How to line a burner pipe

Refractory 1/19
PR RFR P06 15 V1.0

Introduction
ƒ The burner pipe refractory is exposed to chemical attack from clinker melt, alkali attack, thermal shock
from coating drops and overheating, and abrasion from secondary air dust.
ƒ We should always have a lined, ready-to-use burner available at the plant.
ƒ Respecting the basic rules stated in the procedure will improve the life span of the burner pipe.

Safety aspects
ƒ Wear Personal Protective Equipments, as for normal plant works
ƒ Safety rules to apply for concrete mixer
1 See Procedure "How to ensure safety for castable mixing"
ƒ Ensure safe positioning of burner pipe, especially when cast vertically.
ƒ Cordon off the area around the burner with red tape.

Prerequisites
ƒ Ensure that the shuttering mould is available
ƒ Ensure that materials and tools are available in adequate quantities and qualities (anchors, expansion
materials, vibrator, mixer, etc…)
ƒ Cover the axial holes
ƒ Ensure there is a drying system in working conditions on site.

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PR RFR P06 15 V1.0

Basic Rules

1. Anchoring
1.1. Anchors design
Option 1

ƒ The Ω support diameter must be 2 mm thicker than the V anchor diameter (6mm). The Ω support steel
quality is the same as the burner axial pipe steel shell quality. The Ω support is continuous welded
both side to the burner shell pipe.
ƒ The V anchor steel quality is Z8 CN 25-20 / AISI 310. The V anchor passes through the Ω support hole
and is just tack welded.
ƒ Anchor expansion is allowed by two plastic cups fitted on the anchor tips.

Option 2

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PR RFR P06 15 V1.0

1.2. Anchors arrangement

Option 1
ƒ For the burner tip, anchors density must be increased versus the rest of the burner pipe

20
Anchor tip

Burner
tip

70
Staggered pattern

70

1050

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PR RFR P06 15 V1.0

ƒ For the remaining zone, the anchoring pattern must be lighter

Dense
anchoring
zone

Longitudinal movement of the

castable against the anchor is
eased by application of
bituminous paint on the
anchors after welding operation.

Light
anchoring
zone

140

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PR RFR P06 15 V1.0

1000
Ceramic fiber blanket
13 mm thick, 500 70 Expansion joint thickness :
4mm
compressed to 5-6

Blaster

Thermocoupl

70
Expansion joint thickness : 4mm

ƒ If burner is fitted with blaster to clean the tip, it is recommended to add additional expansion seal in
regards of blaster nozzle as described on the above drawing.

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Option 2

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2. Expansion joints
Add 4 straight joints in the lining for expansion
For severe conditions good results have been reported by increasing the number of segments.

4-5 mm
thickness

Joint to be banned from the lower part

of the burner
Expansion joints position (anchors must
be eventually removed)
NEFALIT 16 composed of
ceramic fibers
CLASSIFICATION 1200°C
TEMPERATURE

AT 400°C 0,16
in W/m.K

DIMENSIONS 1000 x 1000

in mm

Rigid ceramic board THICKNESS 2-3-4-5-6-8-10-12

NEFALIT 16 in mm

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PR RFR P06 15 V1.0

Add radial expansion joints

4-5 mm
thickness

Radial
expansion
joint

Axial
expansion
joint

≈ 500 mm

Rigid ceramic board

≈ 300-500
NEFALIT 16

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PR RFR P06 15 V1.0

3. Burner tip thermocouple

It is highly recommended to embed a thermocouple in the bottom part of the burner tip.

Thermocouple 0-800°C
Connected to CCR

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PR RFR P06 15 V1.0

4. Casting preparation
To avoid water to settle on the burner tip after casting, it is recommended to start casting the burner
pipe with the tip on the floor.

Castable
must flash Radial
with the tip expansion
joint

Phlox 1500 C
SR or Gibram
Axial
or equivalent
expansion
joint

≈ 500 mm

Gibram or
equivalent

≈ 300-500
Piece of
wood or
thick
rubber

ƒ To avoid castable to fill nozzle holes, seal the tip

with plastic sheet

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ƒ Shuttering must be prepared made of two or four bolted pieces.

ƒ Ensure that shuttering internal surfaces are cleaned without rust.

ƒ Grease the surfaces with oil.

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ƒ In some cases, burner cannot be cast on vertical position due to burner length… In this case special
shutters and preparation must be applied in order to respect expansion joint installation.

IT IS MORE COMPLICATED

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5. Castable choice
ƒ The burner pipe has two parts:
ƒ The front part (minimum: 1.5 m) which is submitted to heat effects from the flame and the clinker
as well as clinker abrasion coming from secondary air dust. In most cases, it must resist also to
alkaline sulphate corrosion attacks.
ƒ The rear part which is mainly affected by the secondary air temperature and abrasion.
It may be good to use two different qualities of castable for these two parts from a cost point of
view, but one single quality is simpler and more practical.

ƒ For the pipe tip, GIBRAM (2.95 t/m³) + 3 % on dry weight of metallic fibbers can be used. Metallic
fibbers lead to increase thermal shock resistance as they act as crack stoppers. Their application is limited
by the steel alloy, typically 1 200 °C max., DRAMIX type for example.
ƒ Dramix addition has to be discussed with supplier as it may react with mullite and thus have a negative
impact. This effect is reported to be far less sensitive with corundum.
ƒ For the rest of the tube PHLOX 1500 C SR can be selected throughout but is less resistant to abrasion.
Burner pipe position Castable
Tube end (firing side) Gibram + 3% Dramix

Rear position Phlox 1500 C SR

ƒ Other castable types have been used successfully: Corundum, mullite, SiC containing concrete, etc…..

6. Casting Procedure
1 See procedure " How to cast low cement castable (monolithics)" and follow supplier‘
recommendations
ƒ One shuttering should be cast at once.

Drying & Heating

ƒ Setting and hardening of castable will occur in about 24 hours with a normal ambient temperature
(20°C).
ƒ After setting and hardening, It is highly recommended to dried and heated the burner pipe castable.

Heating up prg applied by FUMI-THERM for Sagunto burners

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ƒ If the 650 °C step is not able to be achieved, keep it at 450 °C step for the same period.

Practical example of heating curve monitored by thermocouple

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ƒ Another option is to heat only the tip, building a smaller brick chamber as per the following example

ƒ A third option is to install a heating blanket and a PC temperature controller

7. Air blaster
ƒ To avoid formation of snowman on the burner tip, it is recommended to install an air blaster. The
additional weight should be considered in burner and carriage designs

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PR RFR P06 15 V1.0

8. Others
8.1 Castable reinforcement
ƒ To reduce clinker abrasion on the bottom part of the burner especially with grate cooler process, the
lining on the bottom part of the burner can be thicker.

8.2 Refractory lining protection against clinker impact from the satellite coolers
ƒ The best solution is to create a tray on the upper side of the burner, exactly in the area where the clinker
impacts. This metal tray or box is then filled with loose clinker nodules that can absorb the impact. The
box is built over the regular lining.

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PR RFR P06 15 V1.0

Appendix

1. Datasheets for Gibram, Phlox 1500 for comparison purposes:

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