REFRATECHNIK

Refractory Installation for Rotary Kilns

Vietnam Seminar, November 21-22, 2011

REFRATECHNIK Asia Ltd. Hong Kong
Matthias Franke 1
 REFRATECHNIK

Topic’s to be discussed

• Areas of responsibility • Reference lines

• Brick Shapes • Lining procedure & mixing ratio etc.

– VDZ for Basic Bricks
– ISO for Alumina Bricks • Ring closing (key bricks & key shims)
– Recommendation of Height
• Retainer rings
• Installation tools
• Joining new & old lining
• General lining conditions

2
 REFRATECHNIK

Areas of Responsibility

Design and
Product Support A
Quality of the r
Quality of the
e
Raw Material Production Supplier a
s

o
f

R
e
Supplier & s
Customer p
o
n
s
Installation of Product Seleccion of Product i
b
i
l
i
Operating Conditions
t
Customer y

Temperature
Chemisty
Mechanics
3
 REFRATECHNIK

Brick Shapes: VDZ and ISO

• VDZ - Verein Deutscher Zementwerke (Board of German cement producers) for Basic
Bricks

• ISO – International Standart Organisation for Alumina Bricks

4
 H

L
Basic Bricks: VDZ-shape

A
Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik
Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechni
Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik
Refratechnik Refratechnik Refratechnik Refratechnik Refratechnihni
Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik
Refratechnok Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik
Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik

Basic
B 422
220 mm

Diameter +/-4,0 m

5
REFRATECHNIK
 REFRATECHNIK

Alumina Bricks : ISO-shape

B
622
220 mm
H

Diameter +/-6,0 m

L
A
6
 REFRATECHNIK

Comparison B 622 (VDZ-Shape) with 622 (ISO-Shape)

B 622 622

• A = 74 mm • A = 103 mm

• B = 69 mm • B = 95.5 mm

• H = 220 mm • H = 220 mm

• L = 198 mm • L = 198 mm

7
 H
+/- 1,5%
198 +/- 2mm
Dimensional Tolerance

Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik

ik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik
nik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik
Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik
A
B

ratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik

+/-
+/-

1,5mm nik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik

1,5mm
of bricks used in a Rotary Kiln ( VDZ or ISO ) , acc. to VDZ standard

8
REFRATECHNIK
REFRATECHNIK

9
 REFRATECHNIK

Recommendation of the Brick Height (lining thickness)

• The brick height should be adjusted to the kiln diameter

Recommended Brick Height Kiln Diameter

180 mm < 3,6 m

200 mm 3,6 - 4,2 m
220 mm 4,2 - 5,2 m
250 mm > 5,2 m

10
 REFRATECHNIK
Expansion joints in brickwork

High-alumina, Fire-Clay and lightweight bricks

do not need any additional joints (0,7-0,9 % thermal expansion)

But the rather high thermal expansion behaviour of magnesia bricks

must be compensated by the insertion of cardboard spacers.

Thermal expansion of magnesia bricks = 1.5 to 2 %.

Example: 10 m + 1.5 % thermal expansion = 10.15 m

11
 REFRATECHNIK
Installation Methods

12
 REFRATECHNIK

Bricking Machine REFRA-RIG

13
 REFRATECHNIK

Brick installation with REFRA-RIG is the best way in terms of:

• 1. Work safety & accident prevention

• 2. Lining quality

• 3. Lining progress

14
 REFRATECHNIK
Installation Tools I

15
Installation Tools II REFRATECHNIK

16
Installation Tools III REFRATECHNIK

17
 REFRATECHNIK

Installation tools IV

18
 REFRATECHNIK

Lining start – important general conditions

For starting the lining process the following frame conditions must be given:

• there must be access to the kiln via the kiln hood (kiln bridge),

• kiln shell must be clean and dry,

• temperature inside kiln as well material temperature not lower than 10˚C
(only valid for counties with cold climate)

Very important: If you are using a bricking machine it’s not possible to rotate
the kiln for purpose of execution other jobs (casting the kilns
nose ring, mechanical works etc.) otherwise…

19
 REFRATECHNIK

…it look’s like this:

20
 REFRATECHNIK

Marking the kiln’s center line as axial reference line

21
 REFRATECHNIK
Marking the kiln‘s center line as axial reference line

22
 REFRATECHNIK

Marking the radial reference lines

23
 REFRATECHNIK

Radial reference lines

radial reference line 5 - 6 rings

max. 1.200 mm

24
 REFRATECHNIK

Incorrect alignment of brick rings

25
 REFRATECHNIK

Correct brick ring

alignment

26
 REFRATECHNIK

Lining of the first brick along the kiln’s center line

27
 REFRATECHNIK
Lining of the first brick in “half brick shifted pattern”

28
 REFRATECHNIK

Lower kiln half by means of “half brick shifted pattern”

29
 REFRATECHNIK

Reverse taper

30
 REFRATECHNIK

Brick installation by means of REFRA RIG

31
 REFRATECHNIK

Brick mixing ratio - detailed lining drawing

32
 REFRATECHNIK

Combination of different shapes

33
 REFRATECHNIK
Combination of different shapes

34
Checking the radial REFRATECHNIK
direction of the brickwork

heavy abrasion
crack formation
premature wear

35
 REFRATECHNIK
Radial Welding Seam

Mortar max.
8 mm

Mortar max.
8 mm

>8mm 36
Adjustment
 REFRATECHNIK

Adjustment for
distorted kiln shell
(radial) by means of
mortar (max. 8mm)

37
 REFRATECHNIK

Adjustment for distorted

kiln shell (axial) by means
of mortar (max. 8mm)

38
 REFRATECHNIK

Keeping the sequence of brick qualities

39
 REFRATECHNIK
Closing of brick rings – using a hydraulic jack

40
 REFRATECHNIK

Golden Rule: Adjust the hydraulic jack’s pressure to an amount

of 50% of the used brick quality’s Cold Crushing
Strength (CCS) only

Sample: Topmag AF

• CCS = 70 N/mm² (please see data sheet),

• 50% of CCS = 35 N/mm²,
• Maximum pressure to be applied = 350 bar or 35 MPa or 5075 PSI

Conversion factor: 1 N/mm² = 10 bar = 1 MPa = 145 PSI

41
 REFRATECHNIK

Closing of brick rings

42
 REFRATECHNIK

Closing of brick rings

last
brick 6 mm ?
Bad ! ! !

0 mm OK

43
 REFRATECHNIK
Closing of brick rings

44
 REFRATECHNIK

Closing of brick rings – “Adjusted Brick”

45
 REFRATECHNIK

Closing of brick rings – using of key bricks

• Correct

• Correct

• Incorrect

• Incorrect

46
 REFRATECHNIK

Closing of brick rings - distribution of key bricks

1
2
3
4

47
 REFRATECHNIK

Closing of brick rings – incorrect distribution of key bricks

48
 REFRATECHNIK
Ring closing - keying of brick rings

49
 REFRATECHNIK

Keying of brick rings – always use a shim driver!

50
 REFRATECHNIK

Keying of brick rings – excessive force

51
 REFRATECHNIK

Two key shims adjacent to the same brick - consequence ?

52
 Concentric stress cracks REFRATECHNIK

Reasons:
ƒ Steel plates oxidize , forming magnesioferrite, volume increase. 53
 REFRATECHNIK

Retainer Ring

Material Flow Direction

54
 REFRATECHNIK

Retainer Rings

Material Flow Direction

55
 REFRATECHNIK
Lining start at the outlet retainer ring – what’s wrong?

56
 REFRATECHNIK

Retainer Ring

57
 REFRATECHNIK

Joining new & old lining

58
 REFRATECHNIK

Poorly executed joining

59
 Hot Face

Cold Face
220
200
180
Basic Bricks :

298

TG AF B620 L
2

Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik

Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechni
Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik
b

Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechni

a

Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik

Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechni
= L-shape
L-shape (available as VDZ as well as ISO-Brick)

60
REFRATECHNIK
 REFRATECHNIK

Installation of the last brick ring between new and old lining

61
 REFRATECHNIK

Thank you very much for your kind attention!

62