How to assess the refractory condition

after a kiln stoppage

Refractory
PR RFR P06-02 V1) 1/6

Introduction
ƒ The brick condition assessment is an important step for the following expected results:
ƒ a better identification of critical areas
ƒ a reduction of time loss during installation.
ƒ An adequate preparatory work and a regular monitoring of job quality will lead to fewer kiln shutdowns
for refractory failures.
Objectives
ƒ A systematic approach will help to replace only bricks that will not last the full campaign
ƒ Optimise the brick lining
ƒ Understand the influence of the process conditions upon the lining
ƒ Indicators to monitor progress:
ƒ Number of refractory failures
ƒ Refractory consumption/Tonne of clinker

Safety aspects
ƒ Besides the individual safety equipment, it is forbidden to enter the kiln unless the coating has been
removed, without an adequate tunnel protection or an access hut
1 How to ensure safety for brick demolition & lining works

Prerequisites
Be prepared:
ƒ adequate inventory of bricks in stock in the warehouse
ƒ check of their quality (brand, quantity, damages)
ƒ Brick chart up to date
ƒ Mark distances from nosering on bricks
ƒ Shell scanner pictures and history
ƒ Camera
ƒ Invite the supplier to be present, if appropriate

Time frame
ƒ After coating removal, systematically drill and assess critical areas every shut-down or use a Lineometer.
ƒ Full assessment can take 4 to 6 hours

Tools
ƒ Brick chart on Winbrix
ƒ Coating & Lining Inspection check-list
 How to assess the refractory condition
after a kiln stoppage
Refractory
PR RFR P06-02 V1) 2/6

Action Steps

1. Inspect the refractory before tearing out

Inspect coating, as you progress up the kiln, before tearing out:
ƒ Record the zones of coating, ring formations or anything that has changed, and take pictures
Inspect refractory, after coating has been removed:
ƒ Check the brick alignment, radial, axial
ƒ Pay attention to
ƒ Spalling and distortions (it may provide your with good information about the kiln’s ovality and
alignment, tire clearance and quality of installation)
ƒ Refractory condition over tires, kiln drive and retaining rings
ƒ Wear pattern
ƒ Check the cold gaps of the tyres (note latest ovality & slip readings
ƒ Check the burner pipe (refractory and tip)
ƒ Take photos
ƒ Take coating samples if abnormal coating found
ƒ Fill in the inspection sheet
1 Use the “Coating & Inspection check-list” (Refractory / Job aids)
1 See also the procedure “How to handle a ring formation” (Pyroprocessing)
ƒ Analyse the wear mechanisms
1 See also knowledge document “Refractory wear types”

2. Clean the kiln

Coating and bricks must be removed separately
If the zone is known to be in poor condition, it is possible to tear off the brick and the coating
together. Even in this case, we need to measure and record the brick thickness in relation to its
position in the kiln.

If you are unsure that the bricks should be replaced:

ƒ It has to be free of it’s coating and clean, completely from the nose-ring to the inlet:
ƒ to protect the workers from the falling coating
ƒ to permit a good inspection of the brick lining
ƒ Tear off the coating in the upper first half (using a remote control breaker like the BROKK250 machine),
ƒ Remove the drop material,
ƒ Turn the kiln 180
ƒ and redo this sequence.
 How to assess the refractory condition
after a kiln stoppage
Refractory
PR RFR P06-02 V1) 3/6

Action Steps

Measure the thickness

ƒ Several methods are possible to measure the brick thickness. The use of the linometer can increase the
number of points sampled without drilling.
1 How to measure the brick thickness

In any case, keep the measurement information as records for the follow-up of the lining refractory.
You will need this information to decide witch sections of brick lining should be stripped and also for
the planning of the next shut-down.

4. Drill the refractory

ƒ Make sure the drilling (brick thickness) is done at 2 points minimum (about 120 and 240) at every meter
down the length of the kiln.
ƒ Focus on kiln depressions (thinnest areas).
ƒ Enter the data into your Winbrix database.

Placement of a standard 0 point on the kiln shell is useful for both refractory and kiln alignment. The
same reference should also be used as for the shell scanner.

5. Decide what refractory should be stripped out

Each plant has to establish its own criteria in regard of their past experience
taking in consideration their constraints.

ƒ As a general rule most plants consider that a lining thickness of 60-70% of original brick in the sintering
zone is acceptable for a regular campaign (normally for 1 year).
ƒ Assess if a systematic brick replacement policy is not the best solution in critical areas.

ƒ However, particular attention also needs to be made to the brick condition to check for excessive salt
infiltration, especially when burning waste fuels, operating with difficult raw materials or with poor
combustion. In the case of significant salt infiltration it is necessary to replace the lining even though the
lining thickness appears ok, as the brick structure will be severely weakened and will fail prematurely.
 How to assess the refractory condition
after a kiln stoppage
Refractory
PR RFR P06-02 V1) 4/6

ƒ In case of a very difficult lining section, like transition zones, the use of a brick consumption factor may
be very useful:
ƒ Enter all data carefully in Winbrix and calculate consumption factors
ƒ Analyze history carefully
ƒ Make a relationship between that factor and the thickness of the bricks left.
ƒ Use that figure to find out the thickness of bricks lining you will normally need for your next
campaign for that specific section of lining.

Brick samples of each zone shall be taken (where it appears to be worn) and
analyzed to keep track of evolving processes occurring in the kiln.
ƒ Check the worn out bricks (wear pattern, premature wear, brick spalling, chemical attacks)
ƒ Cut some of the bricks to see the wear in the cross section
ƒ Take pictures of irregularities
ƒ Consider supplier to assist in making post mortem studies

Decide what is the reason for refractory replacement (to minimize re-
occurrence)
ƒ Normal wear
ƒ Improper installation
ƒ Mechanical stress
ƒ Salt infiltration
ƒ Operational concerns: over-burning or number of kiln stoppages
ƒ Non optimal brick selection

This study will help to select the most suitable refractory for this application in a given area.

See examples of worn out bricks in the annex.

 How to assess the refractory condition
after a kiln stoppage
Refractory
PR RFR P06-02 V1) 5/6

Appendix

Examples of worn out bricks

ƒ from Refratechnik n° 55:

ƒ Convex spalling ƒ Concentric stress cracks

ƒ Spiraling ƒ Infiltration of alkali salts

 How to assess the refractory condition
after a kiln stoppage
Refractory
PR RFR P06-02 V1) 6/6

ƒ Corrosion of chrome ore ƒ Hydration cracks