Can any body throw a light that how the Refractory lining in a Cement Rotary Kiln cooler gets

damaged.
What are the different factors that may be responsible for the failure of a Castable Bull nose.

 • High temperature and many/high temperature changes.

 • Mr.Sengupta, Yes high temperature and the abrasion due to clinker dust will damage the clinker cooler refractory. As Mr.Geib
rightly said, major refractory suppliers have different solutions. Hoganas has special precast for this purpose. Proper anchoring
and usage of special castables will also solve this problem.

 • The reasons for damages of the bull nose are well described by Sapathkumar. I was involved in this issue and making trials of
may combinations of design and castables we landed with Hogans design. It works well and stays a good life of 3 years with
some minor repairs depending on the conditions it has gone. The secret is in its Installation and in casting , the methods has to be
followed as per Hoganas ie the mixing, casting temp and anchoring of hanging bricks. The beams have to be properly fixed and
top to be left uninsulated to desipiate heat. The front portion of the bull nose is critical as the slope is imporatnt depending on the
grate angles and sec air trajectory.

 • Another issue with cooler roofs is the accumulation of dust on top of the cooler roof. This adds insulation and allows for
overheating of the steel and anchors.

• In my experience, bullnose failures are RARELY due to insufficient refractoriness or refractory strength. Most failures are
related to improper engineering. 

a) insufficient expansion joints between bullnose, wall and roof. 

b) excessive expansion joints leading to dust infiltration. 
c) absence of metal shelves above and below the bull nose. 
d) overheating of metal anchors. 
e) underdimensioned metal anchors. 
f) differential expansion between anchors, shell and refractory. 
g) too much insulation (anchor overheating). 
h) dust penetration behind the lining. 
i) alkali attack (rare). 
j) improper anchor design, sizing and spacing. 
k) improper brick anchor orientation. 
l) overheating of the base structure (dust accumulation behing the lining). 

if the lining is PROPERLY cast or rammed in place: 

k) improper castable/plastic dryout and firing. 

l) gunning or shot gunning as opposed to forming and cast-vibrating.

 • One of the most important factor which results in the cracks or chunks fall out of the bull nose is the high radiation from the
1400 C clinker which heats the front end of the bull nose and in the next hour sudden cooling if burner trips, kiln trips or feed rate
variations or any other process variations including undergrate airflow rates due to cooler operations, this causes high rate of
change in temperture in the bull nose. This results in localized expansions and contractions which results in fall out of castable
and develops cracks after many cyles. That is why the we were not using anchors , only anchor blocks which were hanged by
cross anchors giving it expansion and contraction causing flexiblle movement. The anchor blocks at the top were open , no
insulation. The anchor bricks has to be has to be used so no need of welding any anchors, its only the bricks and castable. The
cross beams should be strong to take the huge load of the castable. Other factors are also responsible as Racardo mentioned. 
In my opinion , we did not tried if we put in the mass on or two ss pipes and keep air blow to dessipiate the heat from inside the
mass.

 •  In thermal shock situations, it is always better to use thinner linings over insulation to minimize the thermal gradient inside the
refractory. As to using ss pipes inside the mass, it is better to use a castable with a higher heat dissipation coefficient. Used forced
air to cool the base of the metal anchors and keep the support free of dust. A hollow beam is ideal. Some plants divert a small
portion of the forced air flow from the cowlings to the anchor supporting beam.