Refractories on site, what now?

Frank Trube
Presented by Dirk Basten
January 2019, Nigeria
Refractories on site, what now?

• Drawings- Read and understand.

• Site preparation before lining starts
• Daily business during lining works
• Lining is completed / dry out
• Things to observe
Drawings – read and understand
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Drawings – read and understand

1
3
5 2
 4
Drawings – read and understand

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1
3

5
1. Item numbers for different shapes and qualities.
2. Mixing ratio of different shapes in cylindrical parts.
3. Distances of support flanges
4. Informations about „hot spots“
5. Thickness of individual layers.
6. Important additional informations
Drawings – read and understand

Item list for

drawing
Site preparation before lining starts

1. Material check and documentation of actual situation

• Safety precautions

• Completeness (Packing list, Container packing list)

• Damages

• Storage conditions
Site preparation before lining starts

1. Material check and documentation of actual situation

Site preparation before lining starts

1. Material check and documentation of actual situation

Site preparation before lining starts

2. Checking steel work of vessels and documentation of actual situation

• Dimensions

• Deformations

• Conformity of steel work with RT Engineering (acces doors, support flanges…)

Site preparation before lining starts

2. Checking steel work of vessels and documentation of actual situation

Site preparation before lining starts

3. Checking of contractors equipment for quality and quantity

• Mixer

• Gunning machine / Jetcast Equipment

• Brick saw, hand tools…

Site preparation before lining starts

3. Checking of contractors equipment for quality and availability

The supervisor‘s dream

Site preparation before lining starts

3. Checking of contractors equipment for quality and availability

The supervisor‘s dream

continues
Site preparation before lining starts

3. Checking of contractors equipment for quality and availability

welcome to life
Site preparation before lining starts

3. Checking of contractors equipment for quality and availability

High tech brick saw…

CE = China Engineering!
Site preparation before lining starts

3. Checking of contractors equipment for quality and availability

Daily business during lining works

General

1. Lining conditions (extreme heat, extreme frost, water penetration into the vessels)

2. Follow-up on material consumption.

3. Daily documentation of executed work (Installation log, punch list).

4. Weekly documentation of work progress.

5. Photo documentation of executed work.

Daily business during lining works

General

1. Supervision of lining is mainly:

• Checking the use of correct materials in corresponding vessel and area of vessel
• Checking of correct shapes (mixing ratios, thickness…)
• Checking of distance of anchors
• Checking of Panel sizes (monolithic lining)
• Checking of correct amount of mixing water in castables.
• Checking of correct installation of expansion joints (size, distance functionality)
• Checking of storage and handling conditions on site
(weather protection, material transport to site and into the vessels, preheating
of welding rods…)
Daily business during lining works

Refratcory lining

Monolithic lining Brick lining

Mortar lining in stationary parts

Casting / vibrating
and rotary kiln

Dry gunning Clench lining in rotary kilns

Wet gunning

Ramming
Daily business during lining works
Specifics on monolithic lining:

Cast-panel size anchor lay out

Anchor and panel
layout before welding
of anchors
Daily business during lining works
Specifics on monolithic lining:

Cast-panel size
Correct size and distribution
of cast panels.

Expansion joints are clean =

functional
Daily business during lining works
Specifics on monolithic lining:

CE-cast panel size and

expansion joints…
Daily business during lining works
Specifics on monolithic lining:

Quality, distance, welding and completeness of anchors (plastic caps)

Steel type

Diameter

Welding

PPE caps for expansion

Anti corrosive paint ☺ but not needed

Fortunately, the supplier has a copyright

on this type of anchor.
Daily business during lining works
Specifics on monolithic lining:

Quality, distance, welding and completeness of anchors (plastic caps)

Correct welding, distance

and plastic caps.
Daily business during lining works
Specifics on monolithic lining:

Tight installation of
insulation (calcium
silicate boards)

Mositure repellent
surface in contact
with castable.
Daily business during lining works
Specifics on monolithic lining:

No so tight
installation of
insulation (calcium
silicate boards)
Daily business during lining works
Specifics on monolithic lining:

Formwork:
Fixation of formwork on
anchors = no go!!!
Daily business during lining works
Specifics on monolithic lining:

Formwork:
Single board formwork= no
go!!!
Daily business during lining works
Specifics on monolithic lining:

Correct type and fixation of

formwork.
Daily business during lining works
Specifics on monolithic lining:

The „ball in hand“ test is a practical test to check the correct

amount of mixing water in the castable:

too dry consistency optimal consistency too wet consistency

Daily business during lining works
Specifics on monolithic lining:

Impact on water addition to castable:

Daily business during lining works
Specifics on monolithic lining:
Murphy‘s law:

Too much water

Too much vibrating
Bad type of formwork
Daily business during lining works
Specifics on monolithic lining:

Temperatures during installation / setting

• Material (cooling / heating of material)
• Mixing water (ice / hot water)
• Ambient (heating)
Vibration time
Curing procedures (moisturing of open surfaces, heating, cooling)
Setting time (stripping times for formwork)
Daily business during lining works

Refratcory lining

Monolithic lining Brick lining

Mortar lining in stationary parts

Casting / vibrating
and rotary kiln

Dry gunning Clench lining in rotary kilns

Wet gunning

Ramming
Daily business during lining works
Specifics on brick lining:

•Correct mixing of mortars

Daily business during lining works
Specifics on brick lining:
Not so tight installation
of insulation
Daily business during lining works
Specifics on brick lining:

Correct mixing ratio

of bricks in conical /
cylindrical parts.
Daily business during lining works
Specifics on brick lining:

Fully pointed joints.

No“window
framed“ joints
Daily business during lining works
Specifics on brick lining:

Correct placement
of anchor and
anchor bricks in
straight walls.
Daily business during lining works
Specifics on brick lining:

•Correct cutting procedure (wet / dry cutting, min. brick size of cut bricks)

• Wet cutting only for alumina and high alumina bricks.

• Basic bricks, must be cut dry only!

• Min. size of a cut brick is ½ of brick height / lenght

Daily business during lining works
Specifics on brick lining in rotary kilns:

•Since the rotary kiln is a dynamic piece of equipment, the lining has to be executed even
more carefully!

•The lining in rotary kilns can be installed either with mortar or clench, i.e. without
mortar.
No reference lines:

50mm

0mm
The correct way:

0 mm
Start of lining:

Why?

To avoid interlocking of
the indiviual rings,
because...

Start the lining with staggered rings

Start of lining:

…something like this:

Start of lining:

…is a result of this!

Lining is completed
After completion of lining, it is recommended, to dry and heat up the refractory lining
immediately.

Drying out should be done by specialized companies.

Drying, heating and start of production should be a continious process.

Keep in mind, that the basic lining in the kiln is hygroscopic and the hydration process in
the kiln will start soon.
(2 – 4 weeks, after completion of lining, depending on climate conditions)
Things to observe
Besides his work as a refractory specialist, the supervsior has to keep an eye on safety as
well, since it has a direct impact on his work.

General safety on site

•Preheater plattforms, staircases, falling objects…
•Electricity
•Working in confined spaces
•Working on different levels in one vessel
Keep in mind:
A virtually improper installation might last for a long time,
but not in a cement kiln !
Any questions !?