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Chapter 5 Final A5 Edit

The document discusses refractory installation techniques in the tertiary air duct of cement plants. Key points include: 1) Inspection and cleaning of the steel ductwork is required before refractory installation. 2) Refractories suitable for the 800°C tertiary air duct include 35-40% alumina bricks and insulating board/bricks. 3) Installation involves placing refractories at retaining ring areas, then insulating and heat-contact bricks in the lower and upper halves of the duct.

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kING
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138 views

Chapter 5 Final A5 Edit

The document discusses refractory installation techniques in the tertiary air duct of cement plants. Key points include: 1) Inspection and cleaning of the steel ductwork is required before refractory installation. 2) Refractories suitable for the 800°C tertiary air duct include 35-40% alumina bricks and insulating board/bricks. 3) Installation involves placing refractories at retaining ring areas, then insulating and heat-contact bricks in the lower and upper halves of the duct.

Uploaded by

kING
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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REFRACTOTRY INSTALLATION TECHNIQUES

99
IN CEMENT INDUSTRY

Chapter 5:
Refractory Installation in the Tertiary Air Duct

5.1 Inspection of steel works

- For every refractory installation task, a quality


inspection of all steel works in the Tertiary Air Duct
must be performed and corrected first prior to the
refractory installation. For example, inspection of
cracks along the welding seams, and deformities of
the internal shell surface of the Tertiary Air Duct. In
case of welding spot in any shell surface areas, it shall
be smoothed by grinding prior to the refractory
installation.
- Clean the internal shell surface for any possible rust,
scale and corrosion that might occur in some areas,
through scraping with wire brush. In case of oil
deposits or any contaminants accumulated in the wall
surface, clean them with fabric sheet. .

5.2 Procedures for Refractory Installation in the Tertiary


Air Duct

- The tertiary air duct is where the hot air flows from
cooler to calciner via the duct.
- The inside temperature of the Tertiary Air Duct is
approximately 800OC and the refractory lining to be
used must have high abrasion resistance property.
- It is recommended that the refractory linings to be
installed in the Tertiary Air Duct must have an
Alumina (Al2O3) content range of 35%-40%, and low
porosity such as K25D, and the insulation lining
should be HI-16 or Insulating Board.
- Throughout the interior of the Tertiary Air Duct, there
are intervals of Retaining Rings along certain
REFRACTOTRY INSTALLATION TECHNIQUES
100
IN CEMENT INDUSTRY

distances for structural reinforcement and supporting


the load of the refractory linings.
- The refractory installation procedures are listed
below:

5.2.1 First, install the refractory bricks at the Retaining


Ring Areas, wherein these refractory bricks have
special shape designed to cover the retaining ring and
this will help to protect the Retaining Rings from
direct heat contact, as shown in Fig. 5-1.

Retaining
Ring
REFRACTOTRY INSTALLATION TECHNIQUES
101
IN CEMENT INDUSTRY

Retaining
Ring

Fig. 5-1: Pictures illustrating the installation of refractory


linings at the Retaining Ring area

5.2.2 Install the Insulating Bricks or Insulating Board,


which serves as a back up insulation lining, and then
install the refractory bricks which have direct contact
with heat in the lower half of the Tertiary Air Duct.
5.2.3 To install the refractory at the upper-half portion of
the Tertiary Air Duct, a wooden template is to be used
and shall be leveled parallel to the wooden support
curve where the distance from its circumference to the
lining surface must be set at approximately 20-30mm.
5.2.4 Install the Insulating Bricks or Insulating Board and
refractory bricks at the upper-half portion, each
REFRACTOTRY INSTALLATION TECHNIQUES
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IN CEMENT INDUSTRY

individual brick has to be keyed tightly against the


wall using wooden wedges.

Wooden
Wedges

Wooden
Wedges

Fig. 5-2:
Picture illustrating
refractory linings at
the upper-half of the
Tertiary Air Duct
REFRACTOTRY INSTALLATION TECHNIQUES
103
IN CEMENT INDUSTRY

5.2.5 To close up the refractory bricks in each ring, if


cutting is necessary; the portion of the brick closure
must remain at least 2/3 of the original size. Insert the
shimming plates to tighten each ring of the refractory
bricks installed.

Fig. 5-3: Picture illustrating the closure ring installation in the


Tertiary Air Duct

5.3 Repair of refractory lining in the Tertiary Air Duct


(Partial)

- Damages of refractory linings inside the Tertiary Air


Duct often occur in the upper half portion due to
abrasion, while the lower-half portion is covered by
the clinker dusts from the Clinker Cooler, which
protect the lining from damages.
- There are 2 methods to repair the refectory lining in
the Tertiary Air Duct; either with the use of
Refractory Castable or refractory bricks.
REFRACTOTRY INSTALLATION TECHNIQUES
104
IN CEMENT INDUSTRY

5.3.1 Repair the refractory lining with Refractory


Castable.
- In case of non-severe damage of refractory linings or
an inadequate supply of refractory bricks, the use of
Refractory Castable for repair is the option.
- Begin with demolishing and removing the damage
portions of refractory linings.
- Fix the anchors and install the Insulating Bricks and
Insulating Board, and set up the wooden forms/
moulds for castable installation. See Fig. 5-4.
REFRACTOTRY INSTALLATION TECHNIQUES
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IN CEMENT INDUSTRY

Fig. 5-4: Picture illustrating the repair of lining


with Refractory Castable

5.3.2 Repair the refractory lining with refractory bricks


- In case of severe damage of refractory linings and
there are sufficient supply of refractory bricks, the use
of refractory bricks for repair is the option.
- Begin with demolishing and removing the damage
portions of refractory linings, and then install the
Insulating Bricks or Insulating Board and refractory
bricks respectively, the same way it is installed as a
new project.
REFRACTOTRY INSTALLATION TECHNIQUES
106
IN CEMENT INDUSTRY

New
refractory
linings
installed at
the upper-
half portion

Old
refractory
linings
remained
Fig 5-5: Pictures illustrating the repair of lining un-repaired
with refractory bricks

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