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Heating Manual

Refractory Drying and


REFRACTORY DRYING AND HEATING MANUAL

Introduction
Drying and Heating of Refractory is a very significant step to make the refractory lining ready to
work. A good practice on Drying and Heating will result to a good service life of refractory lining. It
also reduces unnecessary downtime arising from improper refractory drying and heating, which
could be costly due to the production loss as well as refractory maintenance cost. To avoid such a
non preferable situation, this manual is considered to be a guide line which must be studied
carefully prior to start any Drying and Heating process.

This Drying and Heating Manual intends to focus fundamentally on the refractory for the NSP-
Rotary Kiln-Clinker Cooler System of Cement Plant.

Drying and Heating for Cement Plant

THE SIAM REFRACTORY INDUSTRY CO., LTD. 1 SIAM CEMENT ROAD, BANGSUE, BANGKOK 10800 THAILAND
What is Drying and Heating Curve?
Definition
Through out whole manual, Drying and Heating Fundamentally, Drying and Heating Curve
would be defined as follows: serves as the roadmap of targeting temperature
at a specific period of time to prepare the
Drying: Focus mainly on the first half of Drying and refractory lining ready for actual operation.
Heating Curve mainly aiming at dewatering
from the castable. Heat for Drying Process Theoretically, the targeting temperature is best
may obtain from a specific burner providing to be measured from the surface of refractory,
for drying purpose, or may come from other which is difficult in practice. The ambience
heat source. temperature is assumed as the best proxy, in
which the measure instrument should be placed
Heating: Comprise the later half of the Drying and at the position representing the temperature by

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Heating Curve. The temperature is raised average.
up to the operation temperature (where the
production is started) by such a rate that no Example of Drying and Heating Curve:
spalling takes on refractory bricks. Mainly,
main burner, e.g., rotary kiln burner, is 600oC
utilized.
400oC

Purpose of Drying and Heating Process 200oC

Drying Process (by auxiliary or main burner)


Basically, the refractory lining composes of (1) 0 4 8 12 16 Hrs
Castable, (2) Bricks and Mortar, and (3) Insulating
Brick and/or Insulating Board as the insulating or backup layer. Drying process fundamentally aims
to remove the excess water from the Castable as well as Mortar to prevent the material from
explosion during the rising up of temperature because of sudden water vaporization, i.e., steam
bursting. In addition, the Drying process will prevent Mortar joint (Brick joint) from loosening from
the entry of high pressure steam as promptly vaporized.

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Heating Manual
Refractory Drying and
The Drying curve is designed mainly in concern with the de-watering from the castable, in which
finally the ending temperature of this Drying curve is not so high. After passing this drying period,
the Heating curve, which concerns mainly on brick spalling and expansion, would be followed.

Drying Process Mechanisms

After installation completed, there would be 3 kinds of water remaining in the material, which are
(1) absorption water, (2) free water content, and (3) crystallized water. The absorption water
does not relate to the reaction with alumina cement and it will evaporate at the room
temperature. Free water content and crystallized water are needed to be removed by the
Drying process.
Free water content, i.e., (1) 10-15% excess water in castable, (2) 30-50% excess water in
insulating castable, and (3) approximately 30% excess water in mortar, would be removed by
keeping the temperature at 100-110oC. However, though the free water is removing, there still
be crystallized water left in the material and should be removed by further heating.

THE SIAM REFRACTORY INDUSTRY CO., LTD. 1 SIAM CEMENT ROAD, BANGSUE, BANGKOK 10800 THAILAND
Crystallized water occurs because of the reaction between Alumina cement and water, and thus
it will reside within the material at the structural level. It can not be easily removed from the
material at low temperature. This crystallized water can cause the castable to explode if not
properly removed. Theoretically, this crystallized water has different phases and would
successfully removed at various temperature as follows:

1. Phase CAH10 removes at 130oC or above. Steam pressure = 4 kg/cm2


2. Phase C2AH8 removes at around 170-195oC. Steam pressure = 15 kg/cm2
3. Phase AH3 removes at around 210-300oC. Steam pressure = 100 kg/cm2
4. Phase C3AH6 removes at around 300-360oC. Steam pressure = 220 kg/cm2

Heating Process (by Main Burner)

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Heating process will raise the temperature of the furnace up to the level of operating temperature.
The heating will start at some point of the Heating curve. The temperature will be raised by main
burner in the manner to prevent spalling of the bricks and castable and ensure the smooth start up
of the cement plant.

Drying and Heating Methodologies for Cement Plant


The Drying and Heating process must be commenced at such the point in time that the actual start-
up of kiln can be continued immediately afterward. If it is done by only main burner, the operation
heating up can perfectly be continued as per Figure 1 & 2. But, sometimes, by the proper
arrangement, it can help reducing risk of the Drying and Heating process, if do it separately by
setting the auxiliary burner at transition housing for dewatering inside the Preheater tower and/or
setting the auxiliary burner at kiln hood for dewatering inside kiln hood and hot zone of clinker
cooler. After removing the auxiliary burner, the operation process is ready to start up. Therefore, it
can be followed by the operation curve immediately that takes around 30-36 hours.

Drying and Heating curve for Initial Start-Up/Major Repairing


The Drying and Heating curve for NSP-Rotary Kiln Cement Plant will take 72 hours in total. The first
36 hours devotes to the Drying Process, in which the suggested curve is as depicted in Figure 1.

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Heating Manual
Refractory Drying and
The temperature mentioned in the curve is taken from C5 outlet. It serves as the proxy to the
temperature distribution as the average temperature in the NSP tower.

Keeping temperature at 200oC for 6 hours will force excess (free) water out from the material. By
the same time, crystallized water phase CAH10 will also be removed.

Temperature would be sustained further at 300oC for 12 hours. During the period, crystallized water
phase C2AH8, some of AH3 and some of C3AH6 will be heated out from the material. Afterward,
temperature must be raised up again to the level of 500oC, in which the remained crystallized water
phase C3AH6 and AH3 will be removed.

T e mpe rature on C5 Cyclone O utle t


600
4 Hrs 6 Hrs 4 Hrs 12 Hrs 2.5 Hrs 7.5 Hrs

500 C A fter 36 Hours,


500
the Dry ing proc ess is

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com pleted, and the
A uxilary B urner is
400 rem oved.

- If the Heating
300 C 75 C/Hr process is not
300
continue, tem perature
will reduce by natural
200 C cooling.
200
33 C/Hr
- From this point, the
Heating process could
be started.
100

40 C/H Hours

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0
0 4 8 12 16 20 24 28 32 36 40

Figure 1: Drying Curve for Initial Start-Up /Major Repairing

Figure 2 shows the Heating curve and the suggested Starting process for the plant. If the Heating
process is immediately started after Drying, the point marked as the starting point would be at the
position of 36 hours with 500oC of C5s temperature. For the case that there is natural cooling after
Drying process and the temperature of C5 (kiln string) drops to 300oC, the starting point for the
Heating process must be marked at approximately the position of 16 hours.

If the Heating process continues immediately after drying process, it would take 36 hours for the
Heating process.

During temperature rising, the rotary kiln bricks are exposed to the most severe heating condition.
As the result, the standard temperature rising speed will be set by the safe rising temperature range
to prevent such brick spalling, especially basic bricks.

There are two importance points to be concerned during heating process, i.e., (1) Spiral, and (2)
Plastic deformation. Good Heating curve must be able to prevent these two points from occurrence.

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Heating Manual
Refractory Drying and
Continuous ly rotate with
B arring Devic e
Turn K iln Turn K iln Turn K iln
k eep K iln rotating by
90 degree 90 degree 90 degree
m ain m ortar 5 th c y clone stage
for every 30 M in for every 15 for every 10
(c alc iner string)
Te m pe ra ture C M in M in
900 870 C
820 C

800
5 th c y clone stage
700 (k iln s tring)

600

500

400 370 C 350 C

300
320 C
1 s t c y c lone s tage 220 C
200

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(kiln s tring)

100 70 C 1 st cy c lone s tage


(c alciner s tring)
0
0 8 16 24 32 40 48 56 64 72 80 88 96 104 112

Figure 2: Heating and Starting Process of Kiln Plant with Calciner

Spiral problem occurs because of gap between basic brick. Basic brick lining of the rotary kiln has
card board to take care the expansion in the longitudinal direction, but it can be easily lost by
burning just only at low temperature range during the heating period when the expansion of bricks is
not much. As the result, there would be gap remained and can cause spiral, if too fast rotation,

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which is not preferable. To prevent spiral problem, kiln rotation must be limited to a minimum speed
at the first period of Heating. It will be increase gradually with the progress of heating process as
shown in Figure 2.

Rapid heating will cause the temperature difference between kiln shell and tire, and may result to a
plastic deformation of the kiln shell because of binding force with tire.

Some Important Notes

Inspection
The kiln lining must, as a minimum, be inspected every 30 minutes from the burners platform.

Temperature
The lining of the burning zone must never be exposed to rapid localized over-heating. The lining
temperature must not exceed 1,000oC and the kiln shell temperature must be held at below 400oC.

The fuel rate must be reduced in case the lining temperature rise too rapid and/or if the temperature
gets too high. In case of excessive kiln temperature occur in the burning zone, if the temperature at
the position after Preheater is in the allowance, the heat must be drawn upstream in kiln by
increasing the draught.

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Heating Manual
Refractory Drying and
Drying Process for Firing Hood and Clinker Cooler
It is preferable for the castable in Firing Hood and Clinker Cooler to apply the drying process by
using auxiliary burner following in Drying Curve in Figure 1. The castable at the position in front of
heat shield would be most serious during the first ignition by main burner and the first drop of hot
cement clinker; thus, the water had better to be forced out as much as possible. (See how to
prepare the works in item Method of Drying and Heating in Firing Hood and Clinker Cooler )

Method of Drying and Heating in Preheater (in case with Auxiliary Burner)

Preparation Works
Prior to drying ignition, clean the furnace inside sufficiently, then remove completely the
foreign substances such as tools, jigs, wooden chips, wooden beam, wreck, trashes and
any wastes especially in the bottom part of any cyclones.
Trust mortar joints and remove surplus mortar after completion of brick installation to
prevent the accumulation of the raw meal. The surface of castable must be repaired if any

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flaws occur.
Install the bricks at every man hole, and totally close each man hole and poke hole.
Check the operation of each damper and set the dampers according to the Operation
Manual.
Setting methods for main dampers are as follows:
Control damper of Tertiary Air Duct Totally closed
Damper of Kiln By Pass Gas Duct, if any Totally closed
Damper of NSP Exhaust Gas Duct Totally closed
All Flap Dampers of Material Chutes Fully opened

Set the connecting gauges and calibrate the thermocouple for measuring the temperature at
5th Cyclone outlet.
For the drying works, castable dewatering is mainly concerned. The auxiliary burner should

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be installed in Transition Housing prior to the drying work (See the burner position in Figure
3).

Work Procedures of Drying and Heating Works


In determining the temperature rising, please carefully follow drying curve in Figure 1 and
limit the variation at minimum.
Complete test run and make adjustment of each equipment prior to starting the drying and
heating works.
Set the auxiliary burner with beams insertion between clearing holes, in the direction
upward blowing.
Oil and air amount for burner should be able to adjust from outside of the furnace.
The capacity of auxiliary burner is enough to push the temperature inside 5th Cyclone up to
200 oC. The capacity of burner will be adjusted and tested before drying process.
Draft the waste gas by adjusting the opening degrees of by-pass stack or exhaust gas duct.
In the beginning, if the draft power to the Preheater is too weak, it is desirable to operate
IDF of waste gas duct slightly until the buoyancy of waste gas becomes sufficiently by the
ascending air current, then draft the waste gas from by-pass stack.
In case of misfiring, totally close the by-pass stack immediately to keep the furnace worm.
After finishing 36 hours drying process, stop supply the oil but continue cooling by its nature
around 10-12 hours without any interruptions. Do not open any man holes if not necessary.

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Heating Manual
Refractory Drying and
When the temperature is low enough to remove the auxiliary burner, remove it so that the
heating process could be continued.
For the heating process, rotate kiln adequately to prevent partial heating on the brick
surface and deformation of kiln shell (See in the Plant Operation Manual).
To control the temperature during drying and heating period, measure the temperature at
the outlet of C-5 cyclone, main controlling location during the operation.

Drying and Heating Apparatuses


Use the drying burner that can control the combustion amount 90-900 litre/hour
Be careful of fuel and air piping not to make them too long for the prevention of the
insufficient combustion due to pressure drop.
Select the drying burner in accordance with the fuel to be provided.
Use the kiln main burner for the heating work.

Precautions for Drying and Heating Works


When installing drying burner, pay attention to the installation position and direction in such

THE SIAM REFRACTORY INDUSTRY CO., LTD. 1 SIAM CEMENT ROAD, BANGSUE, BANGKOK 10800 THAILAND
manner that the burner flame does not contact directly with the furnace wall to prevent local
overheating.
To prevent local overheating, use large gas volume as much as possible. For the purpose,
blow secondary air and dilution air as much as available in such degree that, however, no
misfiring takes place.
To prevent castable explosion or brick spalling caused by rapid temperature rise, strictly
keep the gradient of the drying and heating curve.
Even after a completion of drying period, castable is not yet completely dewatered because
of temperature distribution in the refractory layer in Preheater.

Therefore, even during or after burner changeover, dewatering will still continue. Also,
during the main burner ignition, the gas temperature in Preheater will rise promptly. Thus,
when removing the drying burner, all manholes should be closed to prevent cooling down of

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temperature in Preheater. By this way, not only can force the water out as much as
possible, it can also prevent the refractory spalling during ignition the main burner as well. If
possible, the burner should be changed as fast as possible to keep the furnace wall
temperature drop at minimum.

Fireclay bricks used in the Preheater may crack sometimes by temperature fluctuation in
the low temperature range (200-400oC) depending on the property of the materials. Thus,
pay attention all equipment to prevent the interruption of drying profile temperature due to
extinction of the burner so that temperature fluctuation can be avoided.
Be careful of misfiring caused by the failure of electricity supply during drying works.

Burner Installation Method


Place the beam to the Cleaning Hole A, and set the burner holding beam on it from the
manhole.
Select the beam shape taking consideration of the thermal deformation during the heating
and pay special attention to the setting method of it.
Set the burner with the wire to the burner holding beam in the direction upward blowing at
Transition Housing center.
Arrange the piping to control the oil and air amount from outside the furnace.

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Heating Manual
Refractory Drying and
BEAM

HARMOLE A

PURMER

BURNER
FUEL
SECTION A

BEAM

SET WITH THE WIRE DETAIL B

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Figure 3: Auxiliary Burner Location for Preheater

Prepare the auxiliary burner apparatus


Burner that can make temp. up to 500oC( 90~900 litre / hour) 1 set
Control equipment 1 set
Piping material 1 set
Beam (I 50 x 75) 10 m

Method of Drying and Heating in Firing Hood and Clinker Cooler (in case with
Auxiliary Burner)

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Preparation works
Prior to drying ignition by auxiliary burner, clean any wastes inside Firing Hood, Clinker
Cooler and Tertiary air duct sufficiently.
Trust ceramic fiber joints and fill them fully after completion of brick and castable installation
to prevent the penetration of heat and the clinker materials (during operation). The surface
of castable must be repaired if any flaws occur.
Install the bricks at every manhole and door of Firing Hood, Clinker Cooler and Tertiary air
duct.
Totally close the Rotary Kiln at outlet segment with steel cover to prevent heat loss in
Rotary kiln (See in Figure 4).
Check the operation of each damper and set the dampers according to the Operation
Manual. Setting methods for main dampers are as follows.
Control damper of Tertiary Air Duct Fully opened
Damper of Kiln By Pass Gas Duct, if any Totally closed
Damper of NSP Exhaust Gas Duct Totally opened
All Flap Dampers of Material Chutes Fully opened

Set the connecting gauges and calibrate the thermocouple for measuring the temperature at
Tertiary air duct outlet.
Auxiliary fan should be provided inside Rotary Kiln in case that hot gas can leak into it.

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Heating Manual
Refractory Drying and
In the drying works, castable dewatering is main concerned. The auxiliary burner shall be
installed in front of heat shield of clinker cooler before proceed to drying work (see the
burner position in Figure 4).

Tertiary Air Duct


Fan suction damper
B/H compartment dampers
Rotary Kiln

Burner Location

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close all dampers
in the gas line
Figure 4: Auxiliary Burner Location for Firing Hood

Work Procedures of Drying and Heating Works in Firing Hood and Clinker Cooler
Set the auxiliary burner with beam chair 0.5 meter high from the grate plate and 2 meters
far from Firing Hood door, middle in left and right side.
Oil and air amount for burner should be able to adjust from outside of Clinker Cooler.
The capacity of auxiliary burner is big enough to push the temperature inside Tertiary air
duct outlet up to 150oC (around 200oC at kiln hood area due to distance from thermocouple

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location. The capacity of burner will be adjusted and tested before drying process.
Complete test run and make adjustment of each equipment prior to the drying and heating
works. In determining the temperature rising, please carefully follow drying curve in Figure 1
by 50oC lower and limit the variation at minimum.
Open manhole of Firing Hood to observe the vapor. If evaporation still undergoes, extend
drying time.
Draft the waste gas by adjusting the opening degrees of main B/H fan damper and fan
speed.
After finishing 36 hours drying process, stop supply the oil but continue cooling by its nature
around 10-12 hours without any interruptions. Do not open any manholes if not necessary.
When the temperature is low enough to remove the auxiliary burner, remove it so that the
heating process could be continued.
To control the temperature during drying and heating period, measure the temperature at
the outlet of Tertiary air duct.

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Heating Manual
Refractory Drying and
Drying and Heating Apparatuses
Use the drying burner that can control the combustion amount 90-900 litre/hour as same as
the burner in Preheater.
Be careful of fuel and air piping not to make them too long for the prevention of the
insufficient combustion due to pressure drop.
Select the drying burner in accordance with the fuel to be provided.
The heat from hot cement clinker during initial operation start-up will help de-water the
castable both in Firing Hood and Clinker Cooler.

Precautions for Drying and Heating Works


When installing drying burner, pay attention to the installation position and direction in such
manner that the burner flame can distribute the heat through Firing Hood roof.
To prevent castable explosion or brick spalling caused by rapid temperature rise, strictly
keep the gradient of the drying curve as shown in Figure 1.
Even after a completion of drying period, castable is not yet completely dewatered and
dewatering will still continues. Thus, when removing the drying burner, all manholes should

THE SIAM REFRACTORY INDUSTRY CO., LTD. 1 SIAM CEMENT ROAD, BANGSUE, BANGKOK 10800 THAILAND
be closed to prevent cooling down of temperature in Firing Hood. By this way, the water can
be forced out as much as possible.
Be careful of misfiring caused by the failure of electricity supply during drying works.

Burner Installation Method


Place the beam chair on grate plate around 2 meters from back wall of Firing Hood and in
the middle from left and right side wall to distribute the heat for Cooler roof as well as Firing
Hood roof.
Select the beam shape taking consideration of the thermal deformation during the heating
and pay special attention to the setting method of it.
Arrange the piping to control the oil and air amount from outside the furnace.

Prepare the Auxiliary Burner Apparatus (the same set as Preheater burner)

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Burner that can make temperature up to 450oC (90~900 litre / hour) 1 set
Control equipment 1 set
Piping material 1 set
Beam (I 50 x 75) 10 m

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