Drying out and Heating up of refractory installations in the cement

industry
Dirk Basten
Refratechnik Cement Supervisor Training Course 2012
Refractory installation
of a complete plant
Scheme of the refractory installation of a complete plant

static dynamic static

predominantly castable predominantly bricks predominantly castable
Water sources – physically bonded water

Installation of wet bricks Strictly follow guidelines

Avoid leaking water

 Anme rkunge n: Ge ne re ll sollt e vor de m Be ginn de r Trocknung und de s Aufhe ize ns e in minde st e ns 24 st ündige s Aushärt e n de r Masse st at t ge funde n habe n!
1* > Ofe ndre hung 180° a lle 45 minut e s - Re fe re nzmante lt e mpe ra tur in de r Bre nnzone ca . 100 - 150°C
2* > Ofe ndre hung 90° alle 30 minut e s - Re fe re nzma nt e lt e mpe rat ur burning zone ca.. 200 - 235°C
3* > Ofe ndre hung kont inuie rlich - Re fe re nzmant e lt e mpe rat ur burning zone ca . 260 - 310°C
* t he ore t ical calculat e d she ll t e mpe rat ure - de pe nds on e nvironme nt condit ions

T [°C]
1400

1300 Trocknung Aufheizen

1200

1100
850°C -1000°C
Inbetriebnahme
1000

900

800
3*
700

600 approx 30 K/h

2*
500

400
1*

300 approx 10 K/h

200 approx 13 K/h Entfernen der

Abdichtungen / Start des
100 approx 10 K/h Hauptbrenners

0
0 12 24 36 48 60 72 84 96 108 120 132 144 156 168

t [h]
Typical dry out curve for complete new plant
 Heating diagram of refractory concretes
1500
1400 Heating diagram of refractory
Aufheizdiagramm concretes
feuerfester (AR,
Massen (LCC, MCC,LCC, SC, JC, G,
SC, JC)
1300 MCG, Heating diagramm of refractory concretes (LCC, MCC, SC, JC)
LCG) Stationary areas wall thickness 50- 50- 300 mm
1200
1100
1000
Temperatur / °C
Temperature / °C

900
30 °C/h
800 bis zur Einsatztemperatur
up to temp. of application
700
600
500
10 h / 500 °C Heating Up
400
300
25 °C/h
Drying
200 20 h / 110 - 150 °C
min. 24 h Erhärtungsdauer 15 °C/h
100 min. 24 hrs setting time

0
0 10 20 30 40 50 60 70 80 90 100 110
Zeit nach Einbau / h
Time after installation / hrs
Time after installation / h
 Behaviour of drying rate
Drying rate
as as a function
a function of time
of drying time

100
Phase 1 Phase 2
90

80
Low vapour pressure
low drying rate
70
Drying rate [quantity/h]

60
Drying rate

continous drying Decreasing drying rate

50
rate
40
30
20

10
0
1 2 3 4 5
tkn
6 7 8 9 10 11 12 13
Dryiing time
Drying time [h]
 Phase 1: Pmeniskus > Ppore opening

air
Inlet outlet

T [°C]
100°
100°C Ppore opening
/1 bar

∆P≈ 1 bar
Pmeniskus

20°
20°C
/0.02 bar Pcapillary
Low temperatur, continous airstream with high ventilation
 Phase 2: PMeniskus < Ppore opening

Inlet Air stream

Outlet
T [°C]
350°
350°C Ppore opening
/165 bar

∆P≈ 164 bar

Pmeniscus

100°
100°C Pcapillary
/1 bar

High temperature, low ventilation and airstream

Pressure- and temperatur gradient in a to be dried refractory body
(Dissertation: Modell zur Beschreibung der Trocknung von Feuerbetonen, Ingo Großwendt, 2007, p.25)

250

S a tu r a tio n v a p o u r p r e s s u r e (b a r)
200

150

100

50

0
0 50 100 150 200 250 300 350 400
Temperature (°C)

1500
1400 Aufheizdiagramm feuerfester Massen (LCC, MCC, SC, JC)
1300 Heating diagramm of refractory concretes (LCC, MCC, SC, JC)
1200
1100
1000

Temperatur / °C
Temperature / °C
900
30 °C/h
800 bis zur Einsatztemperatur
up to temp. of application
700
600
10 h / 500 °C
500
400
25 °C/h
300
200 20 h / 110 - 150 °C
min. 24 h Erhärtungsdauer 15 °C/h
100 min. 24 hrs setting time

0
0 10 20 30 40 50 60 70 80 90 100 110
Zeit nach Einbau / h
Time after installation / hrs
Explosive spalling of castable surface (satellite cooler)
Dry out - surface cracking

Typical view on a badly

predried castable , cooler
sidewalls
Explosive spalling of Castable
Spalling of wet LCC castable on burner
Optimized drying schedule
Exhaust gas – sealing of kiln and ducts

Protection against humid exhaust gases (filter, basic bricks)

Evaporation holes in the cycloneroof
lockable socket for controled evaporation
Heating up of kiln
Limiting mechanical components

Contraction at tyre
Temperaturedistribution in brick and kiln shell during heating up

In 8h to 1000°C
Too slowly heating up, too early turning of kiln

Loose lining

migration, relativ
movement
Too fast heating up

Axial and radial pressure

Spalling , cobblestone surface
Done: Drying and heating successfully finished
first clinker in cooler

Typical timing:

78 h – 120 h