INSTRUCTION MANUAL .

Drying-out of newly installed

70001614-1
refractory materials

SF Cooler, kiln hood and tertiary air duct

Erection, Operation & Maintenance and Safety

VIGERSLEV ALL 77 - 2500 VALBY - DENMARK 2040 AVENUE C - PA 18017-2188 BETHLEHEM USA CAPITAL TOWERS 180. KODAMBAKKAM HIGH ROAD, NUNGAMBAKKAM,- CHENNAI 600 034 - INDIA
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List of contents:
Page:
1 General information ..................................................................................... 3
1.1 Scope........................................................................................................... 3
1.2 Definition and abbreviation .......................................................................... 4
1.3 Legend ......................................................................................................... 4
2 The drying-out process ................................................................................ 4
3 Heating up................................................................................................... 4
3.1 Equipment.................................................................................................... 4
3.2 Preparations................................................................................................. 5
3.2.1 SF Cooler grates ............................................................................. 5
3.2.2 Bulkheads........................................................................................ 5
3.2.3 Further draft control......................................................................... 5
3.2.4 Thermocouples................................................................................ 5
3.2.5 Burners............................................................................................ 6
3.2.6 Fuel supply ...................................................................................... 7
3.2.7 Weep holes ..................................................................................... 7
3.3 Firing ............................................................................................................ 7
4 Suggested suppliers .................................................................................... 8

Created by: KlKr Sort code: 4K500 Translated by:

Approved by: Approved date: Reb Pages: 8

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NOTE !
The present instruction manual is concerned with the situations which, according
to the experience of F. L. Smidth, are the most likely to occur. An exhaustive
enumeration of all conceivable situations, which may occur during manufacture,
installation, operation and maintenance of the equipment, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen
in the instruction manual, and which the operator is/or feels unable to handle, it is
recommended that F. L. Smidth is contacted without undue delay for advice on
appropriate action.

1 General information
1.1 Scope

Mandatory!
The local safety legislation for the mentioned equipment must be followed
to any time. The suppliers instructions for the equipment must be
carefully studied and followed.
During the drying-out operation, all openings must be closed and
adequate precaution must be taken to prevent any unauthorized opening
of such openings.
Attention must be given to the risk of personnel being trapped inside the
equipment during drying out. Before the drying-out begins and the
manholes are closed, an authorized operator must make sure that all
workers has vacated the equipment.

If a newly installed lining is heated up too quick one might expect steam
explosions within the lining. The free water will have left the lining when
o
heated above 100 C. But plastic refractories still contains chemically
bonded water until 500 oC. In order to let the water leave through the pore
structure without making damage, the initial heating up process should be
controlled.
The supplier of lining materials and installation will mostly have their own
drying-out instructions and these should always be followed. In absence of
any instructions, the general methods mentioned in the following should be
applied.
The drying-out of the kiln and preheater can be done with the main burner,
but the drying of the cooler, kilnhood and tertiary air duct must be done with
auxilery burners.
The drying-out process is to be applied to newly installed linings both in
new plants and major repairs.
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1.2 Definition and abbreviation

Authorized person An authorized person is a skilled person, who is qualified and who
by either the responsible manager or a qualified person is entrusted
with certain tasks.
Certified person A person who is skilled and authorized from any legal authority to
perform tasks, which must be certified by a third party or which
requires a legal authorization to perform.

1.3 Legend

Mandatory!
This symbol appears in the instruction manual to indicate dangers which,
in case of non-observance, may cause fatal or serious injuries!

Attention!
This sign is shown in the instruction manual where specific attention and
caution is needed to avoid damage to or destruction of the equipment
and/or parts of the installation.

2 The drying-out process

After a preliminary curing at ambient temperature in 24 hours, the lining should be
heated to 500 oC over a period of 96 hours. The temperature is raised with
adequate holding ramps during the period, allowing the temperature to soak into
the material. The main burner should be applied in direct continuation of the
drying-out process.

3 Heating up
3.1 Equipment
The must recommendable way to get the drying-out job done is to let a
company specialized in the job to do it. When supplied with drawings of the
machine and heating curves for the materials, they will supply the
equipment, manpower and know-how for the job.
If you have to supply your own equipment, the best way is to use a unit
including burner, oil pump, air fan and flame surveillance.
The equipment for the job should at least consist of the following:
High velocity gas- or light oil burners with flame surveillance, ignition and
manual operated fuel- and air valves. The burners must be equipped with
heat resistant nozzles.
The size and numbers of burners needed for the job, depends of the size of
equipment to be dried-out. But a total effect of the burners will often be in
the range of 2-5000kW.
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Mandatory!
The burners must comply with local safety legislations!

One fuel tank with a capacity of 3000 litre oil or a volume of gas with similar
energy potential. The tanks should be refilled during the process.
One air fan for each burner with a capacity matching the applied burners.
In case of oil burners: Oil pumps with a capacity matching the burners
requirements, plus pressure to compensate for the transport from the tank
to the burners.
Fuel and air hoses to compensate for the distance between the burners and
fuel/ air supply. The hoses must be able to with stand the fuel pressure.
High pressure fittings for the for the fuel transport system.
Thermocouples with corresponding type of compensation cable and reading
instruments calibrated for the actual type of thermocouble. The CrNi-Ni type
of thermocouple is adequate for the actual temperature range.

3.2 Preparations
3.2.1 SF Cooler grates
To protect the grates for the heat and limit false draft, the grates
must be covered with app. 400mm clinker or mineral wool etc..
3.2.2 Bulkheads
To ensure correct draft and heat accumulation, loosely constructed
bulkheads of a light refractory insulating material should be erected
in the kiln outlet and other places where draft is not desired.
3.2.3 Further draft control
Further draft control can be achieved by opening man doors in the
preheater tower and using the hoisting damper in the tertiary air
duct.

Mandatory!
If it is necessary to use man doors for further draft control, access
through the man doors must be avoided by screening them off in a secure
manner.!

3.2.4 Thermocouples
Thermocouples should be installed at the following points: Cooler,
Kilnhood and tertiary air duct. The thermocouples hot point should
be in the same level as the hot face of the lining. In order to protect
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the cooler grates; the temperature readings for the grates should be
checked regularly, either in the control room or by placing a
thermocouple under the clinker layer.
For correct readings it is important that the thermocouple and the
reading instrument are connected with the correct type of
compensation cable. If remote readings are preferred, common
cable can be used between the reading instrument and a terminal
placed in ambient temperature, the connection between the terminal
and thermocouple must be done with compensation cable.
3.2.5 Burners
The burners are placed in the man doors of the cooler; the number
of burners depends of the size of the equipment and the effect of
the burners. If a burner is placed through the man door behind the
crusher, the chain curtain should be pulled aside and fixed in a
manner making it possible to release it without entering the cooler.
Additional burners can be placed through the main burner hole and
at the man door in the tertiary air duct.
The man doors are bricked just leaving an opening big enough to let
the burner nozzle pas through and a spy hole from which the flame
can be observed. The burners are placed at thresholds, with the
nozzles protruding far enough into the cooler, to avoid direct flame
heat on the steel frame of the man door. The burners are connected
with the fuel and air supply and the control unit.

Bulk head

Burner nozzle
Flame

Ceramic fibre

Figure 1: Burner installation.

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1 Burner
2 Thermocouple
3 Bulkhead
4 Kiln
5 Tertiary air duct
6 Kiln hood
7 Cooler
8 Chain curtain
9 Clinker layer

Figure 2: Suggestions for placement of burners, bulkheads and

thermocouples.

3.2.6 Fuel supply

The fuel is supplied from one central tank, which is easy accessible
for refuelling.
The oil is transported to the burners by the oil pumps and hoses,
make sure that all connections are tightened sufficiently. The gas is
supplied from the plants main supply.

Mandatory!
All gas connections must only be done by certified personnel.

3.2.7 Weep holes

To facilitate the steam to escape, it is advisable to drill some weep
holes in the steel casing. The holes are suggested to be 12 and
placed with a density of one hole per square metre. The holes are
made where large quantities of steam are likely to escape, for
example roofs, walls at the kiln end and around the wear curbs.

3.3 Firing
Once the firing has started it should not be interrupted. Sufficient
personnel must be allocated to take care of the process 24 hours/
day in the 4 days the drying-out takes.
The temperature, burners, fuel tank and all connections must be
controlled every hour. The burners should burn with a clear flame. If
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the flame becomes smoky, the air must be regulated upwards until
the flame just turns clear.
o
The temperature is raised to 120 C in the beginning of the first 24
hours period and kept at this temperature to the end of the 24 hours
period. During the next 24 hours periods the temperature is raised to
2-, 3-, 4- and 500o C.

Temprature rise

600
500
temprature o C

400
300
200
100
0
0 4 24 30 48 58 72 80 96
hours

Figure 3: Heating curve.

At the end of the drying-out programe, the bulkhead at the kiln outlet
is demolished, the auxilery burners in the kiln hood removed and the
kiln is stated according to the kilns process instruction. At the time
when the clinker is about to reach the cooler, burner equipment and
bulkheads are removed and the man doors are closed and secured.

4 Suggested suppliers
Following companies are well known by FL Smidth and can be used
as drying-out specialists for complete drying-out jobs:
Hotwork International
Thermal Hire, UK
Secatherm, France

Following companies are well known by FL Smidth and can be used

as suppliers for drying-out burners:
Thermal Hire, UK
Weishaupt, Germany
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