, the kiln must be rotated three or more times so that the brick can be installed in the lower half of the kiln; using a bricklayer, the upper part of the brick is installed without rotation kiln. In order to avoid longitudinal movement of the ring, it is required that the structure of the lining should always be in the direction from the kiln outlet towards the inlet. The closure of the brick ring must be done without cutting the bricks. Various combinations of design shapes and closed bricks are sufficient to perform a good closure. In the longitudinal direction, the size of a single brick shall not be less than 95 mm, and the single ring shall not be less than 125 mm.

The ring must be closed and the bricks placed from the side, so the rings must be closed one by one and it is best to close the ring before entering the next ring. When preparing to close the ring during the first test, determine the desired brick-shaped mixture and check that the faces of the bricks forming the last joint are coplanar. If not, the mortar must be used for correction. Mixing of standard shapes and key bricks for direct joints up to 4-6 mm thick; the remaining space must be achieved by inserting up to 2-3 steel plates (2 mm thick) so that the correct compression of the ring is achieved. In the absence of open joints, the brick combination is perfect, permanent brick inserts never hit the brick directly with a hammer, but a layer of wood must be inserted. All bricks that may be damaged during the closing operation must be replaced with perfect bricks.

Refractory Installation in the Cement Rotary Kiln


Refractory Installation in the Cement Rotary Kiln:

Installing refractory bricks in cement rotary kiln

The installation of refractory bricks in cement rotary kiln is divided into two types.

Refractory installation and rotation in a rotary kiln

This refractory installation is only suitable for rotary kiln diameters less than 4 meters.

It is only suitable for installing a small number of bricks.

It requires a longer installation time than a non-rotating refractory installation.

The low investment costs of supports and fittings as well as bricklaying equipment are its main advantages.

The necessary requirements for kiln transfer during installation may affect other follow-up work.

There are several refractory installation methods for the rotation of the rotary kiln, which are as follows;

Refractory gunning machine in the Cement Rotary Kiln





Refractory Installation


Screw jack method:

Install the refractory bricks on the lower half of the rotary kiln for approximately 1-3 meters, then suspend the installation and continue the construction below.

A rectangular wooden slat is placed on the installed bricks along both sides of the kiln shaft, and then the wooden slats are pressed against the installed bricks using a screw jack. 

 
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