REFRACTORY INSTALLATION PROCEDURE

EQUIPMENT: 350 TPD VERTICAL SHAFT LIME KILN

CUSTOMER : RSPL LTD
LOCATION : SODA ASH UNIT RSPL LTD.,
SURVEY NO. 471, PORBANDAR HIGHWAY,
VILLAGE – KURUNGA, DWARAKA,
GUJARAT.
CONTENTS:

1. INTRODUCTION
2. SCOPE
3. LIST OF REFRACTORY DRAWING
4. EQUIPMENT & TOOLS
5. MATERIAL STORAGE
6. REFRACTORY INSTALLATION
7. DRYOUT
8. SAFETY
1. INTRODUCTION:

This document refers to the EPC for Refractory Lining of 350 TPD Vertical Shaft
Lime Kiln.
The kiln refractory lining is divided in to Zone A, Zone B, Zone C & Zone D
depending on the process conditions and there are changes in the refractory profile
also in each zone. The hot face refractory materials used are High Alumina Bricks,
Magnesia Bricks, Acid Resistant Bricks which are dependent to zones and back up
using Calcium Silicate Blocks and Insulation Bricks. In some locations Conventional
Castable shall be used. Bricks are bonded using mortars of similar quality, and ceramic
paper shall be used in expansion joints.

2. SCOPE:
a. Erection of Scaffolding inside kiln up to Man hole bottom level.
b. Erection of Movable platform and Winch inside kiln.
c. Installation of Refractory lining as per approved Drawings and Procedure.
d. Dry out as per approved Procedure.

3. List of Refractory Drawings:

Sl. No. Description Drawing Number

1. Refractory Lining Vertical Shaft FLSMIDTH no. 10398551, Ver. : 3.0
Lime Kiln
2. Refractory Lining Vertical Shaft FLSMIDTH no. 10398552, Ver. : 3.0
Lime Kiln
3. Refractory Lining Vertical Shaft FLSMIDTH no. 10407400, Ver. : 1.0
Lime Kiln
4. Refractory Lining – Precast FLSMIDTH no. 10407157, Ver. : 1.0
Blocks
6. Refractory Lining – Bill of FLSMIDTH no. 10407159, Ver. : 1.0
Materials
4. Equipment and Tools

Sl. No. Description Unit Qty.

1. Movable Platform with accessories Set 1
2. Winch Machine with accessories Set 1
3. Scaffolding Material As required
4. Welding machine with accessories Set 1
5. Mortar Mixer Nos 2
6. Brick Cutting Machine Nos 1
7. Mortar drums As required
8. Masonry Tools As required
9. Carpentry Tools As required
10. High Velocity Oil Burners with Set 2
accessories
11. 15 HP Air Blower with accessories Set 2
12. Pumping Unit Nos 2
13. 2KL Oil Day Tank Nos 1
14. Oil and Air distribution pipes As required
15. 6 Point Temperature Recorder Nos 1
16. K Type Thermocouples As required
17. Compensating Cable As required
18 Electric Cables As required

5. Material Storage:
Refractory materials must always be stored in dry, solid places with stable ground
underneath. The storage area must be selected in such manner to ensure dry storage of
the materials even if extreme weather conditions prevail.
It is important not to stack heavier materials on lighter ones in storage. Do not stack
more than 2 pallets on the top of other. All materials must be stored in such an
arrangement that grade and shape name are always visible. Furthermore all refractories
are to be arranged in such a manner that they are accessible at all times without having
to move other materials around. Consequently sufficiently wide path must be ensured
between the individual stacks.
Hysil boards (calcium silicate board) are packed with laminated and cartoon packing in
boxes. Each box is to be unloaded safely and to be kept on wooden pallets.
Insulation bricks are packed in cartoon boxes to be unloaded in wooden pallets. Care
should be taken that no breakage should happen during the unloading.
Dense bricks are packed in wooden pallet to be unloaded directly on the floor with use
of hydra.
Castables & mortar are packed in HDPE bags and unloaded on the wooden pallets.

6. Refractory Installation:
6.1 ACTIVITIES
6.1.1 Scaffolding upto Manhole bottom level inside the Kiln
6.1.2 Erection of Movable Platform and Winch machine.
6.1.3 Fixing of Calcium Silicate Blocks
6.1.4 Insulation Brick Lining
6.1.5 Dense / A. R Brick Lining
6.1.6 Removal of Movable Platform and Winch Machine.
6.1.7 De -Scaffolding
6.1.8 Dry out of Total Refractory Installation
6.2 Work Planning:
Work planning is very important for a smooth and quality lining. On the day of planned
lining activity, all quality parameters associated with lining should be checked for
adequacy like cleanliness of the casing, availability of material, manpower, work
platform, tools and tackles etc
6.3 Surface Preparation:
The work surface shall be completely free of dust, scale, oil, water, dirt and loose foreign
material. The same shall be ensured by means of cleaning manually using wire brushes.
6.4 Procedure for Brick Lining:
6.4.1 Prior to start the Refractory lining, all dimensions like verticality, diameter, height
etc. of the equipment to be measured and recorded. Deviations if any have to be
informed and corrected.
6.4.2 Before starting the lining, mix the required mortars and keep ready in separate
drums. It is always preferable to soak the mortar in water in a day before to start the
lining for the better workability.
6.4.3 The lining shall be started from the bottom base ring.
6.4.4 First the 25mm thk calcium silicate blocks are to fixed with the shell using sodium
silicate solution.
6.4.5 Any gap between the calcium silicate blocks and shell formed due to the shell
undulations should be filled with the calcium silicate blocks paste prepared from the
broken pieces or insulation mortar.
6.4.6 The second layer from the shell has to be lined with 115mm thk W11 bricks of
230mm height with IF-INS insulation mortar.
6.4.7 In the first ring, the third and fourth layers from the shell shall be lined with CH1
bricks of 230mm thick and 115mm height with IF 40 Alumina mortar.
6.4.8 From the second ring, the third layer from the shell shall be lined with 115mm
thick porous W75 bricks with IF – INS 50 Insulation mortar.
6.4.9 From the second ring, the fourth layer from the shell shall be lined with 115mm
thk CH1 Side Arch bricks in the Zone – A, B & D and CH2 side arch bricks in the
Zone – C as per the drawing with IF 40 Alumina mortar.
6.4.10 Cut the first ring of the 115mm thk CH1 bricks in the fourth layer to 172mm
height to stagger the joints with the working layer.
6.4.11 Fifth layer from the shell shall be lined with 230mm thk CH1, HAL 8, BA 1 &
CH AR in Zone – A, B, C & D respectively as per the drawing with the relative quality
of mortars.
6.4.12 Wooden hammers shall be used during the hammering of bricks for proper
setting into position.
6.4.13 Brick cutting machine with diamond cutting wheel must be used for cutting the
dense bricks for keying of individual rings.
6.4.14 Do not use water for cutting magnesite bricks, while cutting with brick cutting
machine.
6.4.15 Care must be taken to avoid the straight joints in brick lining.
6.4.16 During lining, ensure that there is no gap in between the layers and all the layers
are intact with each other.
6.4.17 The mortar joints of brick should not exceed 2mm and all the joints must be
uniformly filled with mortar.
6.4.18 In zone C – use 12mm thick ceramic fibre blanket compressing to 10mm in
between the fourth and fifth layers to accommodate the expansion of Magnesite bricks
in this zone
6.4.19 Use 2mm thk ceramic paper in vertical directions only. Pitch for the hot face
layer – 600mm and for safety layer – 1500mm Pitch. Mortar should not apply on the
face of the ceramic paper.
6.4.20 All the instrument nozzles shall be wrapped with 2mm thk ceramic paper.
6.4.21 No expansion joints shall be provided in the AR brick lining.
6.4.22 In the AR brick lining, the mortar joints should not exceed 5mm thk.
6.4.23 The gaps surrounding the instrument nozzle and man hole arch shall be filled
with castable.
6.4.24 After completion of brick lining, the face of brick lining shall be cleaned properly
and any gaps in the mortar joints shall be filled properly.
6.4. 25.6 The gap between the cylindrical wall lining and roof shall be filled with with
ceramic blanket.
7. Dry Out:
7.1 Air Curing / Natural Drying:
After completion of refractory lining, the lining has to allowed for the natural curing
for 24 Hrs.
7.2 Heat Curing: Dryout shall be carried out as per the below schedule. Flue gas
temperature at the burner and exhaust end side shall be recorded for reference.
7.3 Dryout Schedule: Dryout shall be done in accordance to the following schedule.
• The lining shall be allowed to air dry at ambient temperature for 24Hrs. Min after
completion of lining. i.e. the time between completion of refractory installation and this
is a separate activity.
• Raise the temp. to 125°C @ 25°C/Hr. Hold or Soak at 125°C for Min 24 hrs.

• Raise the temp. to 250°C @ 25°C/Hr. Hold at 250°C for 24 hrs.

• Cool from 250°C to ambient temp gradually not exceeding 50/hr.

• Burners may be switched off after attaining around 200 deg C during the cooling
cycle.
8. SAFETY:
Safety of Man power and equipment must be considered as top priority. The below
points shall be followed for Safety.
8.1 All the staff and workers should wear the required PPE like safety shoes, safety
helmet, etc., while entering into the plant.
8.2 Fall protection equipment-Industrial double harness safety belts, Proper life lines,
Fall arrestor shall be used while working in height and hanging condition at site.
8.3 Proper lighting and ventilation arrangement during lining works at site.
8.4 Material to be kept in safe place not to get contact with rain and dust at site.
8.5 Proper care should be taken while lining, that lining material should not fall on the
persons working below elevations.
8.6 All the motorised equipment and rotating parts should be guarded properly.
8.7 Proper Test certificates / Third part certification should be obtained for the Winch
machine, Chain blocks / Hook chuks, D Shackles etc. prior to start of job.
8.8 While Dryout, the diesel day tank, pumping unit area and the burner operated area
shall be barricaded.
8.9 No hot work shall be allowed near the equipment during dry out process.
8.10 Fire extinguishers should be available near to Oil Pumping Unit, Oil day dank and
Burners location.