REFRACTOTRY INSTALLATION TECHNIQUES

11
IN CEMENT INDUSTRY

Chapter 2
Refractory Installation Preparation Guidelines

2.1 Preparation prior to the refractory installation in the

cement Rotary Kiln

2.1.1 Inspection of the refractory lining conditions in the

cement rotary kiln before removing the old lining.
- Normally, an inspection of the refractory in the Rotary
Kiln can be conducted at least 24 hours after the Rotary
Kiln has been shutdown. The inspection is being
conducted to check the condition of the refractory
lining in the rotary kiln, for example, observation of the
coating formation characteristics, and examination of
any abnormality of the refractory lining. The
inspection is also conducted so that a record and image
of the abnormalities and their locations can be made
(i.e. the characteristics or patterns of the lining on
various conditions such as displacement, spiral,
spalling, crack, over-burnt, chemical infiltration,
refractory lining thickness, and etc.,). These
observations shall be compared to the previous record
of the conditions of the refractory lining.
- The record and image gathered can be used for
determining the quality of the new refractory lining
that will be installed. It can also be used to determine
the type of installation method needed (for example:
increase or decrease of ceramic paper to be installed for
the refractory thermal expansion, amount of refractory
mortar to apply in reducing mitigating the crack or
spalling effect of the lining when it is subjected to high
external stress, especially the area under the tyre ring).
- The data on the conditions of the refractory lining and
coating are associated with the past operational
conditions of the cement production.
 REFRACTOTRY INSTALLATION TECHNIQUES
12
IN CEMENT INDUSTRY

2.1.2 Drilling to measure the lining thickness

- After the inspection of refractory condition in the
Rotary Kiln, drilling to measure the thickness of the
lining should be conducted in every interval of 1 meter.
A report on the lining thickness must be kept and
compared with the records of past lining thicknesses.
- For every meter, 2 measurements of different positions
should be taken and the average values should be
recorded. Normally, the measurements are taken by
drilling from the 4 and 8 o’clock positions.
- The lining thickness information is used for
determining the amount or the length of refractory in
the rotary kiln that needs to be replaced and for
determining the type and quality of refractory to be
installed.

2.1.3 Removal of coating and refractory lining in the

rotary kiln
- For safety purposes, the coating in the Rotary Kiln
must be removed before removing the refractory
lining because after the Kiln has cooled down the
coating is likely to fall off and harm the workers and
machine (demolishing car), as shown in Figure 2-1.
Without the coating, the inspection of the condition of
the refractory is more effective and the demolishing
car is also able to move around easily during the
removal of refractory lining. The removal of coating is
even more necessary in case a forklift is used for
transporting refractory in and out of the Rotary Kiln.
- When the required area of the refractory lining has
been demolished or removed, they are to be moved out
from the Rotary Kiln by discharging to the manhole(s)
of the Rotary Kiln using a CAVO car, as shown in
Figure 2-2.
 REFRACTOTRY INSTALLATION TECHNIQUES
13
IN CEMENT INDUSTRY

Fig. 2-1: Demolishing Car during coating removal

SRIC
SRIC

Fig. 2-2: CAVO Car transporting the removed refractory

through the manhole
 REFRACTOTRY INSTALLATION TECHNIQUES
14
IN CEMENT INDUSTRY

2.1.4 Inspection of the kiln shell condition

- After the old refractory lining has been completely
removed from the area that needs to be replaced, an
inspection of the kiln shell should be made in order to
determine the deformation or distortion or abnormality
in any area of the kiln shell, such as swollen or bended
areas. Identification marks should be made, so that
more attention is paid to these areas during refractory
installation.
- In case there are a lot of rusts or scale formation on the
kiln shell, which are possibly caused by the corrosion
of hydrochloric acid or sulfuric acid generated by the
condensation of chloride and sulfur vapor in the fuel,
the scale must be removed before installing the new
refractory lining. There are many methods of removal
such as the use of iron brush for a small quantity of
scale formation, but the use of sand blasting for the
scale formation over a wide area is recommended.
- Check the various seams and welding joints on the kiln
shell, including any mark that may have been caused
during refractory removal. Smooth the surface of the
kiln shell by using a grinding machine shown in Figure
2-3, before installing the new refractory lining
especially when it is an old Rotary Kiln with a lot of
welding joints.
 REFRACTOTRY INSTALLATION TECHNIQUES
15
IN CEMENT INDUSTRY

Fig. 2-3: Picture illustrating the marks on the kiln shell

caused during the removal of the refractory lining,
thus the surface must be smoothed before re-
installation.
 REFRACTOTRY INSTALLATION TECHNIQUES
16
IN CEMENT INDUSTRY

Fig 2-4: Picture illustrating the kiln shell surface

after the grinding.
- In case not the entire refractory lining is in need of
replacement, after the damaged lining portions have
been removed, use square steel to hold the remaining
refractory in place (every 60 degrees angle or every 1
meter along the circumference) in order to prevent
misalignment or movement of the lining away from its
original position while the rotary kiln turns.

Angle
steel
welded

Fig. 2-5: Picture illustrating the use of angle steel to lock

refractory lining portion that does not require
replacement.

2.1.5 Conveying the refractory materials into the rotary

kiln
- The procedure for conveying the refractory materials
into the Rotary Kiln is very important. Proper
management will allow faster work as no time is
wasted while waiting for refractory materials to be
 REFRACTOTRY INSTALLATION TECHNIQUES
17
IN CEMENT INDUSTRY

conveyed. Having equipment to convey the refractory

materials into the Rotary Kiln does not only save time
and manpower but also reduce possible damages of the
refractory materials during transportation (chipping or
breaking). Normally, the equipment to be used in
conveying the refractory materials into the Rotary Kiln
is a conveyer belt, as shown in Figure 2-6, which is
ideal for small diameter of the Rotary Kiln. The use of
rail tracks or folk lift, as shown in Figure 2-7, is ideal
for a larger diameter of the Rotary Kiln.

Fig. 2-6: Picture illustrating the use of conveyer belt in

conveying the refractory materials into the Rotary
Kiln.
 REFRACTOTRY INSTALLATION TECHNIQUES
18
IN CEMENT INDUSTRY

Fig. 2-7: Picture illustrating the use of rail tracks in

conveying the refractory materials into the Rotary
Kiln.

2.2 Preparation prior to the refractory installation in the

Cyclone Preheater

- Approximately after 24 hours of the shut down of the

Rotary Kiln, start removing the coating formed on the
surface of the refractory lining in the cone area of every
Cyclone, down pipes and riser pipes.
- Start removing the coating from the top of the cyclone in
sequential order downward, by using steel rod to knock
and clear the coating, or using air jet to blast the coating
out from the surface of the refractory.
- The purposes of coating removal are:
• To prevent the coating from falling off when the
temperature inside the Cyclone Preheater cools
down causing injury or damage to areas below.
 REFRACTOTRY INSTALLATION TECHNIQUES
19
IN CEMENT INDUSTRY

• The damage conditions can be more accurately

assessed, so that refractory work quantity can be
accurately estimated.
• To prevent the coating from falling off during
preheating of the kiln after the new refractory
linings have been installed. The coating that falls
off will cause clogging in the down pipe. The
Rotary Kiln must be shut down again to clear the
clogging.
- Scaffolding constructed in the Cyclone Preheater must
be secure and strong, with safety as the highest priority
under consideration.
- All refractory installation workers in the Cyclone
Preheater must wear safety belt when working in a high
rise area.
- Use color spray paint to indicate the areas inside the
Cyclone Preheater where refractory lining replacement is
needed.
- The bottom portion of every Cyclone and riser pipe must
be sealed with plywood or steel plate to prevent danger
that may arise when refractory is removed, including
preventing tools from falling onto workers that are
working below.
- If the bottom portion of the Cyclone is not sealed, it may
cause clogging in the down pipe when thorough
inspection prior to the kiln operation has not been done.

2.3 Preparation prior to the refractory installation in the

Clinker Cooler

- After the Kiln has been shutdown, allow the Grate Cooler
to continue running for a while until there is as little
clinker left as possible so that it becomes easier to work.
- After 24 hours of kiln shutdown, an inspection of
refractory linings inside the Clinker Cooler can be
 REFRACTOTRY INSTALLATION TECHNIQUES
20
IN CEMENT INDUSTRY

conducted in order to identify the areas that need

replacement or repair.
- Set up the scaffolding bestride over the Grate Cooler for
high working areas, then re-inspect the damage of the
refractory lining, and mark the positions where repair is
needed with color spray paint.
- During the removal of the refractory, cover the surface of
the Grate Cooler with canvas or plywood to prevent dust
from falling into the Grate Cooler which causes
blockage.