Chapter 3 Refractory Installation in the Cement Rotary Kiln

$Page 1: Chapter 3 Refractory Installation in the Cement Rotary Kiln$
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REFRACTOTRY INSTALLATION TECHNIQUES

IN CEMENT INDUSTRY

Chapter 3 Refractory Installation in the Cement Rotary Kiln

3.1 Installation of refractory bricks in the Cement Rotary

Kiln

The installation of refractory bricks in the Cement Rotary Kiln

is classified into 2 types.

3.1.1 Refractory installation in the Rotary Kiln with

rotation

- This type of refractory installation is only suitable for

Rotary Kiln that has less than 4 meters in diameter.

- It is only ideal for small quantity of bricks to be

installed.

- It requires longer installation time compared to

refractory installation without rotation (see 3.1.2)

- Low investment cost for support and accessories and

bricking equipment are its major advantages.

- The necessary requirements for kiln rotations during the

installation may affect other subsequent works.

- There are several methods of refractory installation with

a rotation of Rotary Kiln, they are as follows;

3.1.1.1 Screw Jack Method

- The procedures to be followed starting from the

beginning are shown in 3.1.2.1 - 3.1.2.5, discussed in

the succeeding sections.

- Install the refractory bricks on the lower-half portion of

the Rotary Kiln, for about 1-3 running meters, then

pause for installation break and proceed with the

instruction below.

- Place the rectangular timber battens against the installed

bricks on both sides along the kiln axis, then the timber

battens are pressed against the installed bricks using the

Screw Jacks, as shown in Fig. 3-1 and Fig. 3-2.

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Fig. 3-1: Picture of Screw Jack

Fig. 3-2: Pictures illustrating the use of timber batten and Screw

Jack in pressing against the installed bricks

Screw Jack

Sharp pins for pressing

the timber batten

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- The distance between the individual jacks should not be

more than 80cm.

- Tighten the jacks as tight as they can be, as shown in

Fig. 3-3.

Fig. 3-3: Picture illustrating the Screw Jacks tightening

- Inspect any bricks that are not directly pressed by the

Screw Jacks, they should be tightened using wooden

wedges, in order to prevent them from falling while

rotating the Rotary Kiln, as shown in Fig. 3-4.

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Fig. 3-4: Picture illustrating the use of wooden wedges to

tighten the bricks in each ring

- After the inspection, remove all refractory and

equipment from the Rotary Kiln, then rotate the Rotary

Kiln by 90 degrees, and then continue the same

procedures as in the beginning, as shown in Fig. 3-5 and

Fig. 3-6.

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Fig. 3-5: Picture of the Rotary Kiln ready for rotation

Fig. 3-6: Picture of the Rotary Kiln after a 90 degrees rotation

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- Proceed until all refractory bricks are installed

completely in full rings, and repeat the same procedures

until all are completed, as shown in Fig. 3-7.

Fig. 3-7: Picture illustrating the proceeding installation of

refractory bricks to completion

3.1.1.2 Gluing Method

- The procedures to be followed starting from the

beginning are shown in 3.1.2.1 - 3.1.2.5, discussed in

the succeeding sections.

- The adhesive glue consists of resin mixtures with

Hardener.

- The surface to be glued must be kept clean and dry at all

times; the presence of contaminants will affect the

adhesive performance.

- The procedures are shown in Fig. 3-8.

- Begin with section I, install the refractory bricks about

5-6 pieces and leave them until the glue dries up.

- Soon after, install about 10-15 pieces of refractory

bricks in counter clockwise direction, without gluing.

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- Repeat the same procedure with glue as in section II,

install about 5-6 pieces of refractory bricks and leave

them until the glue dries up.

- Rotate the Kiln in clockwise direction and place the

installation area in a convenient position for installation.

- Repeat until all refractory bricks are installed in the full

rings completely.

- It should be noted that the glue to be used must be

within the range of its shelf life, since the bonding

property could degrade if the glue is kept for longer than

its shelf life.

Fig. 3-8: Picture illustrating refractory installation in the

Rotary Kiln with rotation, gluing method

3.1.1.3 Channel or bolt & nut method.

-The method was applied from screw jack method. The

Equipment usage in this method similar to screw jack

method. Only if it doesn‟t use screw jack the important tools are

M-20 bolt, nut, two sides screw bar with 20 mm diameter and

250 mm length, special washer, electric drill, Channel steel or

10x10x400 cm Harden wood and transformer for welding Nut

with kiln shell are required for installation as following;

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1. Cleaning and marking the center line are the first

things for rotary kiln work.

2. Selecting the straight pattern of brick laid which is

easily manage and control the quality of installation.

3. Installing brick by starting at the center line, this

method need 12 meter length and less 25 pieces axial

lay.

4. The marking of nut for welding on kiln shell is

measured in every 5 courses. It has to be cut the side

edge of wedge type brick as shown in the below picture:

In case of gluing application, corner cutting is not

necessary.

Fig. 3-9: Picture illustrating the corner and side cutting brick.

5. Marking every 1 meter length along the kiln and 25

courses of the brick circumference distance then weld

M-20 nut.

6. Using the distance of welded location, drill the 22-

23mm diameter through channel steel or harden wood

7. The special washer can be prepared by cut steel sheet

5 mm thickness, 40*40 mm width and drill 25 mm hole

for washer attachment.

8. Installing cutting bricks by connecting both of cutting

bricks as shown in the below picture.

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Fig. 3-10: Picture illustrating position of fasten installed brick

with kiln shell.

9. The connection of 4 bricks was shown in the picture

which is it need to be installed at higher 3 or 4 courses

more.

10. Screw the steel rod and twist it tightly with the

welded

Nut inside the cutting‟s bricks hole. And lay down the

channel steel or harden wood by placed it over the bolt.

11. Insert special washer and cover it with the cover nut

then

Firmly and tightly twist it.

12. In case of incurring gaps between support steel or

wood bar, wood wedge can be applied by shimming

between brick and channel steel.

13. The fasten bolt and nut shall do the both sides which

already fixing. Next procedure, Kiln rotation needs to

rotate one eighth of the circular length.

14. Install brick with the same pattern. If kiln shell

distorted, mortar can trowel for adjustment.

15. Turn the rotary kiln until reaching its end position.

And brick can be installed only from left or right hand

side direction. Cutting or shimming for tightening brick

courses is necessary.

16. When bricking completed for whole brick courses,

Nut, washer, Channel steel and steel stud will be

removed out.

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17. Starting from the first step again until the bricking

work is done then follow the same procedures for the

next position.

The most important thing is to install and rotate no more than 12

Meters long. If installing distance is longer than separate area, it

is necessary to make sure by turning going well.

18. Seal all the cut brick holes with reliable material such as

C60A castable or Ram it with plastic 80.

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Fig. 3-11: Picture illustrating refractory installation by

Bolt and nut method.

Fig. 3-12: Picture illustrating refractory installation in the rotary

kiln with rotation, bolt and nut method.

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Advantage of bolt & nut method

The advantage of this method is similar to the Screw

jack method. However it is more useful in terms of no

obstruction from Screw jack and longer installation as

well as faster for one time installation compared to

screw jack method.

Disadvantage of bolt & nut method

The weakness is to cutting brick and fulfill it with

castable; which might run not so long, due to the low

quality of product or non-standard installation.

3.1.2 Refractory Installation in the Rotary Kiln without

rotation

- This type of refractory installation is suitable for Rotary

Kiln that has more than 4 meters in diameter.

- The refractory installation time is shorter than

installation with rotating.

- It has higher investment cost for accessories support and

bricking equipment.

- Mult-O-Ring machine is used as bricking equipment.

The refractory installation without rotating the Rotary Kiln has

the following procedures:

3.1.2.1 Cleaning of rotary kiln shell surface

- The kiln shell surface must be cleaned; the cleaning

includes de-scaling and removal of any foreign materials

such as mortars, dusts, and etc. The cleaning could be

done by sand- blasting, grinding, and etc., and

equipment to be used may include de-scaling hammer,

brush, and broom.

- The foreign materials may cause uneven kiln shell

surface and affect the quality of installation in the kiln

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lining which will result in loose installation of bricks

against the kiln shell.

3.1.2.2 Positioning of the Rotary Kiln

- The positioning of the Rotary Kiln should be rotated

wherein the manholes and deformed kiln shell areas are

located at the bottom (at 6 o‟clock) which is necessary

for easy and quality installation. 3.1.2.3 Locating the center reference line

- It is essential to locate and draw the center line reference

of the Rotary Kiln. Use the Levelling Bar and plumb to

mark the center points in every 1-2 meters and connect

the points to serve as center reference line. The more

center points from outlet through inlet direction could be

utilized to check kiln shell alignment and accuracy of

the centre line. The corrected centre line can count on

the harmony of most of center points. The marking

acceptance per center line is 80% of all center points.

- The most important thing is that center line which

marked with 2 center points is highly in risk of incorrect

line deviation. The incorrect center line marking will

cause alignment of bricking ring to be wrong and

shorten brick life. The quality of misalignment bricking

installation could be obviously notice as snaking brick

line.

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Fig. 3-13: Locating the center point of the Rotary Kiln by using

the Leveling Bar and Plumb 3.1.2.4 Drawing of circumference lines

Center line and Cross section line by Kiln non

Rotation

- After the center reference line is drawn, draw the

circumference line after every 1 meter interval from the

center reference line using a Steel Compass, 1- 2 meter

length, to locate and mark the intersection of two curve

lines, as shown in Fig. 3-14.

- Draw the circumference line fully along the

circumference of the Rotary Kiln by connecting the

intersection marks, as shown in Fig. 3-15. The lines are

used for controlling and monitoring the alignment of

refractory bricks installation.

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Fig. 3-14: Picture illustrating the use of Steel Compass to locate

and mark the intersection of two curve lines

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Fig. 3-15: Picture demonstrating the drawing of the

circumference lines in every 1 meter along the

circumference and throughout the length of the

Rotary Kiln where the refractory bricks are to be

installed.

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- In addition, if the Retaining Rings are to be used as

reference to draw the circumference lines, it must be

ensured that the Retaining Rings have been aligned and

welded correctly to prevent an erroneous reference point

and, consequently, an incorrect alignment of the

circumference line drawn.

Center line and Cross section line by Kiln Rotation.

- This method is easier than the non kiln rotation method

by just checking and drawing center line then rotating

kiln every 20 degree. The center line can be drawn by

several center points and alternatively draw along with

kiln rotation.

- Certer line must be exactly separated for every meter

with steel compass.

- Turning approximately 16 times and drawing 1 meter

marking point from the center lines, called cross section

lines, until completed.

- Actually it quit very necessary to check center line on

the last line according to Man-hole at 6 O‟clock.

- During turning kiln, cleaning, repairing, kiln

deformation checking & marking brick location can be

done at the same time.

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Fig. 3-16: Picture illustrating kiln center line and

radial controlled lines marking.

3.1.2.5 Starting procedures for refractory brick installation

- Place the Angle-Bar Steel (or any alternative) on the

center reference line, press one side by putting weighs

(use of bricks) to fix the Angle-Bar in place and prevent

it from moving. Then start installing refractory bricks on

the other side for about 3-5 pieces along the reference

center line for 2-3 running meters in a row, as shown in

Fig. 3-17.

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Fig. 3-17: Picture illustrating the refractory bricks installation

after the center reference line is drawn

- Remove the Angle-Bar Steel, and start to install the

refractory bricks on the other side, the installation shall

be balanced on both sides (left-right) throughout the

Rotary Kiln.

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Fig. 3-18: Picture illustrating a balanced installation of the

two sides- left and right

3.1.2.5.1 Non- Parallel Joint (Stagger Joint) installation

method

- For brick installation at the non-parallel (stagger) joint

of refractory, a piece of wood (the same length and half

thickness of the refractory bricks) is required to place

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alternately in every ring at the beginning point of

refractory brick installation on that ring (from the

reference center line alignment), thus obtaining stagger

joints between each ring, as shown in Fig. 3-19.

Fig. 3-19: Picture illustrating the stagger joint of refractory

bricks installation between each ring

3.1.2.5.2 Parallel joint installation method

- For bricks installation in the parallel joint of refractory

bricks, make sure that the joints between the adjacent

bricks of each ring are parallel, then begin to install the

refractory bricks on each ring at the same reference, thus

it does not require placement of wood like the previous

method and obtain the parallel brick joints.

- It should be observed that during the installation of

refractory bricks, regardless of any method, every brick

must be tightened (tight against the kiln shell and each

other) by using Plastic Head Hammer to prevent loose

installation of refractory bricks on each ring.

- A hammer to be used for the refractory bricks

installation shall not be a rubber head hammer or metal

head hammer, but a plastic head hammer, which can

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better absorb the reflected force and is effective for

refractory bricks installation. A plastic head hammer is

an essential tool to tighten the bricks which will prevent

lining spiral problems after kiln operation.

Fig. 3-20: Picture illustrating the parallel joint of refractory

bricks installation between each ring

Fig. 3-21: Picture of Plastic Head Hammer [left] that is

recommended for refractory bricks installation

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3.1.2.5.3 Advantage and disadvantage of brick straight and

stagger joint pattern.

- The selection of bricking pattern is one of the popular

question being asked for lining work. It has to emphasis

on the skill of brick layer, brick size tolerance, smooth

kiln shell condition, corrective centerline marking and

counter measure for brick lining.

- The simplest thing to do is checking brick dimension

and size tolerance of both combined brick. In case that

the size tolerance is different from 0.5 -1.0 mm on brick

length. Clearance will caused the adjacent brick could

not put in the shorter length with the ordinary one or

longer length brick. Once If size tolerance became more

serious parameter. The stagger joint brick lining method

is recommended to avoid corner chipping. For

equivalent and zero size tolerance brick combination is

suitable for stagger and parallel joint pattern.

- Another unpleasant shell condition, the stagger pattern

brick lining is the key point incurring uncontrolled

alignment of bricking ring causing easily damage from

thermal mechanic.

- Skill of brick layers is the major part for pattern of

bricking method decision. The skillful brick layer

always pays attention to quality installation with

uniform mortar pasted, hammering, brick‟s surface

seated on shell and cleaning dirt. The stagger pattern

surely more difficult to clean while bricking compared

to straight pattern. Once the dirt is more difficult to

clean causing poor quality of bricking. Straight joint

pattern on brick lining should have more advantages in

this case.

- Closing the ring with straight pattern will be closed

quicker due to it can read easily from the previous ring.

- Practically installer trusts in stagger pattern however the

stagger pattern will cause bricking rate lower than

straight pattern approximately by 15-20%.

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3.1.2.6 Refractory Installation in the Upper-Half portion of

the Rotary Kiln

- After the refractory bricks are laid completely at the

lower-half portion for at least 8-10 meters, mobilize the

Mult-O-Ring into the Rotary Kiln, a machine needed for

installing the refractory bricks at the upper-half portion

of the kiln. The procedures to be observed are as follows

3.1.2.6.1 Set up the Mult-O-Ring

- First begin to install the Mult-O-Ring Support and fix

the platform, assemble and install the Arch Support and

check the various conditions listed below before starting

the refractory installation.

o Check the level of the Mult-O-Ring Support as

indicated by the levelling bar that is located next

to the Mult-O-Ring Support Beam.

o Check the Pneumatic System that operates the

Pneumatic Jig whether there is any leakage of

air pressure and the air pressure should not be

lower than 5 Bar.

o Check the space (distance) between the Arch

Support and the hot face of the refractory bricks,

the distance should be around 100 mm.

o In case the distance of the Arch Support is not

proper, it can be adjusted by using the folk lift to

move the platform either upward or downward

then lock the desired height/level using the

adjustable lock-bar.

3.1.2.6.2 Installation of refractory bricks at the Upper-Half

portion by using the Mult-O-Ring

- Installation in the upper-half portion requires ample

luminosity of lighting equipment, ventilation fan, and

piling of bricks into groups according to sizes and

computed quantity ratio, as these will promote better

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work efficiency. In addition, the Mult-O-Ring shall have

the support frame for safety purposes, see Fig. 3-17.

- In carrying the bricks onto the platform the weight of

the refractory bricks and other equipment should be

considered in order not to overload the weight support

capacity of the Mult-O-Ring.

- The installation procedure in the upper-half portion has

the same principles as the lower-half portion.

- Each brick installed at the upper-half portion shall be

temporally pressed and supported by the Pneumatic Jig,

and each must be tightened against the kiln shell and to

each other as much as possible by using the plastic

hammer.

- In case any of the individual rubbers attached to the

Pneumatic Jig is found to be worn-out and shorten,

which consequently become unable to reach the surface

of the bricks when pressed, the use of cardboard,

plywood, or shimming plate could compensate the

shorten length by placing it above the worn-out portion

enabling it to reach and press the bricks against the kiln

shell as tight as it can be, see Fig. 3-23.

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Fig 3-22: Picture illustrating the refractory installation at the

upper-half portion by Mult-O-Ring with the safety

frame and platform

Fig. 3-23: Picture illustrating the use of shimming plates to

offset the shorten length of the worn-out portion of

the Pneumatic Jig attached rubber enabling to press

or support the bricks tightly against the kiln shell

- In installing refractory bricks on each ring, there should

be a balanced installation rate between the two-sides,

Arch

Support

Pneumatic Jig

Shimming

plates

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while following the circumference curve of the kiln

shell. Once the remaining space to be installed between

the two sides has reached 0.8-1.0 m., apply the

Hydraulic Jack to tightly push the two-sides of the

refractory bricks against each other, as shown in Fig. 3-

24. Then turn off the air pressure valve of the Mult-O-

Ring to release down the Pneumatic Jigs and then move

the Mult-O-Ring through slide rails to the next

installation ring position.

- The closure procedure of each ring and the use of

shimming plates are to be discussed in the succeeding

topics.

- After the refractory bricks have completely reached 1.5-

2.0 running meters, remove the wheels‟ lock-bars of the

Mult-O-Ring support, then push the Mult-O-Ring

manually or by Forklift.

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Fig. 3-24: Picture illustrating the use of Hydraulic Jack

3.1.2.7 Ring closure installation

The last refractory brick to be installed for ring closure is one of

the most important steps that determine the quality of

installation work and shall adhere to the principles below;

- In each ring, once the remaining space to be installed

between the two sides has reached 0.8-1.0 m., as shown

in Fig. 3-25, measure the exact distance between the

two-sides of the opposite bricks, and calculate the

quantity combination of full and key bricks to be used in

advance to improve the installation time rather than

doing trial and error approach which consumes more

installation time.

- The last brick to be used as ring closure should be the

full bricks and not the key bricks, which are better at

adsorbing the stress from hitting during the ring closure

than the key bricks.

- The installed key bricks shall not be adjacent to each

other rather they should be installed alternately with full

bricks, and the key bricks to be installed in each ring

must not exceed 4 pieces, as shown in Fig. 3-26.

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Fig. 3-25: Measuring distance of the remaining space to

calculate the bricks combination for ring closure

Fig. 3-26: Picture illustrating the allocation of key bricks and

shimming plates

- When the last brick has been inserted as a ring closure,

the bricks within the ring are often remained loose (un-

tight), therefore the shimming plates with a thickness of

2-3 mm. are to be inserted between the bricks until the

ring is sufficiently tightened. Take note that the ring is

tightened when there is difficulty and friction force

observed when inserting the shimming plate. In

Steel

Shimmed

Plate

Key

Brick

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inserting the shimming plates, use proper equipment

such as Pneumatic Hammer, or hammer to push or hit

the shimming plate until it fully penetrates into the small

gap between the bricks, as shown in Fig. 3-27.

- The shimming plates shall be sharpened at its insertion

edges and lubricants such as grease shall be thoroughly

applied for ease of insertion. Also, it is strongly

prohibited to insert the shimming plate more than 1

piece per joint, and shall not be more than 4 pieces per

ring.

- The shimming plates shall only be inserted in between

the full bricks, as they have higher strength to overcome

the collision force from shimming.

Fig. 3-27: The use of hammer to hit the shimming plate

3.1.2.8 Installation of refractory bricks on the deformed/ distorted kiln shell area.

The deformed or distorted areas are, for example, swollen and

bended portion, where they might have experienced abnormal

temperature or conditions that caused bricks falling down or

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thin lining. Such areas need special installation procedures in

fixing the deformities following the principles below.

- In case the deformation or distortion in the kiln shell

area is small and does not exceed 2-3 mm. from the

original curve, use the Refractory Mortar to compensate

the deformed area, as shown in Fig. 3-28. In doing so, it

would keep the bricks combination installed in the area

and not deviate from other non-deformed areas.

Fig. 3-28: Picture illustrating the use of Refractory Mortar to

compensate the deformity


area is larger and exceeds 3 mm. but less than 8 mm.,

use the Refractory Plastics or Castable which can

withstand the weight better than the Mortar. If need to

use the Refractory Castable, remove the coarse grains

and use only the fine grains, mix with water and apply

to patch-up the deformities, then leave it set before

installing the bricks and follow the original designed

bricks combination ratio.

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area is extreme and exceeds 8 mm., repair of kiln shell is

strongly recommended. This could be done by welding

the steel plates and smoothing the surface by grinding,

as shown in Fig. 3-29.

Fig. 3.29: Welding applied in the kiln shell area with extreme

deformation

3.1.2.9 Installation of refractory bricks at the Retaining

Ring Area inside the Rotary Kiln

The installation of refractory bricks at the Retaining Ring area

could be done in several ways, for example, Chipping or Cutting

Method, Installation above the double Retaining Rings and

Fixing Anchors as shown in Fig. 3-30, Refractory Castable

Method, as shown on Fig. 3-31.

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Fig. 3-30: Picture illustrating the refractory installation at the

Retaining Ring area

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Fig. 3-31: Picture illustrating the installation of C 60 A at the

Retaining Ring located in the middle of the Rotary

Kiln

Fig. 3-32: Picture illustrating the installation of supporting

castable at brick retainer.

3.1.2.10 Installation of refractory bricks at the Tyre Areas.

It is known that the refractory linings under the tyre areas are

often more damaged at the hot face of the bricks and form more

brick spalling, as compared to other areas (shown in Fig. 3-33).

This is a result of either excessive mechanical stress generated

under the tyre area or high kiln ovality value exceeding 0.1% of

the Kiln Diameter length.

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Fig. 3-33: The condition of refractory lining under tyre area

with the spalling effect.

- When installing bricks on this area, it is strongly

recommended to apply Refractory Mortar with thickness

of not more than 2 mm. between each side of every

bricks installed below the tyre area, along (+/-) 1.5 - 2.5

running meters from the center of tyre area, as shown in

Fig. 3-34.

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Fig. 3-34: Picture illustrating tyre area

- It is noted that the application of Refractory Mortar

would increase the installation time as compared to

normal clench lining installation method, as show in

Fig. 3-35.

Fig. 3-35: Graph of brick installation rate

3 Meter

(15 rings)

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- The application of Refractory Mortar method usually

takes more time than other methods. Especially at the

upper- half portion, if the masons are inexperienced and

apply Refractory Mortar too quickly, the ring may be

loose.

Fig. 3-36: Picture illustrating tire area and covering mortar

applied.

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Fig 3-37: Installing refractory bricks at the tire area with

refractory mortar

- For the convenience and efficiency of the refractory

installation, SRIC had set a team to study and innovate a

“Pre-Mortared Brick System” to solve those

disadvantages of mortared lining. By this system, the

advantages of clench lining and mortared lining are

combined. The refractory mortar is applied on the

bricks‟ surface from SRIC plant and those bricks are

ready to be installed as clench lining. The applications

of this system were applied in many Cement Rotary

Kilns and the outcomes were very satisfactory. All

previous difficulties were solved, especially the speeds

of installation were approximately 2.5 times faster than

regular mortared lining, as shown in Fig. 3-35.

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Fig. 3-38: Picture illustrating the Pre-mortared Bricks

installation under the tyre area

In case the problem of mechanical stress in the lining under the

tyre area is not severe, it can be mitigated by inserting 1-2 mm

thickness Ceramic Paper, 1260C, between the sides of the bricks

at an interval of 7-10 pieces of refractory bricks (radial

direction) of each ring along (+/-) 1.5-2.5 running meters from

the center of tyre area.

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Fig. 3-39: The pictures illustrate good performance of Pre-

Mortared Brick after 8 months of service

3.1.2.11 Cutting of refractory bricks for the installation on the

last ring.

To complete the installation of the last portion or last ring, the

installation of the last ring often requires brick cutting, as shown

in Fig. 3-40. The important principles for the installation of the

last ring are given below;

- The cut brick shall remain at least 2/3 of their original

length.

- The bricks in the last ring that is adjacent to the old

lining or Retaining Ring must be the original un-cut/full

bricks.

- If cutting is required in more than 1 ring, the cut brick

rings must not be adjacent to each other.

- In all cases, the cutting of bricks must not be for more

than 3 rings. To remedy the cutting work, or to reduce

cutting of rings, SRIC produces special length bricks for

the last ring installation, they are 150, 200, 230, 250,

M.4-7 with Pre-Mortared Brick

good performance

M.2-4 without Mortar some surface spalling

Good performance after 8 months of service

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and 300 mm. in length which help to reduce the possible

cutting to 1 ring only.

- Before the installation of the last ring that is adjacent to

the remaining old lining, the bearing that were

previously temporarily fasten to the old lining as

protection to its movement must be removed and the

kiln shell surface of the area must be smoothed by

grinding.

2/3 L<X<L : Cutting of bricks for 1 Ring

X = remaining space to cut the bricks

L = original length of full bricks

1/3 L<X<2/3L : Cutting of bricks for 2 Rings

0 <X<1/3L : Cutting of bricks for 3 rings.

Retaining Ring or Line of the Old Lining

Retaining Ring or

Line of the Old

Lining

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Fig. 3-40: The picture illustrates the cutting of bricks for 2

rings

3.2 Installation of Refractory Castables in the Rotary Kiln

- Other than the refractory bricks lining in the Rotary

Kiln, Refractory Castable are also to be installed in the

Kiln Outlet and Kiln Inlet areas.

- Normally, the kiln inlet and outlet areas are

approximately 1-2 meter long and install with low

cement castable.

Cut Brick

Full Brick

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- The Refractory Castable are to be installed in the Kiln

Outlet/areas either before or after the installation bricks

in the Rotary Kiln, as shown in Fig. 3-41 and Fig. 3-42.

However in normal practice, the sequential order is to

install the Refractory Castable in the lower-half portion

first, and then rotate the Rotary Kiln 180 degrees after

the castable is set and remove the forms/ moulds.

Afterwards, the installation of the refractory bricks as

well as the remaining parts to be installed with

Refractory Castable follows. This method will allow

more time for the installed Refractory Castable to cure,

which will reduce the possibility of Refractory Castable

explosion during the heating up period.

Fig. 3-41: Installation of Refractory Castable before the

installation of refractory brick in the Rotary Kiln

Kiln Outlet

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Fig. 3-42: Installation of refractory castable after the installation

of refractory bricks in the Rotary Kiln

- The installation of Refractory Castable could be done in

3-4 panels at the bottom portion of the kiln

simultaneously at a time. After they have been set,

approximately 2-3 hours, the Rotary Kiln could be

rotated to install the castable on the succeeding panels,

and so on until all panels have been fully installed. This

method does not require covering or closing of moulds,

and thus can be ensured that the Refractory Castable

will be consistently filled up by means of gravitational

force as visibly observed. The Refractory Castable

installation of this method often done before installation

of refractory bricks.

- For Refractory Castable installation method for the

whole lower-half portion without kiln rotation, rotate the

Rotary Kiln 180 degrees after the installed castable is set

to install again the castable in the remaining portion.

The moulds are needed to be covered or closed at the

casting panels so that the Refractory Castable will not

spill out especially at the side panels of the kiln.

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- The installation procedures for the Kiln Inlet are the

same with the Kiln Outlet. Depending on the work

quantity, that is if Kiln Outlet requires total

demolishing/ removal and installation, they can be done

simultaneously.

- The detailed guidelines for mixing and installing

Refractory Castable, including preparation of anchors

and mould setting shall strictly follow the Refractory

Castable Installation Guidelines explained in Chapter 7

to ensure the best quality outcome of the installation.

- The most appropriate type of Refractory Castable for the

Kiln Inlet and Kiln Outlet areas is Low Cement

Castable, because of its

o High mechanical strength at both ambient and

working temperature.

o High resistance to clinker abrasion.

o High resistance to thermal shock.

o High resistance to alkali and chemical attack.

- The appropriate Refractory Castable to be used in these

areas are TufDura S 300 and TufDura S 600 which are

the special series of Low Cement Castable containing

Silicon Carbide, produced by special technology. Such

castable have excellent abrasion and thermal shock

resistance properties. Alternatively, C60A and C70A

could also be used.

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Fig. 3-43: Picture illustrating the marking of anchor positions,

alternating pattern

Positions marked for fixing anchors

Positions

marked for

fixing

anchors

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Fig. 3-44: The anchors are fixed at the Kiln Outlet area

Fig. 3-45: Picture illustrating the preparation of wooden moulds

for installation of Refractory Castable at the Kiln Outlet

Area

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Fig. 3-46: Pictures illustrating the installation of Refractory

Castable during casting

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Fig. 3-47: Picture of Kiln Outlet area lined with Refractory

Castable after completion of installation

- The entire refractory repairing for cement rotary kiln was not

only brick, but also castable repairing too. The areas with do

need repairing such as outlet area, inlet area.

- By general, kiln outlet and inlet length approximately 1-2

meter long will be installed with low cement castable.

- Kiln outlet repaired refractory can be installed before and

after brick installing as show in Figure 9-42 and 9-43. In

generally practice, castable shall be installed firstly at lower half

portion then kiln will be rotated 180 degree. The sequential on

installation with was illustrating step by step as below pictures.

Installing will be completed on former no 1-11 and rotated 180

degree for the less installing on former no. 12-20.After castable

became hard, formers had been released and brick started in

next step. With this method, the installed castable have

sufficient and more time for curing which can prevent castable

explosion cause from initially heat up.

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Fig 3-48 : picture illustrating castable installation prior brick

will be installed.

Fig. 3-49: Installation of refractory castable after the

installation of refractory bricks in the

Rotary Kiln

SRIC

(KILN OUTLET)

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Fig 3-50: picture illustrating casting position.

- Castable installation can be described in 2 methods as

following.

1) For this method, boundary of former have to be located

after anchor completely welded for castable installing

as illustrated in picture before. Former will be shuttered

at side views of kiln outlet and reinforced with steel rod

or anchors by wire rod. Then the first portion of

castable will be installed within 120 degree. After

castable became solid or 2-3 hours later, Kiln will be

rotated 120 degree for adjacent casting on the second

time. Castable will be installed as previously done in

next step.

1

2

3

4

5

6

7

8

9 10

11

12

13

14

15

16

17

20

18 19

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Fig. 3-51: Installation of refractory castable at nose

ring step by step. 2) In some occasion as above installing method, castable

might face with it will not completely fulfil at the

corner from unskilled installer. We can solve this

problem with other installing method by placing the

wood expansion joint on radial direction firstly. (Please

see figure 3-52) Castable will be filled close to axial

expansion joint level; Wood expansion which prepares

will be installed as illustrated in Figure 3-54. For this

method, it‟s ensuring that improperly casting problem

will not happen.

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Fig. 3-52: Installation wooden former at bottom dead position.

Fig. 3-53: Picture illustrating the side former for prevention

castable spill out.

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Fig. 3-54: Picture illustrating charging of castable at side

from top part.

- Installation castable with surface covered former.

- For this method, castable will be installed a half lower

part . Kiln will be rotated for the less of castable

installation. This method needs former to cover on castable

surface which prevent castable spillage. The most specific

formers placed at left and right side especially 3-4 formers

from center.

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ภาพแสดงการติดตั้ง steel rod ส าหรับใช้ยึดแบบไม ้

ภาพแสดงการติดตั้ง radial expansion joint กับ steel rod

Fig 3-55 : picture illustrating tie rod for supporting.

Fig 3-56: picture illustrating radial expansion joint.

Plywood 3 mm. installed as radial expansion joint.

Steel rod apply for support plywood.

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Fig 3-57: picture illustrating castable feed in

prepared former.

Pour castable here

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Fig 3-58: picture illustrating insertion of axial

expansion while casting.

- For the last formers at both left and right sides, it had to

adapt castable former with extra castable opening hole to

charge castable and include vibrator insertion as Fig 3-57.

Anyhow, it shall apply vibration at external of formers

surface while casting which can assist castable flowing.

- For kiln inlet‟s casting position, it has the same guide

line as casting at kiln outlet with base on amount of

repairing areas. If castable at kiln outlet and inlet were be

replaced. These both sides were be managed and executed

in the same time.

- Mixing castable detail and its installation, anchor,

former preparation are followed casting instructions refer in

chapter 7 strictly. In order to achievement the best

installation quality.

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Fig 3-59: picture illustrating the remaining of casting position.

Fig 3-60 : picture illustrating

castable extra hole at the last

former.

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- Installation castable without surface covered former

For this method, boundary of former have to be located

after anchor already welded for castable installing as

illustrated in picture before. Former will be shuttered at side

view of kiln outlet and reinforced with steel rod or anchors

by wire rod. Then the first portion of castable will be

installed within 120 degree. After castable became solid or

2-3 hours later, Kiln will be rotated 120 degree for adjacent

casting on the second time. Castable will be installed as

previously done in next step.

Fig 3-61:

picture

illustrating

Sequent of

uncovered

former

casting

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In some occasion as above installing method, castable

might face with incompletely fulfil at the corner from

unskilled installer. We can solve this problem with other

installing method by placing the wood expansion joint on

radial direction firstly. (Please see figure 3-56) Castable

will be filled close to axial expansion joint level; Wood

expansion which prepares will be installed as illustrated in

Fig 3-58. For this method, it‟s ensuring that improperly

casting problem will not happen.

- The suitable refractory concrete for kiln outlet and kiln

inlet should be low cement castable according to its

properties following.

1) High strength at low and high temperature.

2) Ability to anti abrasion from clinker and raw meal.

3) Ability to withstand for suddenly temperature

changing.

4) Good for anti chemical reaction cause from Alkali.

- The suitable refractory castable shall be installed in this

area are TUFDURA 300, TUFDURA600 with contain low

cement and silicon carbide ingredient. The compound

properties gain higher properties on abrasion and sudden

temperature or might consider to use C-60-A castable for

installation.

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Fig 3-62: Installed refractory castable completely.

3.3 Final inspection of installation works

- After the completion of refractory installation in the

Rotary Kiln, before moving out the Mult-O-Ring, the

quality of installation of refractory bricks must be

individually inspected for their tightness in every ring.

This could be done with the use of plastic-head hammer

or timber batten to knock the upper-half portion of the

bricks installed in every ring. In case any of the

refractory brick is found loosen, insert again the

shimming plates until they are sufficiently tight. Then

the Mult-O-Ring can now be removed out of the Rotary

Kiln.

SRIC

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Fig 3-63 Picture illustrating ring tightening checked.

- In order to make sure that the whole rings are already

perfectly installed, kiln might be rotated 180 degree and

physical checking on brick surface and mark ring by

ring again.

- In case that brick surface still have some clearance

mortar or shim plate have to be applied. For the small

clearance 1 mm or less mortar is preferred and the wider

clearance than 1 mm shim plate is necessary to insert

and impact with plate driver until it tight enough.

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Fig 3-64 Picture illustrating the 180 degree kiln rotated prior

ring tighten all clearances.

- The damaged brick or corner chip can be applied with

mortar. However serious damaged brick which is

chipped or broken into surface depth nearly 30 % of

brick thickness must be fixed by partial replacement.

For upward installing has to be detected and replaced at

the right position if found during final inspection.

Fig 3-65 Picture illustrating the upturn brick installed.

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Fig. 3-66: Picture of completed refractory installation work

3.4 Installation of Refractory Castables for Main Burner

(or Burner Pipe)

3.4.1 Horizontal casting

This simple method is widely use in cement factory with

acceptance on easily arrangement. The burner body

must be cleaned from dirt and mark for suitable anchor

welding prior to horizontally former closing.

- The Main Burner is the major burner of the production

process in burning kiln feed to be the quality expected

cement clinkers.

- Normally, it is located at the front gate of the Rotary

Kiln above the Cooler.

- The Refractory Castable recommended are Low Cement

Castable, for example TufDura S300, TufDura S600,

and C60A, because they have properties of high

mechanical strength at ambient and working

temperature, thermal shock resistance, high abrasion

resistance and anti-oxidation.

- At the tip of the burner approximately 1 meter in length,

the refractory lining should be thicker of about 10 cm.

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than the normal burner body thickness in order to yield

better resistance to clinker abrasion.

- The refractory installation procedures for Main Burner

are listed below;

3.4.1.1 Place the Main Burner on the „bedding frame‟, as shown

in Fig. 3-67.

3.4.1.2 It might be possible to repair the refractory without

removing it but the use of scaffolding is needed, as

shown in Fig. 3-68.

3.4.1.3 Demolish the damaged portion of refractory and clean

the metal surface with metal-brush. In case the body of

the burner is severely damaged, fix it by welding and

grinding.

Fig. 3-67: Picture illustrating the damaged part of Main Burner

that requires repairing

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Fig. 3-68: Picture illustrating the refractory maintenance of the

burner at its original position (without removing)

3.4.1.4 Fix the stainless steel anchors, which have the grade

above SUS 310S, and apply compatible Welding

Electrodes to the selected anchors. Remove the welding

deposits along the welding seam joint to check its

consistency.

3.4.1.5 There are 2 types of mould for installing the Refractory

Castable, one is a wooden mould affixed with

galvanized iron sheet, and another is made of metal

sheets, with half circular shape and approximately 1

meter in length.

3.4.1.6 Before installing the Refractory Castable, wrap the Main

Burner with Ceramic Fiber Blanket, 13 mm. thick, with

glue or wire. This will protect the Main Burner from

heat transfer from outside to the metal surface during its

operation, as shown in Fig. 3-69.

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Fig. 3-69: Picture illustrating how the Main Burner is

wrapped with Ceramic Fiber Blanket

3.4.1.7 Assemble the moulds prepared, one by one, starting

from the lower-half portion. The casting can be started

right after the completion of assembling the mould. The

continuous use of vibrator will ensure a consistent

smooth flow of the Refractory Castable in filling up the

mould fully.

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Fig. 3-70: Picture illustrating the installation of Refractory

Castable at the lower-half portion of the Main Burner

3.4.1.8 Remove the moulds from the casting panels, only after

the Refractory Castable are already set. Then insert the

Ceramic Fiber Blanket- 6 mm. thickness, or Cardboard

or Plywood 4 mm. thickness in between the connecting

sides to other adjacent panels (both radial and axial sides

directions) in order to create the expansion joints that

allow possible expansion of the Refractory Castable, as

shown in Fig. 3-71.

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Fig. 3-71: Picture illustrating the insertion of expansion joint.

After the completion of installation at the lower-half

portion, begin to install in the upper-half portion following the

preceding procedures.

3.4.1.9 After the completion, inspect all the installation quality

for any non-filled pores. This can be done by using

metal hammer to knock on the casted Refractory

Castable and observe the reflection sound. A fully filled

castable gives strong solid sound.

3.4.1.10 The heating up time of the Refractory Castable

installed in the Main Burner is the same as that of the

Rotary Kiln, which is around 24 hours.

3.4.1.11 The alignment of the Main Burner must be set

right in the center of the Rotary Kiln which will give the

frame fire right into the center and will not affect any

sides of the refractory lining from direct fire contact,

which deteriorates the service life of the lining.

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Fig. 3-72: Picture illustrating Refractory Castable installation at

the upper-half portion of the main burner

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Fig.3-73: Picture of Main Burner completely lined with

Refractory Castable

3.4.2 Vertical casting.

The vertical casting is better in vibrating quality than horizontal

casting, since we could put vibrator through formwork in

straight way not in curvature. However this method needs

special equipment to lift and lock the burner body.

For vertical casting, the preparation steps have to be done same

as horizontal casting such demolishing old refractory, cleaning

burner shell, fixing the anchor and these jobs could be done on

floor before stand the burner up.

3.4.2.1 Prepare Scaffolding for casting along burner length; the

casting step could be done from both top to bottom or

bottom to top.

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Fig 3-74: Picture illustrating on site preparation for vertical

casting.

3.4.2.2 Wrap the Main Burner with Ceramic Fiber Blanket 13

mm. thick, with glue or wire. The Ceramic Fiber

Blanket will protect the Main burner from heat transfer

from outside to the metal surface during its operation.

And cover the Ceramic Fiber by plastic sheet as shown

in Fig 3-75.

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Fig 3-75: Picture illustrating of Ceramic fibre wrap around

burner body.

Fig 3-76: Picture illustrating plastic sheet was used to cover on

ceramic fibre blanket.

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3.4.2.3 Assemble the moulds prepared, half circular shape with

700-1000 mm. length, from one side. Starting casting

there and move to above section after castable already

set and insert Ceramic Fiber Blanket 6 mm. thick for

radius expansion joint.

Fig 3-77: Picture illustrating casting in vertical direction at one

side.

Fig 3-78 : Picture illustrating radial expansion joint with

ceramic fiber blanket.

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3.4.2.4 Continue casting work, repeat, until completion one side

casting. Remove moulds from all casting panel and

insert Ceramic Fiber Blanket 6 mm. thick for axial

expansion joint.

Fig 3-79: picture illustrating an axial expansion joint with

ceramic fibre blanket.

Begin casting work on another side by aassembly the moulds

prepared, cast by preceding procedures.

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Fig 3-80: picture illustrating completed casting.

3.5 Application of gunning castable instead of casting.

- In emergency cases, Refractory materials can be utilized for

preheater cyclone, cooler wall, hot gas duct and riser pipe with

castable rather than brick. The more advantage and convenient

of material preparation are attracting while compared to brick.

- However, refractory repairing with castable required a lot of

man power and former preparation. Moreover timing was being

utilized longer as necessary for castable setting before former

release to next casting. In the urgent case with customers have

limit on time and man power. Repairing with gunning castable

is most alternative appropriation, due to it‟s not necessary to

employ 50-60 man power. In additional reason, former will not

be required and shortly times spend while waiting for castable

curing and setting. This method shall minimum operating time

spending.

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Fig 3-81: Picture illustrating various kinds of refractory materials being chosen for preheater

cyclone.

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Fig3-82: Picture illustrating refractory materials chose for

Clinker Cooler.

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- Repairing by gunning castable can be applied on existing

material‟s surface without dismantling. However this principle

was recommended to dismantle the whole damaged area and

install new anchor then gunning will be operated.

- Regarding to amount of anchor per area and expansion joint

for installation with following to casting standard.

Fig 3-83: The perfected anchor welding which have been

installed with gunning castable.

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Fig 3-84: Picture illustrating on gunning castable has

Being applied on bull nose‟s existing surface.

Fig 3-85: Picture illustrating bull nose after gunning

Successfully did.

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Fig 3-86: Picture illustrating cooler‟s roof had

been gun in over head direction.

Fig 3-87: Picture illustrating cooler‟s roof with

Complete installed by gunning castable.

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Fig 3-88: Picture illustrating the 8 months gunning

castable performance with well physical figure.

- Gunning castable installation shall be prepared some facility

such as

1) Air compressor with minimum capacity 650 CFM at 700

Kpa.

2) Constant water pressure 250 Psi.

- Avoiding for low impaction and too high rebound. It shall be

considered by operating with competent person.

- The essential of gunning castable will primarily nozzle

concern and summarized in 3 points as following;

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Fig 3-89: Picture illustrating the effective of nozzle angle.

1. Nozzle angle

For installation in the general area, the nozzle

shall be installed in a perpendicular angle to the

work piece being installed with gunning

castable, otherwise the amount of rebound will

be high and cause to reduction of the compact.

There is an exception for the corner that gunned

by directing the nozzle in the plane bisecting the

angle of intersection of the two surface

2. Nozzle distance

Distance between the nozzle and surface is

about 0.5-1.0 meter

Distance > 1.0 meter rebound increase ,

compaction and strength reduce Distance < 0.5 meter rebound also increase if

no reduction in pressure

3. Nozzle motion

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Fig 3-90: Picture illustrating nozzle motion.

A steady circular or elliptical movement of the

nozzle across the surface

The nozzle should not be directed toward one spot

for extended periods increase rebound , difficult

control the thickness of the layer

consistency moved consistency compacted area.

Documents

Chapter 3 Refractory Installation in the Cement Rotary Kiln