Bricking Solutions

8/6/2019 Bricking Solutions

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Global Refractories Conference

CEMENT and LIME8-9 December 2008Cologne, Germany

Who's in Charge anyway, You or Your Kiln?

Speeding kiln refractory maintenance while keeping it safe

Xavier d'Hubert, Bricking Solutions


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Kiln Access

Removal of Old Refractories

Materials Handling

Installations of New Refractories

Kiln Safety

Safety Issues for Kiln Maintenance

Components, Innovationand Training


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Introduction

Sadly, we still have accidents in the Cement Industry during themaintenance of the Kilns / Precalciners / Coolers; and some are fatal.

Lets not forget that the kilns, preheaters/calciners, and coolers are hostilesplaces to work. These are confined spaces, often still hot, with difficult

access, dusty, dark, but more critical with potentially falling bricks, coatingor foreign objects. In addition there is the pressure to complete the jobquickly as a single day outage cost an average of 100,000 Euros of lost

production.

What are the issues:

Installing and moving the necessary equipments (bricking machines,

access ramps, ) outside and inside the kiln,

Removing and bringing inside the kiln hundred tons of debris, coating, old

and new bricks,

Do a quality job when installing the bricks as it is as important as the bricks

quality itself in ensuring a long life,

Do everything safely.


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Introduction

FLORIDA ROCK Winter 2005

Aalborg Cement Fall 08


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Kiln Access RampKEY FEATURES FOR THE KILN ACCESS RAMPS:

Safe & ease of installation, good procedures, light weight

Strength, to handle heavy load, to handle demolition machineoperating from the bridge

Accessories: V-rail to prevent fall while keeping wide passage,protection from bricks falling from hood roof

Quality of manufacturing (6061 T6 aircraft grade aluminum,welding,)

Yearly inspection (cracks, welds, .)

Cavities, lifting rings & eaves for easy kiln installation and

removal

Designed to support almost 7.000 kg with a 3:1 safety factor

Easy to assemble with bolt & pin connections


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Kiln Access Ramp


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Safety Inspection Cages & Tunnels

KEY FEATURES FOR THE SAFETY CAGES/TUNNELS

These are widely used to

a/ Allow walking inside the kiln with coating on or when bricks are loose to

make inspections, walk through to the kiln outlet to reach the inlet side.

b/ Can withstand 1.2 m fall of a 120 kg rock with a 3:1 safety factor,

c/ Provide a safe passage under the coated zone (under certain conditions)

The main criteria is the optimum mix between weight (light) and sturdiness(high)

Features that make the cages/tunnels easier to carry inside the kiln:Shoulder harnesses,

use of Bobcat/forklift for motorized transportLightweight aluminum construction allows for tunnel sections to be movedeasily

Legs can be adjusted for uneven terrain inside of kiln

Side can be lifted for easier inspectionFoldable cages when necessary


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Safety Inspection Cage & Tunnels


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Safety Inspection Cages & Tunnels


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Materials Handling Port-A-Track, Bedding Cart, Conveyor

KEY FEATURES FOR THE CONVEYING SYSTEMS

1. Limit the need for motorized engine inside the kiln, use conveyorsinstead (manual or pneumatic) (for safety reasons but also to protect

the bricks on the floor)

2. While inside the kiln, limit the handling of heavy loads,

3. Insure movements are predictable using railing,

Modular system for transporting full pallets of brick into kiln (Port-A-Track) with Brake system holds cart on track

Easily assembled and advances with a leap frog method using 1.5mand 3m track sections

Modular elements, hydraulic drive (Conveyor)

Near 3.000 kg capacity platform with large working space (beddingcart)

Stair step design reduces worker fatigue (bedding cart)


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Materials Handling Port-A-Trac, Bedding Cart, Conveyor


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Demolition MachinesKEY FEATURES FOR THE DEMOLITIONS MACHINES

Compact, can operate in low headroom

Tracks give excellent mobility can cope with 30o gradients, move

over and work on rubble

Designed to work with powerful hydraulic hammers

Flexible three-part arm ensures precise and quick positioning of

hammer moil point

Long reach

Accuracy

Subtle operation with no damage to shell or refractory to be retained

Remote control safe for the operator

Electric drive = no noise when hammer is not active and requires less

maintenance than diesel engine


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Demolition Machines


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KEY FEATURES FOR THE BRICKING MACHINES

Light weight for easy installation but extremely robust, capable ofreceiving 4,500 kg load,

Can me moved by hand,

Flexible to accommodate diameter variations,

Quality of constructions with aviation grade aluminum, certifiedwelders, certified design engineer, worldwide certifications

Adjust the arch in minutes with up to 4 easy arch adjustments utilizingscrew jacks or hydraulic jacks no tools required

Each arch has its own 3-way Master Valve that can be operated

independently or in unison

Large working platform 4.2m (4,500kg) or 5.2m (5,500kg)

Complete range of machines from Mini-Econ-O-Ring (1.2 m dia.) to

FDEF (4.2m to 6.8m dia, double arch, adjustable)

Bricking Machines


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Bricking Machines


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Bricking Machines


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Debris RemovalFEATURES:Quick-Hitch for most style loaders

Radiused leading edge to penetrate rubble andreduce machine and operator impact

Wear Plates on sides and bottom ensurelong life


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Brick Alignment

FEATURES:It ensures precise placement of brick

It produces a continuous light laser parallel in

the axis of kiln

A penta-prism device refracts the laserperpendicular onto the kiln circumference

The line can be marked on kiln as an exactreference for brick installation


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ARCH CARRIER

Designed to carry assembledBricking Machine arch in andout of kiln with a fork lift

Enables ring and scaffoldframes to be moved without

being disassembled.

Important Components

LASER TARGETDesigned to allow easy and fast setting of theburner in its position inside the hood/kiln.

Accessories are designed to facilitate the safe operation ofthe equipment, reducing handling, heavy lifting, reducing

time to set-up and use the equipments .


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INOVATIONS & TRAINING

Transfer for pallets of brick to the

burn floor or Preheater Inspection.

Angled conveyor withaccess to the rig.

Bricking Solutions are specialists. Consult withthem whenever a situation occurs that requires

an innovative approach. We have the rightengineering and manufacturing team to design

specific equipment

The best designed and built equipments

when poorly used wont help reduceaccident rates. It is very important to set inplace procedures for yearly inspection of theequipments (looking for welds, cracks)

New equipments should only be used after

proper training.


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KEY FEATURES FOR OTHER SYSTEMS:

Are developed with the clients, often tosolve a safety issue,

Are often inexpensive solutions to oldproblems,

Other Developments

EXEMPLE: (under development):

SCAFFOLDING FOR PREHEATER CYCLONES


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Conclusion # 1Beware of the imitations, not all bricking machines are created equal


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Conclusion # 2

There have been many innovations and progresses made in the field of

kiln refractory installation and maintenance over the years


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Conclusion # 3Safety and work conditions are key.


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Conclusion # 4

Xavier dHubert 33/ 9 52 80 55 93 [email protected]

Mr. Jacques at St. Lawrence reported the first usage of a Kiln Refractory Maintenance Systemnot only resulted in a 24 hour tear out time savings, but installation production rose from the

typical 1.5m of tops and bottoms per 8 hour shift to 6.1m of tops and 9.15m of bottoms per an 8hour shift.

With the use of a bricking machine and pallet mover system, Mike Kelly of Ash Grove Midlothianreduced their downtime, increase kiln usage factor, lowered lost time accidents, and increasedmorale. In Dec. of 2006, Mike reported that in 10.5 hours his crew of 10 installed 70 rows of brick.

The Aluminum Kiln Access Ramp, designed for Holcim Holly Hills, was easy to install, despiteits length, using the over-head sling installation method. One would expect a long aluminumbridge to have more flex than steel, however what flex was there while in use, was minimal & not

a concern, Bobby Compton, Industrial Services Company.

R&D Partner, Tom Van Cott, Safety Manager, needed a safe passage for men and material undercoating to effect repair and inspections in the upper transition zones. His inquiry led to the designof a Personnel Protection Tunnel System incorporated from Safety/Inspection cages. EssrocPicton has been successfully using the tunnel system since 2003.

Trust the expertise.

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