How to perform trials

Refractory 1/3
PR RFR P07-31 V1

Introduction
ƒ Selection of bricks for the refractory lining has to be done very careful to avoid any incidents. This is true
even if a brand has been successfully used in other plants under similar conditions, but is even more
essential if the brick is used for the first time. Therefore new brand have to be tested according to a well
defined procedure

Objectives
ƒ Applying the test procedure (in combination with related procedures (How to select refractory, …) should
help the plant to have a set of brands in their “Kiln Equivalency Chart” (KEQC) which are well suited for
a specific kiln zone ensuring the required lifetime at optimum cost.
ƒ Criteria:
ƒ Clear reports for all performed tests analysing the trials with advantages/disadvantages
ƒ No incident when performing a trial if it can be shown to be due to the brick quality

General definition of trials

ƒ There are different types of trials:
ƒ “Type A” trials use brick where already experience exists, but they are not now included and
recommended in the Division Equivalency Chart.
ƒ “Type B” trials are trials with newly developed bricks within Lafarge where no wide experience
exists up to now..
ƒ If a brick is recommended in the DEQC*, no trial of this brick is necessary.

* Division Equivalency Chart

Prerequisites
Tests of refractory have to be carefully planned:
ƒ Analyse carefully the Division Equivalency Chart;
ƒ Apply the procedure refractory selection to select the best quality for the test – assuming a type A trial
ƒ Ensure that you have the resources to follow the test
ƒ In principle, we do not do type B trials on sold-out kilns?

Time frame
ƒ Tests lasts normally two kiln full campains, Nevertheless after the first period, if results are positive, then
a second trial period is not necessary and we continue with the next step.

Tools
ƒ If WinBrix is going to be used, the standard file must either contain this brick already (type A trial) or
contain a couple of ‘dummy’ bricks, TRIAL1, TRIAL2 (type B trials), or the tool cannot be used.
 How to perform trials
Refractory 2/3
PR RFR P07-31 V1

Action Steps

1. Decide which type of trial you want to do

Definition of the two types of trials:
Type A Trial
ƒ A type A trial will be done to improve refractory performance in a certain kiln/kiln zone or to optimise
refractory cost.
ƒ Type A trials can be done with bricks of higher quality or lower price, which is not now recommended in
the Division Equivalency Chart.
Type B trial
ƒ Refractory suppliers develop new brands with the target to improve the bricks or to offer cheaper bricks
with a good quality. Also new suppliers appear on the international market.
ƒ For new brands where no sufficient experience exists, it is necessary to do basic tests
ƒ After this “type B” tests are successful the brands will be included in the DEQC, but only recommended
as category 2 (a type A trial will be necessary if you want to use it).

2. Initiation of the trials

ƒ Main target is to justify a trial and to minimize the risk by proper planning
Type A trials
ƒ Type A trials will be initiated together between the
plant and the TC
ƒ A good assessment of the process/mechanical
interactions needs to be carried out by the plant
with TC assistance
ƒ Refractory responsible of the plant and the TC
communicate and agree on quality, quantity, and
timing of the test
Type B trials
ƒ A type B trial will be initiated by the focus group
(refractory experts of a region, TC refractory
responsible and region purchaser). If no focus
group exists the TC responsible has to organise a
team case by case with the same responsibles
ƒ Background information on the brick will be
gathered and distributed in the group
ƒ Assessment of the brick
ƒ Reference list, tests reports from manufacturer
ƒ Review brick history in other plants as far as
possible
ƒ Process/mechanical condition/interactions
ƒ Manufacturing site visit and report (if necessary)
ƒ If a brick in question passes all aforementioned test,
candidates for a trial will be solicited
ƒ Must have a (written) agreement of the plant
manager, DEX, the RdR and the TC refractory
champion
ƒ New supplier purchase order should include
tolerance levels of brick geometry and a certificate
of analysis to show conformance to physical
properties.

Procedure Template developed by

 How to perform trials
Refractory 3/3
PR RFR P07-31 V1

3. Trial Quantity
ƒ Trial quantity should be at minimum 1 kiln diameter of length for type B trials and type A trials.

4. Reporting

All trials require a trial report to be posted in the Cement portal’s Refractory Domain.

ƒ Begin at initial installation

ƒ Update whenever brick thickness is measured
ƒ Update when brick is removed
ƒ Test reports will be validated by the TC refractory champion

5. Follow up actions
ƒ Each trial should be discussed at the TC level (Focus group and/or TC refractory champion). All plants of
the region should be informed about the test results
ƒ The TC refractory champion keeps track of all trials
ƒ Update kiln and Division Equivalency Chart according the test result
ƒ It is recommended to ask for a Post mortem analysis of brick from supplier, even if not failed

Procedure Template developed by