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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.
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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
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.
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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:
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.
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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
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.
800
5 th c y clone stage
700 (k iln s tring)
600
500
300
320 C
1 s t c y c lone s tage 220 C
200
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(kiln s tring)
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,
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.
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.
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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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
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.
HARMOLE A
PURMER
BURNER
FUEL
SECTION A
BEAM
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Figure 3: Auxiliary Burner Location for Preheater
Method of Drying and Heating in Firing Hood and Clinker Cooler (in case with
Auxiliary Burner)
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.
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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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.
Prepare the Auxiliary Burner Apparatus (the same set as Preheater burner)