Refractory training

Monolithic installation
 Content

1 Purpose of Castable
2 Types of Castable
3 Castable Storage
4 castable Design
5 Monolithic Installation

September
2010 2
1 Purpose of Castable

September
2010 3
Brick or castable?

 Advantages of castable
 Exceptional performance in certain cases
• crushing strength 140 N/mm 2
• chemical resistance
• dry joints
• easy to repair

 Disadvantages
 Difficult
• to set up
• to dry
• to demolish

September
2010 4
 Main Castable Application
Roofing
Cooler, cyclones, tertiary air
setting chamber, precalciner
and kiln hood
Rotary Kiln “Static” parts
Nose and retaining rings, Kiln hood ; cooler : bull nose,
inlet cone, kiln outlet downfall, sidewalls, horse shoe ;
tertiary air setting chamber ;
cyclones : lower part of the cone
and chute duct ; riser duct ;
smoke chamber and elbows in
general
September
2010 5
2 Types of Castable

September
2010 6
 Monolithic

 Types of monolithic material

 Dense castable
 Insulating castable
 Plastics or ramming mass

 Installation method
 Pouring low porosity
 Gunning 24 to 30% porosity
 Ramming layers

 Sometimes, use of metallic needles in some castables

Pouring is always recommended for castables

September
2010 7
 Types of dense castable

 Conventional castable
• smelted chamotte
• secar chamotte
• secar chamotte 19-25% porosity
• secar corundum

 Low cement castable

• 5 to 8% cement
• 8 to 12% porosity

 Ultra low cement castable

• 2 to 3% cement
• 4 to 8% porosity

 Plastic ramming castable

 Self flowing castable

 Gunning mix

September
2010 8
 Physical properties of the Low Cement
Castables - LCC

 High density

 Low porosity

 High mechanical strength over the whole temperature range

 Significant high strength over the critical range 800 to 1 200 °C

 Low corrosion rate

From now, this Refractory Training refers only to Low Cement Castable by
Vibration

September
2010 9
 Castable Brick

Planning/preparation Planning/preparation

Anchoring

Shuttering/gas trapping

Homogenisation

Dosing

Mixing

Transport Transport

Pouring

Vibration Laying

Setting/hardening

Curing

Drying

Heating-up Heating-up
September
2010 1
 Types of Castables

Roofing Rotary Kiln “Static” Parts

Corners (Bull nose) : Gibram
SR or similar
Upstream cooler roof : LCC
with high alumina (> 80 %)
Cyclone roofs : LCC with 45 %
alumina
Retaining and nose ring :
Gibram SR or similar.
Inlet cone : LCC with 45 to 60
% alumina.
Smoke chamber and riser duct
: LCC with 45 to 50 % alumina
- SiC.
Precalciner cone : LCC with 45
to 85 %, depending on
precalciner type.
Cyclones : LCC with 45 %
alumina

LCC = Low Cement Castable by Vibration

SR = Fast dry (with organic fibres)

SiC = Silicon Carbide

September
2010 1
3 Castable Storage

September
2010 1
 Castable Storage

 In a dry place

 The maximum storage capacity is stated on the individual data sheets

 Material which has hardened in the bags cannot be used by additional

crushing

 Do not use any castable that has become lumpy

 In all cases of material stored for a long time, samples should be taken
before use in order to determine cold crushing strength

 Cold winter : the castable should be stored in warm rooms at 25 °C during

48 hours

September
2010 1
4 castable Design
 Insulation Layer
 Wearing Layer (Position, Interlocked, Sizes
and Thickness)
 Types of Anchor (Ceramic and Metallic)
 Types of Support (Kiln, “Static” Walls,
Ceramic Anchors)
 Anchor and Block Arrangements
 Expansion Joints

September
2010 1
 Insulating Layer
 Insulating layer has a maximum operating T°

 If it melts, it becomes thermal conductive

 It should always be given a water-repellent surface

Insulation
Example of work •Lightweight refractory bricks
•Diatomaceous silica
•Calcium silicate
1/2
•Insulating castable
Water-repellent surface
Metallic •Bitumen paint
surface •Acrylic lacquer
•Polyethylene cover
50 mm insulating boards
2/3 50 mm insulating castable
200 mm dense castable
September
2010 1
 Wearing Layer – Interlocked

Roofing Rotary Kiln “Static” Parts

Interlocking is required to There must be no interlocking. Interlocking is required to

prevent gas infiltration which
attacks the anchors, holders
and burns the beams.
The blocks should be
independent and separated by
expansion joints (ceramic
fibre).
prevent gas infiltration and
penetration of dust which
attacks the anchors and burns
the walls.

They should be aligned in

function of the nose ring
plates.

September
2010 1
 Wearing Layer – Interlocked

Gas trapping in
vertical wall

Ceramic fibre expansion joint

6 mm compressed to 2 mm

“Female” form “Male” form

September
2010 1
Wearing Layer – Interlocked

Gas trapping in
vertical wall

Ceramic fibre expansion joint

6 mm compressed to 2 mm

Gas trapping in
vertical wall
September
2010 1
 Wearing Layer – Block Sizes

Roofing Rotary Kiln “Static” Parts

800 x 800 mm or less than 400 x 400 mm or less than Typical is 800 x 800 mm but
0,64 m². 0,16 m². always less than 1,0 m².

In the nose ring, it has the

same dimension as the plate.

September
2010 1
 Wearing Layer – Block Thickness

Roofing Rotary Kiln “Static” Parts

Typical is 200 mm or Minimum is 200 mm. Typical :

according to lining design
recommended by the It can be thicker depending on Cooler : 230 mm
refractory material supplier. kiln diameter.
Preheater : 150 mm

In this case, many different

thickness are possible
depending on the specific
casting place.

Lining design recommended

by the refractory material
supplier should be followed.

September
2010 2
Anchoring

 Not recommended

September
2010 2
 Type of anchor – Metallic ( V )

 Install floating anchors free to move in the 3 dimensions

 Anchoring of 16 to 20 per m² (more at burner lining)

 Coat the anchor with scotch tape and provide plastic cap to the V
tips

 The two legs of the V should not exceed ½ and ²/3 of the thickness
of the wearing layer

 The V angle should be 15° (inside insulating layer) and 60° (inside
wearing layer)

 The point where the “legs” of the V are bent to form an angle of
60° should be 20 mm deep in the wearing layer

 The V anchors are always made of heat resisting steel (stainless

steel AISI 310)
September
2010 2
 Types of anchor – Metallic ( V )

Typical anchor diameters

Roofing Rotary Kiln “Static” Parts

8 to 10 mm 8 to 10 mm 6 to 8 mm

Example :
Anchor design
for burners
Ø = 5 mm

September
2010 2
 Types of anchor – Metallic ( V )

Example :
Anchor design
for kilns.
Block thickness :
250 mm

September
2010 2
 Types of anchor – Metallic ( V )

Example :
Anchor design
for kilns.
Block thickness :
220 mm

September
2010 2
 Types of anchor – Metallic ( V )

Example :
Anchor design
for roofing.
Block thickness :
200 mm

Cooler Roofing

September
2010 2
 Types of anchor – Metallic ( V )

Example : Support
Anchor design
for roofing. The support must
be inserted in the
Tack welded
insulating layer

Metallic anchor

September
2010 2
 Types of anchor – Metallic ( V )

Example :
Anchor design
for “static” walls.

Metallic
Anchor
Tack welded

The support must

be inserted in the
insulating layer Support
September
2010 2
 Types of anchor – Metallic ( V )

Tack welded
Example :
Anchor design
for “static” walls.

The support must

be inserted in the
insulating layer
Support

Metallic anchor
September
2010 2
Types of Support - Kilns

 Anchors support should be an “Omega” (Ω).

 The Ω diameter is always 2 mm thicker than the anchors diameter

 The Ω should be made with the same mechanical characteristics of

the metal base quality, where they are welded

 Coat the Ω with scotch tape and fill up the empty space of the hole
with an insulating material (fibre or wool)

 The Ω should be welded in the kiln axis direction

 The Ω tips should be continuously welded in both sides but not at

the ends

 The V should be positioned in the middle of the hole and tack

welded in the Ω or in the kiln shell.
September
2010 3
Types of Support - Kilns
 At nose ring plates, it is also possible to weld the support on the head
of the bolts, taking into account the number of bolts available at each
plate and anchoring arrangement.

 In this case, the steel quality of the support and bolts should be
compatible taking into consideration welding process.

September
2010 3
 Types of Anchors – Ceramic

Clamp
Insulating layer

Claw

Wearing layer
Ceramic anchor assembly Claw coated with wool
September
2010 3
 Anchor Arrangements - Roofing
 Mixed anchoring : V of the metallic anchors are installed inverted,
staggered and always perpendicular to the pipes

 V tips are bent at 0 and 90°

 Ceramic anchors are located in the middle of the metallic anchors

and hung in any position

 Anchor density is 20 anchor per m² : 4 ceramic and 9 metallic

anchors in 0,64 m² (800 x 800 mm).

 This arrangement is also valid for “static” walls where mixed

anchoring is required : smoke chamber, riser duct, cooler sidewalls
(front) and kiln hood.

September
2010 3
 Block Arrangement

 Carry out staggered arrangement except for the blocks casted in the kiln
outlet

 Staggered arrangement prevent gas infiltration

800 mm

800 mm

Staggered panels
September
2010 3
 Expansion Joints – Nose Ring
 Expansion joints are used to prevent damages in the nose ring caused
by the expansion of the brick lining

 Nose ring plates must be casted separately

 4 mm ceramic cardboard or compressed ceramic fibre covered by a

plastic film should be installed :
1
 between the plates (side to side)
2  between the plate and the refractory ring (castable or brick) in front
of the plate
3  between the inner rib of the plate and the castable laid on the plate

September
2010 3
 Expansion Joints – Nose Ring

Ceramic cardboard = 4 mm

3
September
2010 3
Thank You All

September
2010 3