Installation of refractory materials in rotary kilns

– techniques, installation instructions and methods (part I – III)

G&W Training Program: Refractories in the Portland Cement Industry

Cairo, June 9-14, 2007
Lars Vieten, REFRATECHNIK Cement GmbH
Part I:

Installation of refractory materials in cement rotary kilns

– lining methods & lining tools
Requirements and loads on the refractory lining
in cement rotary kilns
Methods of installation in the rotary kiln

The applied installation method must generally satisfy 3 requirements:

1. Safety for installation personnel

This is a question of accurately complying with the installation
instructions, particularly in the case of the screw jack, bolt and
gluing method

2. Installation quality
The bricks must be installed in such a way that the lining fits
tightly against the kiln shell and subsequent loosening or
twisting is impossible

3. Acceptable bricking progress.

This can also be improved by the use of fork-lift trucks, roller
conveyers and other additional equipment
“Screw Jack Method”
Advantages of the crew jack method:
1. Low investments for supports and bricking equipment.
2. Kiln can be rotated during the repair.
3. Bricklaying is always carried out in the optimum position in
terms of bricklaying technology, i.e. in the zone between
6 and 9 o`clock. This gives good lining quality.

Disadvantage of this method:

1. It is only possible to install maximum lengths of 5 running metres.
2. Frequent rotation of the kiln necessitates frequent modification
of access paths and electrical wiring.
3. Method is suitable for rotary kilns of a diameter in excess of 4.40 m.
4. Safety risk (this is minimal provided adequately dimensioned
supports are used and the bracing systems accurately fitted).
5. Bricking progress is about 14 to 16 working hours per tonne.
“U-Iron and Bolt Method”
“U-Iron and Bolt Method”

Wooden wedges
Advantages of the U-iron and bolt method:
1. Kiln can be rotated as required during installation work.
2. No construction in kiln from scaffolding, platforms or supports.
3. Minimal costs for equipment and materials required.
4. High bricking progress, about 8 to 10 working hours per tonne.
5. Safety risks (only insignificant when fixing and welding
on bolts properly).
6. Bricks can be installed over a length of up to 20 metres.

Disadvantages of this method:

1. The nuts welded on the kiln shell remain in the kiln. As a result,
the brickwork is destroyed in the event of any relative movement
between the brickwork and the kiln shell.
2. A proper keying of bricks to be placed in the brickwork from
above is often not possible and such bricks are even damaged
already during keying.
“Gluing Method”

REFRABOND® – bricking
procedure for rotary kiln
REFRABOND® – bricking procedure for rotary kiln
1. kiln rotation 2. kiln rotation

starting-
point

starting-point

3. kiln rotation 4. kiln rotation

starting-
point

starting-
point
Advantages of the gluing method:
1. The kiln can be rotated at all times during the lining work.
2. There is always free access to the lining work, since no
scaffolding or platforms are required.
3. Installation always takes place in the ideal kiln position.
Consequently this is quality wise the best lining method.
4. Minimal costs for the procurement of material, etc.
5. High bricking progress, about 7 to 9 hours per tonne.

Disadvantages of this method:

1. Storability of REFRABOND® Normal and Plus in hot countries
6 months maximum.
2. Kiln must always be rotated for lining - as in the bolt and
screw jack method.
3. When gluing bricks over welding seams there cannot be made any
corrections with mortar on the a-side of the bricks. The bricks
which are to be glued must therefore generally be cut to size while
those being located between the glued sections can be mortared.
Three different types of adhesives are available so that the gluing job can be done
safely and without any problems at any outside temperature whatsoever.

Type I: REFRABOND® Normal

This is an epoxy-based synthetic resin adhesive. The
adhesive is applied at temperatures between +5 and +25°C.
The pot life after mixing is between 10 and 25 minutes.
Type II: REFRABOND® Plus
This is also an epoxy-based synthetic resin adhesive. It is
used at temperatures between +25 and +50°C, the pot life
after mixing in this case being between 5 and 15 minutes.
Type III: REFRABOND® Minus
This is a poly-acrylate-based adhesive. The curing process
here is initiated by a pulverised activator. REFRABOND®
Minus is used at temperatures between -25 and +10°C.
The pot life after mixing in this case is between
5 and 10 minutes.
Installation with REFRABOND®
Installation with
REFRABOND®
Installation with REFRABOND®
 Installation with a
“Wooden Template”
Advantages of the wooden template method:
1. Since the kiln is not rotated, access paths and electrical wiring
only have to be laid once.

2. Method is very reliable.

Disadvantages of this method:

1. Kiln cannot be rotated during the entire lining period.
2. It is difficult to install key bricks over head.

3. In the case of mortar bricking, bricks are often seen to detach

from the kiln shell after rings have been closed.

4. Bricking progress is about 16 to 18 hours per tonne

of bricks for installation.
Installation with “Pogo Sticks“

pogo stick
Advantages of the pogo sticks method:
1. Since the kiln is not rotated, access paths and electrical wiring
have to be laid only once.
2. Method is very reliable.

Disadvantages of this method:

1. Kiln cannot be rotated for the entire period required for bricking.
2. If mortar is used for installation, the bricks are observed to
detach from the kiln shell after rings have been closed.

3. Key bricks are difficult to fit.

4. Bricking progress is substantially the same as in the screw jack

method, i.e. about 12 to 16 hours per tonne of bricks.
 Installation with a
hydraulic bricking machine
REFRA-Rig
REFRA-Rig

• Newly designed and modified bricking machine exclusively made by

REFRATECHNIK
• Adjustable diameters from 3.5 – 6.5 m (MINI-Rig 1.8 – 3.4 m)
• Free adjustable twin wheels, additional supports on working platform
• Foldable side railings
• Mortar protection shields for switches
• Excellent price / performance ratio
REFRA-Rig
Advantages of using a bricking rig:

1. Since it is wheel-mounted the entire structure can easily be

moved in the kiln so that there is no need for the platform to be
continually rebuilt as in the two preceding methods

2. Since the kiln does not have to be rotated, there is no need to

modify access paths and electrical wiring etc.

3. The method is very reliable

4. High bricking progress (about 6 to 8 hours per ton)

Disadvantages of the bricking rig method:
1. Kiln cannot be rotated during entire period of installation.
2. Installation with mortar is difficult. Valves may stick due to dripping
mortar. Also, lining detaches from kiln shell after the rings have been
closed.
3. High investment costs of about $50.000,- to $80.000,- plus additional
costs for spare parts and maintenance.
4. When applying this installation method we observed that especially in
kilns with a diameter exceeding 5.00m the theoretical mixing ratio of
the brickwork could not be followed all the time. The reason for this is
that the kiln shell tends to flatten in the lowest and in the highest point
of the kiln diameter and in these parts always more bricks of the less
tapered types are used, i.e. shapes 622 or 822. Contrary to the
aforementioned, right on the flanks, i.e. in position of the bearings,
more bricks of the more tapered ones, e.g. shapes 222 or 422, have to
be built in. Especially during heating-up and first rotating of the kiln
this produces some additional mechanical stress to the surface area of
the brickwork causing spallings.
REFRA-Rig
REFRA-Rig
REFRA-Rig
REFRA-Rig
REFRA-Rig
REFRA-Rig
REFRA-Rig
REFRA-Rig
REFRA-Rig
REFRATECHNIK‘s new ”MINI-Rig“, smallest size
MINI-Rig
MINI-Rig
MINI-Rig
Installation Tools I
Installation Tools II
Installation Tools III
Installation Tools IV

“REFRA-Test“
Part II:

Mortar, clench (or metal shim) lining

Expansion joints

Keying of brick rings

Installation with mortar or clench
lining method

double layer lining

insulating layer
1. Installation with mortar

Advantages compared with other methods

¾ Refractory bricks installed with mortar form a virtually

gas-tight monolithic unit.

¾ Any mechanical loads are distributed more

uniformly over the entire lining, so that brick
hot face spalling is rarer.

¾ Differences in brick dimensions in the rotary kiln,

particularly in respect of taper, can readily be
compensated for by means of mortar, so that it is easier
to follow the theoretical mixed lining ratio.
The following points must always be observed when
laying refractory bricks in rotary kilns with mortar:

The mortar must be mixed in accordance with the

manufacturer´s instructions.
There are basically 3 types of mortar available for rotary kilns:

a) High-alumina mortar our grade KX-R

b) Magnesia mortar our grade AG-R or PX-R

c) Fireclay mortar our grade CX-R

2. Clench lining method

Points to be observed:

¾ The a-side of the bricks must be completely in contact

with the kiln shell and the horizontal joint must point
in the direction of the kiln axis.
¾ The brickwork of the next ring often becomes stepped,
particularly near welding seams in the rotary kiln. To
compensate for this, thin mortar joints may be applied
initially between the bricks and, in the case of larger
welding seams, beneath the bricks. In no case any steel
strips should be used to compensate for this.
¾ The clench lining should not be chosen for mechanically
unstable kilns or in tyre areas respectively with large
ovality due to the low compensation for tension.
Checking the radial direction
of the brickwork

heavy abrasion
crack formation
premature wear
Correct installation of brick
rings in a rotary kiln
Correct lining
3. Installation with Metal Shims

From our experience, the installation with metal shims has not
proven satisfactory. The following should be noted in
case of an installation of bricks with metal shims:

Any irregularities in the kiln shell must be corrected by changing

the mixed lining so that the a-side of the bricks always lies firmly
against the kiln shell and the horizontal joints point in the
direction of the kiln axis.
Mortar should be used to compensate for any irregularities at
welding seams and distorted kiln zones. Never place steel strips
between the bricks for additional compensation.
When closing the rings, ensure that the bricks here are inserted
without metal shims, to avoid by all means the insertion of two
metal shims into one brick joint.
Expansion joints in Brickwork

High-alumina, alumina-rich and lightweight bricks

do not need any additional joints.

Different thermal expansion behaviour of magnesia bricks

must be compensated by the insertion of cardboard spacers.

Thermal expansion = 1.5 to 2%.

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

Expansion joints in individual kiln zones

Outlet zone
If this zone is lined with high-alumina bricks, no expansion
joints are provided. If magnesia-spinel bricks are used in the
outlet zone, expansion joints of 2 mm per ring are to be provided
between the individual rings in each case.

Lower transition zone

This zone is fundamentally lined with magnesite bricks (preferrably with
magnesia-spinel bricks). A 2 mm expansion joint has to be considered
after each brick ring (by cardboard spacers).

Sintering zone
This zone is always completely lined with magnesia-chromite,
magnesia-spinel or other chrome free magnesia bricks (magnesia-hercynite).
Here again, 2 mm expansion joints are to be provided after each ring.
Expansion joints in individual kiln zones

Upper transition zone

This zone is also lined with magnesite bricks: magnesia-chromite
or chrome-free magnesia bricks. Here again 2 mm expansion
joints are inserted after each ring.

Safety zone
The safety zone is lined with alumina-rich or high-alumina
bricks. No extra expansion joints are needed.

Preheating zone
Lightweight or fireclay bricks are used in the preheating zone.
Again, no expansion joints are provided.

General note: no change of brick quality in the tyre area !

Expansion joints in a
rotary kiln lining (A)
Expansion joints in a
rotary kiln lining (B)
Keying of brick rings

¾ Only original bricks should be used to close the rings.

¾ If a number of keying bricks are used, they should be used
in alternation in each case with standard VDZ or ISO shapes.
¾ Ensure that the horizontal joints of the bricks point exactly
parallel to the kiln axis in the closure zone.

¾ The metal shims for keying the individual bricks should have a
thickness of not more than 2mm.
¾ Never use more than one metal shim per joint.
¾ Distribute the keying shims over the entire closure area.
¾ Sharpening of metal shims makes insertion much easier.
Keying of alumina brick lining in kiln outlet zone
 • Make sure that the a-side of the last
bricks are tightly pressed against the
kiln shell and that the horizontal joint
extends in the direction of and parallel
to the kiln axis

• Make the opening for the last brick in

such way that a standard VDZ or ISO
shape brick fits

false • The last brick must be installed duly

parallel to the adjacent bricks

• The ring is secured by knocking in

keying shims which should be
distributed over the entire closure zone
false
Keying (clench)
Keying of brick rings
Keying of brick rings
Keying of brick rings
Keying of brick rings
Keying of brick rings
Keying of brick rings
Keying of brick rings
Keying of brick rings
Keying of brick rings
Keying of brick rings
Keying of brick rings
Installation with REFRA-Rig
(keying of magnesite lining)
Installation of the last
brick with clench lining
 chamfer

Installation of the
mortar to be filled in
last brick with
mortar

Calculate the opening for the last brick so that a standard VDZ
or ISO shape can be inserted into it from above.

The opening at the b-side of the lining is equal to the a-size of

the closure brick to be inserted.

The opening for the closure brick is filled to a good third with
mortar
Installation of the last brick with mortar

The brick, on which the edges of the a-side are broken on both sides of a
length of about 2 cm, is pressed into the mortar from above by knocking in
with a rubber hammer to such an extent that the mortar is forced out
through the open joints on the surface of the brickwork.

keying shims
Part III:

Installation of refractory materials in cement rotary

kilns over deformed kiln shell and welding seams

Lining of last ring

Relining of a rotary kiln

1) Reference lines are drawn on the kiln shell near the

vertical welding seams every 1.2 to 1.6 m.

2) If only some areas of the rotary kiln have to be repaired,

the vertical welding seam nearest the old brickwork is
also taken as a reference line.

3) For placing the first layer a horizontal welding seam can

be taken as a reference line. The starting line is
determined at the lowest point of the kiln.

The lowest point in the kiln is determined at the start of the

section to be lined. The same is done at the end of the section
to be lined. These two points are then connected by a line.
Reference lines are drawn on the kiln shell near the
vertical welding seams every 1.2 to 1.6 m.
• For placing the first layer a horizontal
welding seam can be taken as a reference line.
horizontal welding joints The starting line is determined at the
of kiln shell
lowest point of the kiln.
auxiliary line
parallel alignment
e.g. chalk line

parallel alignment

vertical welding joints

of kiln shell

•If only some areas of the rotary kiln have to be repaired,

the vertical welding seam nearest the old brickwork
is also taken as a reference line.
Relining of a rotary kiln
Relining of a rotary kiln
Relining of a rotary kiln
Laying bricks over welding seams

The following should be noted:

1) In case of welding seams projecting more than 8 mm

from the shell, the brick there above should be cut out.

2) In the case of welding seams below 8 mm, the bricks

are backed with mortar so that the rings at the welding
seams can also be installed parallel to the other brick
rings.

3) Bricks being installed by the glueing method have to be

cut out above the welding seams.
Correct installed bricks
welding seam higher
than 8 mm

Laying bricks over welding seams

to be cut on installation
to be filled with mortar the following should be noted:
welding seam higher
than 8 mm

• In case of welding seams

projecting more than 8 mm
to be cut on installation from the shell, the brick there
to be filled with mortar above should be cut out.
welding seam
max. 8 mm • In the case of welding seams below
8 mm, the bricks are backed with
mortar so that the rings at the welding
seams can also be installed parallel to
to be filled with mortar
the other brick rings.
welding seam
max. 8 mm • Bricks being installed by the glueing
method have to be cut out above the
welding seams.

to be filled with mortar

Badly deformed kiln shell
Installation of Refractory Bricks
over distorted kiln Shell

The following details should be noted:

1) The a-side must fit tightly against the kiln shell.

2) Horizontal joints exactly in the direction of and
parallel to kiln axis.

3) Over distorted kiln shell with mortar lining.

4) Compensate any irregularities with mortar

5) Leave the deformed part open and put finally the bricks
over the distorted area.
Adjustment for distorted
kiln shell (radial)
 filled with mortar
max. 8 mm

Adjustment for distorted

kiln shell (axial)

filled with mortar

max. 8 mm
Adjustment for distorted
kiln shell (axial)
Brick lining under a
deformed kiln shell
Bad installation of bricks
Collapse of brick lining
Recommendation of last ring lining by using
L-shapes (bricks of 300mm length)

L-shape bricks

new lining old lining

Installation of the last ring between
new and old lining

Problems occur when joining the new to the old lining. The
distance to be bridged is often somewhat larger than a
standard VDZ or ISO shape brick. In such cases two bricks
always have to be cut.

To remedy this problem, REFRATECHNIK produces

B- and ISO-shapes in a length of 300mm.

VDZ ISO
B 220 L 220 L
B 620 L 620 L
B 222 L 222 L
B 622 L 622 L
Installation of the last ring between new
and old lining