Drying Out Heating Up of Refractory Linings

Drying out and heating-up of refractory linings
Stefan Thomas
Refractory installation
of an entire plant
dynamic
mainly bricks
How much water has to be removed?

In case of a preheater lined with 2000 tonnes of refractory materials,
around 1000 tonnes thereof being refractory concretes
average water content of 8 % 80 tonnes of water to be vaporized
What measures help before drying out

Use exact amount of water (as less as possible during installation of all
monolithics)
Stitching of evaporation holes (castable layer thickness >150mm)
As much as possible time for natural evaporation
Drying out and heating-up diagramm of refractory

castables/concretes
(RCC, MCC, LCC, SC, JC)
Two different kinds of water are found in the refractory lining:

1. Physically bonded water (free water):
removed at 100-150C
Conversion of physical and chemical bonded water to the vapour phase
by evaporation or vaporisation.
Evaporating already during setting process at room temperatures
and normally vaporising at 100C
2. Chemically bonded water (water of crystallization):

removed at 300-800C
water but more difficult to be removed.
Removal by vapour-diffusion or vapour-flow.
Decomposition of water containing minerals.
Water will be expelled at 300-800C at the end of the drying out process
and within the heating-up process.
Physically bonded water

Wet cutting of bricks (only Al-bricks! )
Too much water in castable
Physically bonded water in expansion joint material

(rainwater)
Chemically bonded water under the

scanning electron microscope (SEM)
Hydration of magnesium oxide

Formation of cracks due to brucite (Mg(OH)2 )
formed in the sintered structure
hexagonal brucite sheets
Acc.V Spot Magn Det WD Exp

25.0 kV 4.0 540x SE 9.8 17 CRB Analyse Service GmbH


Behaviour of drying rate
Behaviour of drying rateasas

a function
of drying
a function
of drying
time time
Phase 1
Phase 2
90
Low vapour pressureLow drying rate
80
70
Drying rate
Drying rate (weight/h)
100
60
Const. Drying Rate
Decreasing Drying Rate
50
40
30
20
10
0
1
tkn6
Drying tim e
Drying time (h)
10
11
12
13
Drying out and heating-up diagramm of refractory concretes/castables

(RCC, MCC, LCC, SC, JC)
Phase 1: Initial phase:

Evaporation of physical bonded water is relevant
Evaporation commences already during setting process at T < 100C:

Water is partly incorporated into the mineral lattice structure
> 24 h in room temperature! The longer, the better!
Vaporisation of free water at 100C
Physical bonded water can be found in very fine capillaries

Higher temperatures are necessary to overcome capillary forces
Vaporisation of capillary water at >100C (100-150C)
Saturation vapour pressure as a function of temperature
Phase 1
Phase 1
Temperature in C
Saturation vapour pressure in bar
20
0.02
50
0.12
100
150
200
15
250
40
300
86
350
165
Saturation vapour pressure as a function of temperature
Cold Face
Hot Face
Phase 1: Pmeniscus > Poutlet

Air flow
Inlet
Outlet
T [C]
100C
/1 bar
Poutlet
Pmeniscus
20C
/0.02 bar
Pcapillary
Low temperature, constant gasflow with high ventilation
P 1 bar
Evaporation holes stitched and protected with straw
Phase 2: Pmeniscus < Poutlet

Inlet
Air flow
Outlet
T [C]
350C
/165 bar
P 164 bar
100C
/1 bar
High temperature, low ventilation and air flow
Poutlet
Pmeniscus
Pcapillary
Desteaming holes are only necessary on the top of the cyclone

roofs to control the desteaming progress
As they dry, LC castables cause more problems due to:

Lower proportion of water
Lower porosity
Higher capillary forces
Lower water
vapour pressure
Slower drying rates
Lower water content of castable does not mean faster drying out and heating up!
IIlustration of an entire refractory installation

alumina bricks
gear
basic bricks
tyre
static
high rate of monolithics
dynamic
mainly bricks
static
high rate of monolithics
Time is money! So why heating-up slowly?

Spontaneous
explosion of
water
Why do we need to heat-up the system slowly?

Different elements of the system have their individual and particular
thermal behaviour and properties.
Different expansion coefficient
Different thermal conductivity
Different elasticy
Different strength
Different temperatures within the same material
All elements have to be treated as a whole system since they closely coexist
to each other and are integrated therein accordingly.
Temperature distribution in brick and kiln shell during heating-up
Hot Face of Brick

Temperature in C
Mid-Depth of Brick
Cold Face of Brick
Kiln Shell
Time in hrs
Thermal expansion of magnesia spinel bricks and kiln shell

Hot
face
Kiln
shell
1200
400
1000
800
600
Compression
Point of equal expansion
300
Safe zone
200
prauC
tem
400
200
thermal expansion of
the kiln shell
rancetolis
100
-1
N/mm2
thermal expansion of
magnesia spinel bricks
0
100 50
1
0
2
%
relative expansion
Heating-up is limited by the tyres and other mechanical parts
Squeezing at the tyres
Girth Gear
Recommondation to heat-up installations with grate-cooler and

tertiary air duct
Before drying, at least 24h conditioning time for all masses

Closing kiln inlet and cooler outletopening (Ytong o.a.)
Adjustment of air flow with TAD slider.
Configuration of multiple high velocity burners and thermal elements
Fuel, ideally gas or light fuel-oil
Drying out and heating- up using exclusively the

central burner
Drying out and heating-up has to be done in one step.
To protect the refractory lining in the rotary kiln, whole time for drying
out and heating-up is limited to 72 hours.
(Drying out should take max. 36 hours.Heating-up is to start immediately
afterwards and is to be finished after 72 hours).
Turning of rotary kiln should start at shell outside temperature of 100C
(aprox.6-8 hrs after ignition of flame).
Tyre clearance is to be controlled at regular intervals to avoid a
squeezing of the rotary kiln by the tyre.
In emergency case cooling of kiln shell may be required.
Drying out and heating-up using exclusively the

central burner
T2
ILC
T3
Riser
Drehofen
Kiln
Cooler
Khler
R
Steigi T1
schacht
s
e
r
FLS Kuwait
1. Drying out and heating-up using exclusively the central burner
Raw meal feeding is started in KHD and Polysius plants if the inlet chamber
temperature exceeds 850 C.
In case of FLS plants, raw meel feeding commences once a temperature of

920 C is reached in the lower cyclones.
Drying out and heating-up with calciner burner
2. Drying out and heating-up using exclusively the calciner burner
Theoretically possible and easily to be managed at first glance, but:

calciner burners are not designed for small quantities of fuel
danger of overheating of the brickwork opposite the burners

sufficient heat distribution up to the cooler benches not possible
2. Drying out and heating-up using exclusively the

calciner burner
Expected temperatures at Kuwait Cement Co., (FLS)
2. Drying out and heating up using exclusively the calciner burners

Actual temperatures at Kuwait Cement Co., (FLS)
Practically not advisable
3. Drying out and heating-up using the central burner and

calciner burner (no auxiliary burners)
Theoretically possible, but:
Drying out and heating-up time is limited (see process with central burner)
Early turning of rotary kiln is required.
Temperatures in rotary kiln do rise very fast Danger of squeezing
Too fast drying of castables/wear benches in the cooler as drying only
commences after first clinker has arrived.
.0
6.
03
20
03
03
03
20
20
.0
6.
.0
6.
20
03
03
20
.0
6.
.0
6.
04
03
02
02
01
03
20
20
.0
6.
03
03
03
20
20
20
.0
5.
.0
5.
.0
5.
.0
5.
01
31
30
30
29
03
:5
3:
03
00
28
18
18
6:
1:
5:
5:
:3
:3
:1
:1
54
39
3:
1:
:3
12
22
08
18
03
:2
03
48
39
7:
7:
1:
:0
:0
:2
12
22
07
17
Temperatur in C
Drying out curve with actual temperatures measured during the process
600
500
Sollwert
400
TC 1 Mestelle 1
300
TC 2 Mestelle 2
TC 3 Mestelle 3
200
TC 4 Mestelle 4
TC 5 Mestelle 5
100
Typical auxiliary burner assembly situation for gas

Clean, easy manageable fuel but high safety requirements
Typical auxiliary burner assembly situation for light oil

Fuelstorage and distribution simple, but heavy smoke development
4.1. Plants without tertiary air duct

Distribution of auxiliary burners:
Two auxiliary burners in the cooler
Two auxiliary burners in the kiln hood
Two auxiliary burners in the inlet chamber
Two auxiliary burners in the lower cyclones
When applying this method, drying will take longer than with the main
burner method and is therefore advantageous to the kiln lining.
Heat distribution in all vessels is very equal, particulary drying in the cooler
can be commenced at its optimum.
Total drying and heating-up time is limited and any interruption after drying
is not possible.
Turning of kiln necessary if shell temperature exceeds 100C.
4.2. Plants with tertiary air duct

Rotary kiln has to be closed by a bulkhead.
Cooler exhaust gas duct or connections have to be closed (bulkheaded)
Distribution of auxiliary burners:
similar to previous method
Drying and heating time is not limited but recommended to range between
100 and 125 hours.
It is easy to follow up the drying and heating-up scedule as well as to
follow the holding time.
When applying this method it is possible to do the final heating at a later
stage since the rotary kiln was cold and not affected by the heat.
Burner being introduced wet, without drying out

Explosive character
of steam
Burner Drying
Burner Drying
Burner Drying
Dry out or barbecue preparation in raw meal pipe?
Good idea to get rid

of waste but please
Professional drying of pipes with heater mats

(max 450C)
Drying out cooler section

Grate plates covered
with insulationboards
Bulkhead at the end
Before drying out cooler section

Thick layers like wear
banks require special
care
Drying out is a must
LCC castable sensitive
due to high amount of
chemically bonded water
Installation of wear banks
always in the end
Clinker for protection

of the grate plates
Lower part fo
wearbanks have been
cleared again to
ensure temperature
access during dry out
Prevention of thermal
shock
Grate plates covered

with clinker
Bulkhead at the end
Bulkheaded kiln outlet

Rockwool and scaffolding
Calcium silicate boards

with metal framing
Bulkheading of a cooler exhaust gas duct

Closing of secondary
air with rock wool
Drying out, equipment , gas tanks
Drying out equipment
Support burner
Lightoil burner in action

Positioning of support
burners at cooler side
wall door
Drying out, equipment

Single burner control
29
.0
5.
20
30
03
.0
1
5.
20 7:0
30
7:
03
48
.0
07
5.
20
:0
31
7:
03
03
.0
22
5.
20
:2
01
1:
03
39
.0
12
6.
20
:2
01
1:
03
39
.0
03
6.
02 200 :33
:5
3
.0
4
18
6.
20
:
02
03 15:1
.0
8
0
6.
20 8:1
03
5:
03
18
.0
22
6.
20
:3
04
1:
03
28
.0
12
6.
20
:3
6:
03
00
03
:5
3:
03
Temperatur in C
Heating up protocol for comparison
600
500
Sollwert
400
300
200
100
0
TC 1 Mestelle 1
TC 2 Mestelle 2
TC 3 Mestelle 3
TC 4 Mestelle 4
TC 5 Mestelle 5

Burners at cooler side
wall
Openings closed tightly
False air prevention
Support burners squeezed in cooler side door
burner at cooler side
wall
burner at cooler side
wall
Burner pointing into
the cooler but not at
the roof

Support burner pointing
into the cooler
Direct flame contact to
be avoided
Grate covered with clinker
Cooler drying out

Oil leaking down into
cooler

First clinker arrives at
cooler
Serious thermal shock
for side walls
Thermal shock at castable

surface causes cracks.
Typical in cooler section
Hot clinker in direct
contact to thick castable
layer.
Explosive mixture
After drying out cooler section

Drying out with gas
Clean and smooth
surface

Smooth surfaces
No cracks
No damage
Expansion joints clear

View box in good shape
No cracks

Drying out with light oil
burner
Surface blackened but
smooth

Drying out with light oil
burner
Lining appears black by
carbon layer

Drying Out Heating Up of Refractory Linings

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Drying out and heating-up of refractory linings

How much water has to be removed?

What measures help before drying out

Drying out and heating-up diagramm of refractory

Two different kinds of water are found in the refractory lining:

2. Chemically bonded water (water of crystallization):

Physically bonded water

Too much water in castable

Physically bonded water in expansion joint material

Chemically bonded water under the

Hydration of magnesium oxide

hexagonal brucite sheets

Acc.V Spot Magn Det WD Exp

Acc.V Spot Magn Det WD Exp

Acc.V Spot Magn Det WD Exp

Behaviour of drying rate

Behaviour of drying rateasas

Low vapour pressureLow drying rate

Drying rate (weight/h)

Const. Drying Rate

Decreasing Drying Rate

Drying time (h)

Drying out and heating-up diagramm of refractory concretes/castables

Phase 1: Initial phase:

Evaporation commences already during setting process at T < 100C:

Vaporisation of free water at 100C

Physical bonded water can be found in very fine capillaries

Saturation vapour pressure as a function of temperature

Saturation vapour pressure in bar

Saturation vapour pressure as a function of temperature

Phase 1: Pmeniscus > Poutlet

Low temperature, constant gasflow with high ventilation

Evaporation holes stitched and protected with straw

Phase 2: Pmeniscus < Poutlet

High temperature, low ventilation and air flow

Desteaming holes are only necessary on the top of the cyclone

As they dry, LC castables cause more problems due to:

Higher capillary forces

Slower drying rates

IIlustration of an entire refractory installation

Time is money! So why heating-up slowly?

Why do we need to heat-up the system slowly?

Temperature distribution in brick and kiln shell during heating-up

Hot Face of Brick

Thermal expansion of magnesia spinel bricks and kiln shell

Heating-up is limited by the tyres and other mechanical parts

Squeezing at the tyres

Recommondation to heat-up installations with grate-cooler and

Before drying, at least 24h conditioning time for all masses

Drying out and heating- up using exclusively the

Drying out and heating-up using exclusively the

1. Drying out and heating-up using exclusively the central burner

In case of FLS plants, raw meel feeding commences once a temperature of

Drying out and heating-up with calciner burner

2. Drying out and heating-up using exclusively the calciner burner

Theoretically possible and easily to be managed at first glance, but:

danger of overheating of the brickwork opposite the burners

2. Drying out and heating-up using exclusively the

2. Drying out and heating up using exclusively the calciner burners

Practically not advisable

3. Drying out and heating-up using the central burner and

Typical auxiliary burner assembly situation for gas

Typical auxiliary burner assembly situation for light oil

4.1. Plants without tertiary air duct