SRIC InstallTechnique

Refractory Installation
For cement Rotary Kiln
THE SIAM REFRACTORY INDUSTRY CO.,LTD.

WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
What did affect to refractory life?

Quality of Refractory
Refractory
The Correct Installation
Operation Process

Refractory installations Requirements

1)
Installed with qualificable acceptance.
2)
Optimum time or suitable schedule

Safety for all related persons.
3)

Refractory Installation for

Rotary Kiln
1)Preparation before shutdown.
Gap, migration ,Kiln Ovality Check.
Interpret & Analysis
Mechanical Adjustment

Kiln Ovality Check

Kiln Shell Replacement in case shell too thin

2) Refractory Materials Checking(3

Checking(3 months Earlier)
- 3 months before shutdown shall check.
Quality of materials, appearance, Package.
Quantity of Material, classification, spared
refractory.
- 2-4 weeks before shut down or final check is very
important.

Brick Combination.
Diameter 4.6 m
ISO Shaped brick 620 : 420

78 : 62
4:3
VDZ Shaped Brick B 620 : B420

B420
48 : 145
11::3
ISO Shaped brick less shortage problem, lined

faster & stronger than VDZ Shaped brick.

Warehouse & Material handling

3) Machines, tools Equipment checking

- De
De--bricking Machine.
- materials Transferred Machine.
- Bricking Machine.
- Pneumatic
jack hammer.
- Concrete mixing machine.
- Brick Cutting Machine.
- Forklift, lifting hoist, belt conveyer.
- Bridge.
- Lighting, welding & Carpenter tools etc.

10
4)Man power preparation.

1 month before shutdown.
-Training the precaution & safety course.
- Refractory knowledge.
- Refractory installation knowledge.
- Skilful & trained man-powers needs.

11
Preliminary work before dede-bricking.

Refractory Inspection after kiln cooled down.
-24 hours afterward, prepare to inspect physical
coating forming, coating thickness, smoothly,
length, Refractory appearance
-Record, picture
-Abnormality, damage, worn, sampling
1) line of used brick might displaced from before.
2) Cracking, spalling, Damaged feature.
3) Remaining thickness
Drilling, UT.
12
Remaining Thickness
UT Tester
Tester.
Drilling method.

13
-Correct all necessary data, analysis and evaluate to

improve refractory life time such as
1) Applied Ceramic Fiber to release stress from
thermal expansion & uneven brick retainer.
2) 2) Mortar Applied at tyre or high mechanical
stress area.
3) Select suitable refractory for necessary
application
-Resume all data and linkage to operating condition.

14
*Plan to locate refractory to be replaced.

Coating and Brick Dismantling.
Coating
-Chipping from kiln outlet to kiln inlet
direction.
SRIC
* De
De--bricking machine.

Coating removing
15
Brick
-Chipping from kiln inlet to kiln outlet direction.
* De
De--bricking bricking machine, Temporary brick
stopper in case partial replacement and prevent
sliding of existing bricks.

16
Brick
-Removing damage brick and waste from rotary kiln.
By Man hole, Rotate and drop to cooler, Manually
removing

17
Kiln Shell inspection

-Deformed Area & Marking with color spray.
-Scaling, rust & acidic coated on shell, sand blasting.
-Shell welding joint, another welding spot, kiln mark.
Vertical welding joint

Horizontal welding joint

18
Transportation of refractory to kiln.

19
How to correctly carry out the

bricking of cement rotary kiln?
-Installation method
-Kiln rotation
Screw jack, gluing, channel method.

-Without Kiln rotation formwork method by use
wooden mould
Pneumatic O-Ring.

20
Bricking with kiln rotation

Screw jack.
- Lining achieved by laying a half section long 510 meter and tighten with screw jack.

21

channel method
-The method was applied from screw jack method.
Bricks have been laid and tighten with channel and
fasten with bolt and nut.
Channel steel
Wood wedge
Welded nut

22

Gluing method.
- Lining achieved by applied epoxy resin &
hardener with 5 pieces of brick long 5-10 meter.
install next 5-10 pieces same length without glue.
Consequence to the previous when glue is
already hard.

23
Bricking without kiln rotation.

Formwork method.
1)Formwork or contour
- use wooden made arch support, hydraulic
jack and wood wedge for insist brick lining.

24
Bricking without kiln rotation.

2) Pneumatic or MultMult-O-Ring.
- Applied from pneumatic cylinder
independently with arch support to install a
half upper ring.

25
Methodize and its comparisons.

Kiln rotation method.
1) advantage
Simple method regarding to necessary equipment.
Low investment cost.
2) Disadvantage
Kiln has to be rotated during lining process.
- Take risk if bricks are not adequately fastened and slip.
Ring cannot be tightened prior closing.
Kiln diameter larger than 4 meter might cause screw
jack slipped & shell distorted.

26
Methodize and its comparisons.

Without kiln rotation method.
1) advantage
Safe in operation.
Gain accurate brick installed for brick ratio and conform to shell.
Kiln does not to be rotated.
Suitable for small and large kiln diameter.
Highest speed up bricking rate.
Manage and relate in parallel activities.
2) Disadvantage
Very high cost on an equipment .
High affordability to assemble an equipments.

27
Installed 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
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
Formwork method

28
Kiln Rotation and place Man hole at 6 O o Clock

The Center line will be checked with accurate tools.
-Aluminum bar dimension 25x
25x50x
50x3000 mm.
-Leveling bar
-Plumb bob
-Compass. ?????????
-Nylon wire
-Measuring tape.
-Chisel ,Steel Hammer ,Color spray.
29
Center line and Cross section line by Kiln Rotation

fixed.
1) Place an aluminum bar on kiln outlet crossways.

30
2) Check aluminum bar and adjust level with leveling

bar

31
3)Place & made Plump bob on level to center of

aluminum bar. (calibrated form QSD)
4) Gently spot the end of plum to kiln shell.
5) Marking with Chisel and spray the point round
shaped color.

32
6) Every 5 meter check the center points.

7) Draw string wire from beginning point to last point.
8) Spray color cover string and remove string off.

33
3.4 Circumferential lines or radial controlled lines by

Kiln rotation fixed..
-Separated the center line with compass and cross
exactly 1 meter along.
10
11
12
13
14

34
- Use point 1,3,5.and point 0,2,4,6..set for

crossing With compass radius 1.8 meter.

35

36
- Draw more the lateral lines which achieved from

crossing pattern.
0

37
-Extended scaffolding and draw higher lateral lines
and cross section line together.

- The half upper section will do during bricking.

38
Center line and Cross section line by Kiln Rotation.

-Check and draw center line then rotate kiln 20o
alternately
- Separated the center line in every meter.
10
11
12
13
14

39
-Rotate kiln 20o and check the second center line.
10
11
12
13
14
10
11
12
13
14

40
-Turning approximately 16 times and draw the

center lines with cross section lines until completed.
- Actually it is very necessary to check center line
on the last line according to ManMan-hole at 6 Oclock.
-During turning kiln, cleaning, repairing ,kiln
deformation check& marking brick location can be
done at the same time.

41
Checking & marking shell

deformation

42
Bricking.
H--beam 100x
100x100
100xx3000 mm.
-Use Channel bar or H
place align to the center line.
- Support the other side of H
H--beam with heavily
substances such as bricks.
10
11
12
13
14

43
Brick pattern
1)Straight joint pattern.
2)Stagger joint or Bonded pattern.

44
1) Always clean dirt away from kiln shell.

2) Place Channel bar along and aligned to the center
line.
3) Gently install first course of brick from brick
retainer or existing brick as figure.

45
Straight joint pattern.

46
Stagger joint or Bonded pattern.

pattern.

47

48
Kiln deformation
-
Nominated brick ratio by installed

frequently larger or smaller size more on
deformed area.
2 or 3 mm. different in level can adjust

with mortar.
During 4-8 can threat the deformed shell

with plastic refractory or fine grain size
castable.

49
Convex deformed kiln shell
X
Concave deformed kiln shell
X
50

51
Welding Joint

52
Wrong combination
Larger brick lined more than ordinary

Smaller brick lined more than ordinary

53
Right Combination

54
Mortar applied here

Mortar applied here
55
Mortar applied at lower and upper section

56
Prohibit for using

adjustable plates.
X
Reasons
-Loose lining.
-Interfaced cracking

57
Remove channel bar and wooden spacer off, clean all

dirt, install the adjacent section along 8-10 meter then
assemble MOR.

58
Bricking at brick retainer.

1)cutting brick as shape and cover brick retainer
Material flow
2)Install with refractory concrete.
Low cement castable C-60-A

59
Bricking at brick retainer.

3) install with brick and castable.

60
Install brick at tyre area or high mechanical stress areas.

-
Motar is being trowelled 1-2 mm. thick at axial& radial

brick sides at tyre area 3-5 meter long.
Or use the pre mortared brick.
3-5 meters
3-5 meters
3-5 meters

61
Install brick at tyre area or high mechanical stress areas.
Mortar applied at radial

& axial sides.
Pre mortared brick

62
Brick cutting principle.

1) The cutting ring shall be remain 2/3 off original length.
2) From brick retainer nor existing ring brick at the adjacent
must be original length.
3) Whenever cut more than 1 ring,The cutting ring must be
separated.
4) Cutting many rings take long time and high cost, Special
longer brick might higher advantage.
X
BRICK STOPPER
L
63

1)
2/3 L< X < L
1 Ring Cut
Cut
2)
1/3 L< X < 2/3 L

Cut
3)
0< X < 1/3 L

Cut
BRICK STOPPER
2 Rings Cut
Cut
BRICK STOPPER
3 Rings Cut
Cut
Cut
BRICK STOPPER
4) With 1 cut of brick LL--300 mm. shape.
Cut
BRICK STOPPER

64

Cut
Cut

65
How to install a half upper section.

Set up Mult
Mult--O-Ring.
-Assemble platform, support rack.
-Connect and adjust arch support.
-Pneumatic hose, connecting coupling, control valve.
-Check all joint, spacer rod, clearance interval kiln
shell and rubber plate simultaneously.
-Space between brick surface to rubber plates must
be adjusted to 100 mm.

66
-In case the distance between rubber and brick
surface is misaligned, adjust the height of platform

or radial of arch support needed.
-UnUn-uniform of intervening distance of brick
surface and rubber can cause some brick loosen
during installation proceeding.
-Check air pressure, main air required 5 bar
minimally.
-Lubrication oil for trapping water condensed in
hose need to be replaced from filter.

67
Set Up Mult-O-Ring

68
-lay up brick in both sides and open cylindrical valve one

brick per cylinder.
-Applied hard surface plastic hammer in each brick during
install frequently.
- brick ring can be closed by pressing at axial side with
pneumatic jack approximately 2800
2800--3000 kg/cm2.
- Release pressure all pneumatic valves and remove
Arch support to next ring.

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

69
-Check the distance from left & right of closing and

calculated or simulate by use installed brick.
-Follow the precaution, avoiding and try best ratio, minimally
key brick, separated when it were being keys. By mean of
maximum tighten ring without any damage or displacement
later.
- 3-4 pieces in an axial drive of steel shimmed plates
maximum allowed until ring tighten enough is accepted.
-While ring closing period, the next ring shall be installed
brick up.

70
Closing the ring

-Applied pressure 2800 kg/cm2 safe
enough for tightening the ring.

71
Closing the ring

Key Bricks
Steel shim 4 pcs, maximum, 2-3mm., thk.
Key Bricks
Steel shim 4 pcs, maximum, 2-3mm. Thk.
X
X
72
Closing the ring
MS-80-AF
620
420
P20
P+20
804
741
804
741
804
738
804
738
804
734
804
734
804
731
794
731
794
732
794
728
794
728
794
724
784
721
784
722
784
722
784
718
784
718
784
714
774
712

73

74

75
Final check and ring tightening

76
Steel Anchors With Plastic Cap.
Flat bar Shape
Round, rod Type
Flat bar footing with holder.
Corrugated Type
Corrugated shape with holder

77
Stainless anchor property.

Stainless
steel
grade
AISI 253 MA
Composition
%C <0.05-1,%Cr 20-22,%Ni 10-12
Scaling
temperature
1150 o C
Sulphide resistance
%C <0.1,%Cr 21,%Ni 11
< 1150 o C
AISI 310
%C <0.045,%Cr 16-18,%Ni 10-14,%
Mo 2-3
< 800
AISI 316
%C <0.2,%Cr 22-24,%Ni 12-15
< 917
AISI 309
%C <0.04,%Cr 18-20,%Ni 8-10.5
AISI 304
< 800

78
Kiln outlet casting.

-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.
- Followed castable user guide whenever castable must be installed.
Ceramic fiber board 10 mm.Thk.
Low cement castable 60%
High Alumina Brick

KB-70-PB,BX-80

79

Anchoring
310,, SUS 253 MA with welding
-Welding suitable anchor SUS 310
electrode
-AWS 309,
309, 310.
310.
- Visually checking, Impact test.

80

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
-Wooden form
-Steel mould.

81
Ceramic fiber board 10 mm.thk

82
Some problems might be found while casting

Impurity in panpan-mixer & Surrounding
Flash Setting or Rapid setting of castable
Immediately action
1)
Clean all equipment
2)
Use only drinkable water while mixing.
3)
Cooled down castable & surrounding

83
Some problems might be found while casting

Castable not setting or very long time setting
Immediately action
1)
Reduce mixing water.
2)
Installed some heater fan & spot light.
3)
Add some accelerator.

84

SRIC InstallTechnique

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Refractory Installation

For cement Rotary Kiln

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

What did affect to refractory life?

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

Refractory installations Requirements

Installed with qualificable acceptance.

Optimum time or suitable schedule

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

Refractory Installation for

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

Kiln Ovality Check

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

Kiln Shell Replacement in case shell too thin

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

2) Refractory Materials Checking(3

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

ISO Shaped brick 620 : 420

VDZ Shaped Brick B 620 : B420

ISO Shaped brick less shortage problem, lined

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

Warehouse & Material handling

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

3) Machines, tools Equipment checking

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

4)Man power preparation.

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

Preliminary work before dede-bricking.

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

-Correct all necessary data, analysis and evaluate to

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

*Plan to locate refractory to be replaced.

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

Kiln Shell inspection

Vertical welding joint

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

Transportation of refractory to kiln.

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

How to correctly carry out the

Screw jack, gluing, channel method.

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

Bricking with kiln rotation

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

Bricking with kiln rotation

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

Bricking with kiln rotation

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

Bricking without kiln rotation.

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

Bricking without kiln rotation.

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

Methodize and its comparisons.

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

Methodize and its comparisons.

THE SIAM REFRACTORY INDUSTRY CO.,LTD.

Installed rate in each method

Screw jack method

less than gluing

M-O-R (Clench or dry

M-O-R (With mortar)

THE SIAM REFRACTORY INDUSTRY CO.,LTD.