Professional Documents
Culture Documents
FOR
REFRACTORIES
PART 3 REFRACTORIES FOR CEMENT KILN SYSTEM
UDC 666’94.041
PRICErRs 50.00
-
PRINTED IN INDIA
AT PRINTOGRAPH, NEW DELHI
AND PUBLISHED BY
BUREAU OF INDIAN STANDARDS, NEW DELHI 110 002
CONTENTS
Page
FOREWORD ... 7
1. INTRODUCTION ... 9
MEMBERS
SIIRI’R. K. SANGHI ( Allernate to
Shri I. C. Modi )
SHRI P. S. V. ANANTHANA- Engineering & Mineral Industrial Research
RAYANA Laboratory, Bangalore
SHRI B. N. GHOSII Tata Iron and Steel Co Ltd, Jamshedpur
SURI S. K. MITRA ( Al/ernate )
SF~RIT. K. GHOSH Tata Refractories Ltd, Beliahar
SI-~RIA. V. HINGORANI Steel Authority of India Ltd (Bhilai Steel Plant ),
Bhilai
SHRI B. S. VENKATARAMIAM
( Altefnate )
SHRI S. K. JHUNJHUNWALA Orissa Industries Ltd, Rourkela
SARI M. M. SAH~J( Alternate )
SHRI MANMOHAN SINGH Steel Authority of India Ltd ( Bokaro Steel Plant ),
Bokaro
SHRI A. S. KHALKHO ( Altcrnate )
SI~RI N. C MUKHERJEE India Firebricks & Insulation Co Ltd, Marar
SIXRI S. K. MUKHEKJEE Bharat Refractories Ltd, Hokaro
SHRI J. R. K. MURTHY Harry Refractories & Ceramic Works Pvt Ltd,
Calcutta
SHRI N. C. SAFIA ( Alternate )
SHRI R. C. NANDY M.N. Dastur B Co (P) Ltd, Calcutta
SHRI A. K. GHOSH ( Alternate)
DK J. D. PANDA Dalmia Institute of Scientific and Industrial
Research, Rajgangpur
DR N. SAROO ( Alternate )
DR T. V. PRASAD Engineers India Ltd, New Delhi
CDR M. S. BALI Directorate of Production & Inspection ( Naval ),
Ministry of Defence ( DGI ), New Delhi
J>T-CDR B. K. MISHRA
( Alternate )
SHRI D. N. BANERJEE Indian Iron & Steel Co Ltd, Burnpur
SHRI A. K. MUKHERJF,E
( Alternate )
DK G. BANERJEE Central Glass & Ceramic Research Institute
( CSIR ), Calcutta
SHRI S. P. BANERJEE( Alternate )
SHRI BHARA’~ BHASKAR Ishwar Industries Ltd, New Delhi
SHRI RAJEEV BHASKAR ( Alternate )
DR A. K. CHATTERJEE Associated Cement Companies Ltd, Bombay
SHRI S. K. BISWAS ( Alternate )
SHRI B. K. CHATTERJ~Z. Ministry of Defence ( DGOF )
~HRI D. K. MUKHERJEE
( Alternate )
SIIRI S. K. CHATTERJEE Steel Authority of India Ltd ( Durgapur Steel
Plant ), Durgapur
SHRI S. K. DUTTA ( Alternate )
SHRI M. H. DALMIA Orissa Cement Ltd, Rajgangpur
SHRI K. K. PRASAD ( Alternate )
‘RI S. K. DAS Directorate General of Supplies & Disposals ( Ins-
pection Wing ), New Delhi
SHRI R. N. SAHA ( Alternate )
SHRI A. C. DEY Steel Authority of India Ltd ( Alloy Steel Plant ),
Durgapur
5
SP : 37 ( Part 3 ) - 1987
Secretary
SHRI S. M. BHATIA
Joint Director ( Metals ), BIS
6
FOREWORD
Refractory materials are costly and a sudden failure of any refractory may
result in g.reat loss of time, product and equipment. Therefore, the selection of
refractories suitable for a particular application is of paramount importance.
Cost-benefit-analysis is often the basis of selection of such refractories. A refractory
best suited for an application may not necessarily have the longest life. In
selecting the proper refractory, a balance is struck between the initial installed
cost and in-service performance.
Steel industry uses over 70 percent of the refractories consumed in the country.
However, integrated steel plants employ a team of refractory engineers and
specialists for selection and use of refractories. On the other hand,-non-ferrous
sector, glass industry, and other high temperature and corrosion intensive
industries Cl0 not always employ refractory specialists. The application of
refractories in such industries is nevertheless very critical and any premature
failure may lead to long down times and loss of production.
The Handbook will be published in parts; each part dealing with particular
industry/process. It is intended to cover the refractories used in the following
industries:
No handbook of this type can be made complete for all times to come at the
very first attempt. During the course of use of this Handbook, it may be
possible to make suggestions with regard to improving its utility. All such
suggestions may be passed on to the Bureau of Indian Standards. These
suggestions ,wiIl be taken into consideration while revising the Handbook. The
suggestions/with regard to presentation of the Handbook will help in improving
the presentation of other parts which will be printed subsequently. A complete
list of Indian Standards for refractories is also given ( see Appendix A ) for the
convenience of the user.
SP : 37 ( Part 3 ) - 1987
1 [KILN SK*
l- ----l ,
L---___-__J
2.2 In actual operation, the semi-wet and semi-dry b) lepol preheater kilns, and
process kilns turn out to be of identical nature and c) suspension preheater kilns ( with or without
hence the broad classification of kiln systems is precalciners ).
reduced to the following three main types:
2.3 The broad characteristics or the three kiln
a) long wet/dry kilns, systems-are given below.
NOTE 2 The schematic diagrams of the above kiln systems are given in Fig. 2.
PRECALCINER KILN
FIRING HOOD IISCHARGE ZONE I COOLING 1 BURNING ZONE ISINlERINGl TRANSITION ZONE DRYING ZONE INCLUDING INLET ZONE
GAS TEMPERATURE : 1100-llOO°C GAS TEMPERATURE : 1300 -t600°C CALCINING OR PREBURNINGI CHAIN SECTION
GAS TEMPERATURE:!OOO-120O’C
: SLIGHT CHEMICAL ATTACK GAS IEMPERATtJRE:!fOO-1300°C GAS TEMPERATURE :180 -850% GAS TEMPERATURE: 100-800°C
CHEMICAL ATTACK: SLIGHT CHEMICAL AlTACK : VERY SEVERE
: MODERATE CHEMICAL ATTACK :SEVERE CHEMICAL ATTACK : SLIGHI CHEMICAL ATTACK : SLIGHT
SLAG ACTION i NONE SLAG ACTION SLAG ACllON : VERY SEVERE
THERMAL SPALLING: MODERATE lHERMAL SPALLING : VERY SEVERE SLAG ACTION : MOOERATE SLAG ACTION : N0N.E SLAG ACTION : POSSl8LE DUE
THERMAL SPALLING : VERY SEVERE
AW?ASION : HODERAIE THERMAL SPALLING : SEVERE THERMAL SPALLING : SLIGHT TO VOLATILES
ABRASION : VERY SEVERE ABRASION : SEVERE
ABRASION : MODRATE TO ‘ABRASION : SEVERE THERMAL SPALLING : MODERATE
SEVERE ABRASION : SLIGHT
h t-.
u
J
COOLER
GAS TEMPERATURE : lOOO- LOO’C
CHEMICAL ATTACK : NONE
SLAG ACTION : NONE
THERMAL SPALLING :‘MODERATE TO SEVERE
ABRASION : SEVERE
CYCLONE
STAGE I
SUSPENSION PREHEATER
I4 STAGE )
GAS TEMPERATURE : 330-1100%
CHEMICAL ATTACK :ALKALI,SULPHAlE
AN0 CHLORIDE
SLAG ACTION : POSSIBLE OUE 10
VOLATILES
THERMAL SPALLINO : MODERATE
TRANSIlfON ZONE
ABRASION : SEVERE DISCHARGE ZONEXOOLING~
(CALCINING OR PREEURNINGI
GAS IEMPERAlURE:liOO-1300? GAS TEMPERA~URE:l~OO-ll~c,
CHEMICAL AlTACK:SEVERE CHEMICAL ATTACK :SLIGHl
CYCLONE
SLAG ACTION : MOCXRPJE SLAG ACllON :MODERAlE
STAGE III
THERMAL SPALLING:SEVERE
ABRASION :MODERAlE
TO SEVERE
I ITHERMAL WALLING :VERY
S&ERE
:VERV
SEVERE
PRE- HEATING ZONE
I
BURNING ZONEISINTERINGI
GAS TEMPERATURE : @JO-1100°C
IGAS TEMPERATURE 1300-16Od)C 1
CHEMICAL ATTACK : MODERUE
. MODERAlE CHEMlCAL ATTACK :VERY SEVERE
SLAG ACTION
RISER THERMAL SPALLING : SLIGHT SLAG ACTION : VERY SEVERE
DUCT ABRASION : HODCRATE THERMAL SPALLING:VERY SEVERE
ABRASION :SEVERE
I I _: II
s_E==--??z =_I .__._-P
COOLER
GAS lEMPERAlURE:1000-400°C
CHEMICAL ATTACK : NONE
SLAG ACTION I NONE
THERMAL SPALLING : MODERATE 10
SEVERE
ABRASION : SEVERE
IS
SP : 37 ( Part 3 ) - 1937
*With precalciner, the gas temperature will be 350 to 1 100°C and the material te.nperature will be up to 900°C.
4.2 Preheating Zone - Far this zone the choice 4.3 Calcining Zone
of refractories mainly depends on the process.
4.3.1 In the calcining zone of long or suspension
4.2.1 Lqng Wet Process Kilns .- Abrasion and pre- preheater kilns as well as in the lower cyclones of
sence of moisture requires the use of a dense, low- precalciner kilns; dense, low porosity, low iron
porosity aluminous firebricks for long wet process bricks or castables with good alkali resistance are
kilns. Use of insulating bricks, particularly chemi- preferred. The break-up insulation lining can also
cally bonded, presents a risk due to moisture be considered.
penetration, 4.32 Precalciner vessels are also lined with hrgh-
strength, dense, high-alumina spalling resistant
4.2.2 Long Dry Process Kilns - The use of hot face brick;. .The back-up insulation is possible. A
insulating bricks is preferred in the long dry process high-strength castabie is required for* the burner
kilns. quarl.
4.2.3 Lepol Grate Prtheatcrs - In the lepol grate 4*4 Burning and Transitioxa Zone
preheaters, for the drying and heating chambers,
low porosity aluminous firebricks are used above 4.4.1 Refractories for the burning and transition
the grate levei. A backing of low ‘conductivity zones must be able to withstand high thermal loads,
insulating bricks may help in reducing heat losses. temperature fluctuations, chemical attack and
To form a stable platform high strength castables, abrasion. The transition part of the burning zone
anchored to the shell, are required. Below the is subject to large variations in temperature as the
grate level, high strength insulating bricks may be protective coatmg is taxed to its limit in this area.
preferred. Low duty firebricks are recommended
4.4.2 Depending on the kiln size and severity of
for the lining of suction chambers.
operations, thelining material for this zone is
selected from the following types:
4.2.4 Suspension Preheaters - The top three cyc-
lones and riser pipes of suspension preheaters are a) High alumina bricks of 70 to 75 percent
usually lined wit-h dense low porosity aluminous alumina content
firebricks or equivalent monolithics. A back-up b) Silicate bonded magnesite-chrome bricks
insulation lining is often preferred for reduction of
heat losses. Chutes are also lined with dense low c) Direct bonded magnesite-chrome bricks
porosity firebricks. Where it is difficult to instal d) Sintered and tar-impregnated dolomite
brick work; a dense, medium duty refractory cast- bricks
able is used, e) Magnesite-alumina spine1 bricks.
14
SP : 37 ( Part 3 ) - 1987
4.5 Discharge ( Cooling ) Zone entire cement kiln systems. The standard has also
adopted the IS0 specification for wedge shaped
4.5.1 With variation in protective clinker cooling, bricks for use in cement kilns ( IS0 5417-1986
the lining in this zone is subjected to hot clinker, Refractory bricks for use in rotary kilns -
flame and dust-laden secondary air, thermal shock Dimensions, which was at the draft stage at the time
and high.temperature abrasion. High-alumina of formulation of IS : 10607-1983 ). The relevant
bricks with good elasticity and strength characteris- part of IS : 10607-1983 is given in Table 3.
tics form the standard lining of discharge zone.
4.5.2 For end-discharge kilns, silicon carbide 7. PRESENT CONSUMPTION TRENDS
bricks have proved satisfactory for the nose ring
owing to their particularly high resistance to wear. . 7.1 Based on a survey of the Indian cement industry
Alternatively, monolithic castables with comparable for the period 1980-85, it has been observed that
properties, securely anchored to the shell by heat- the specific consumption (kg/t of clinker ) of
resistant steel anchors, may be used with advantage. refnactories for kilns with more than 60 percent
capacity utilization is as follows:
4.6 Coolers
Spccijc Consumption of Refractories
4.6.1 The refractory linings of cooling c&s, no ( kg/t of Clinker )
matter how difficult their design may be, have C__-_-_-h_- M-v--_ ~
similar requirements for resistance to thermal shock, Process Burning <one Other <ones
impact, abrasion and erosion. The only lining
materials that can be considered, therefore, are fire- Wet 1’03 0’65
clay bricks and high alumina bricks of high strength Dry 0.95 0.57
or suitable castables.
7.2 As compared to the international norms, there
4.7 Firing Hood and Burner Pipe is enough scope for reduction in refractory con-
sutnption through improved practices and materials.
4.7.1 Although brick-lining is not uncommon for
firing hoods, abrasion resistance and elimination of
8. REFRACTORY INSTALLATION
complicated brick cutting can be satisfied by using
PRACTICES
monolithics. The lining of burner pipes is restricted
to high strength refractory castables for abrasion
8.1 The adoption of refractory practices primarily
resistance to dust-laden gases.
depends on the following three factors:
5. LINING THiCKNESS IN ROTARY KILNS a) Operational safety,
5.1 The thickness of the lining of rotary kilns b) Proper installation, and
primarily depends on the diameter. The following c) Minimization of placement time.
lining thicknesses have been recommended by the
Development Panel of the DGTD for Refractory 8.2 Depending on whether a rotary kiln needs to
Industry: be rotated or ;a:? be kept stationary at the time of
lining, the instal!ation practices are further classi-
Kiln Dia (m) Lining Thickness (mm) fied as:
> 5.2 250 a) Rotary methods, and
> 4’2 < 5.2 220 b) Formwork methods.
> 3.6 < 4.2 200
> 3.0 < 3’6 180 8.2.1 Rotary Me/hods - In the rotating methods
the work is carried out at the kiln bottom and the
5:; 3-o 160 lining proceeds on intertittent rotation of the kiln.
The fixation of the bricks on rotation is done by
6. INDIAN STANDARD SPECIFICATIONS
any one of the following techniques:
FOR CEMENT KILN REFRACTORIES
a) Screw-jack method,
6.1 The Jndian Stnndarcl for refractories for cement
rotary kilns ( IS : 10607-1983 Specification for refrac- 1~) Glueing, and
tories for cement rotary kilns ) aims at rationalizing c) Bolting.
the rcqrrircnrcnts of refractory bricks and castables.
This stnnrlnrd ditl not itlc~lutle tile basic: bricks for 8.2.2 Formloo)-k Method ‘-- The curved fosmwork
use in cctneut kilns tlrre to non-availability of usage tnethods are safer in operation and permit very
data at the tirtrc of formulation of the standard. accurate installation af bricks. In these methods
The relevant extracts ofthis standard are given in the lower half of shell is lined without any parti-
Table 2. ‘I’his Indian Standard has recommended cular aids and then the upper half is lined with the
the use of 3 grades of high alumina and alumino- aid of curved formwork. There is a wide choice
silicate bricks. ‘l’hree grades of dense castables of equipment from simple wooden form to
and one grade of insulating castable for lining the hydraulically operated mechanized forms.
T&m 2 REQUIREMENTS FOR REFRACTORIES FOR DIFFERENT ZONES OF CEMENT I(ILNS
( Chsc 6.1 j
CHARACTERISTICS/ 35 PERCENT 55 PERCENT 70 PERCENT Gsam - 300 GRADE - 400 GRADE - 500 INSULATING io
CObfPOSITIOJ ALTIXINA
BRICKS
ALUMINA
BRICKS
AL’OXINA
hW3KS
REFRACYORY
CASTABLE
REFRACTORY
CASTABLE
REFRACTORY
CASTABLE
CASTABLE s
i%l,O* percent, Min 35 55 70 50 50 90 -
FL,O, percent, Max 2.5 2’5 3.5 6.0 2.0 0.5 3.5
30 34 36 - - -
PCE ( ASTM ), Min
TABLE 3 SIZES OF WEDGE SHAPED HIGH ALUMINA BRICKS FOR CEMENT KILNS
17
APPENDIX k
LIST OF INDIAN STANDARDS ON REFRACITORIES
IS: