Refractory failures, analysis and their

impacts
Umesh Hosur
CEM-Asia

03 June 2020

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
De-Brief about 29th April session on Refractories

Following topics were discussed on 29th April-2020 session conducted on

topics mentioned below:

● Introduction about refractories

● Classification of Refractories & their usage in different industries
● Raw materials and their manufacturing process
● Types of refractories and their selection
● Present performance of Refractoriness in our plants
● Refractory failure and loss of clinker production etc

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Content
● Introduction
● Refractory Precautions- while resuming operation after Covid19
lockdown
● Brief introduction on Refractories & Costs
● Refractory related Preventive measures to avoid unexpected kiln
stops

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
When refractory fails?

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
A variety of wear mechanisms limits the service life of
refractory linings

Ref.: RHI

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Refractory wear mechanisms predominate…

~20%

thermal

mechanical chemical

~20% ~60%

Ref.: RHI

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Predominant Wear Mechanisms in Rotary Kilns

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Static areas Refractory wear impact

Low

Medium

High

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Factors influencing the Kiln Refractory performance

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Wear Mechanism

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Process / Chemical attack

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Wear Relevant Elements

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Enrichment of Volatile Elements

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Wear Relevant Element of Alternative Fuels

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Kiln Cycles

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Consequence of Alkali Salt Infiltration

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Wear Process: Alkaline Salt Infiltration

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Alkali Salt Infiltration

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Corrosion of Brick Bonding

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Corrosion of Calcium-Silicatic Brick Bonding

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
ASR > 1: Alkali Attack on Alumina Bricks

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
ASR > 1: Alkali Attack on Alumina Bricks

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Examples of Alkali Spalling

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
 GL-2, AM: PH cyclone
Alkali Attack: Failure of Steel Shell due to body cracking issue
Expansion of Alumina Refractory before using petcoke

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Shell Temperature Guidelines for static areas

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Thermal Load

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
 BG and BT-2 Kiln Burning
zone : Ongoing issue
Clinker Melt Infiltration

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
 DL Kiln LTZ: Ongoing
issue
Wear Process: Clinker Melt infiltration

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Overheating of High Alumina Bricks in the Outlet Zone

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
PCPF Ceramic Kiln outlet Tip casting

Following kilns installed

with these blocks

1. Madukkarai
2. Kymore-2
3. Rabriyawas
4. La- Union
5. Lugait

Following plants are

scheduled to
installed these
blocks
6. Maratha
7. Bhatapara-1
8. Bhatapara-2
9. Marwar Mundwa

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Overheating of SiC Mullite Bricks in the Safety Zone

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Wear Process: Effect of Frequent Thermal Shocks

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Thermal Shocks

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Too Fast Heat Up

Overstress at
Hot face

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Combination of Wear Mechanisms (CBZ after 5 months)

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Mechanical Load

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
 Wadi-2 Kiln calcination
zone: Ongoing issue
Reasons for Mechanical Load

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
 RB Kiln UTZ: Ongoing
issue
Kiln Shell Deformations (Permanent Due to Host Spot)

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Kiln Shell Deformations: Reversible Deformation Due to too high
clearance

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Kiln Shell Deformations: Kiln shell Constriction Due to too low
clearance

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Reasons for Mechanical Load

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Recommended Tyre Creep and Ovality

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Possible Consequences

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Influence of Tyre Ovality

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Reasons for Mechanical Load: Wrong Installation

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Signs of Mechanical Overload

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Maximum Shelf Life

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Hydration of Magnesia Bricks

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Hydration of Magnesia Bricks

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Hydration

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
How to Check for Hydration

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Lab Test: Differential Thermogravimetry (DTG)

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Wet Bricks

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Wet Lining Sections

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Measures to Avoid Hydration

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
 Kiln refractory lining activity register during shutdown

Date: Shift:

1 2 3 4 5
Names Key Mesons:

Names of other 1 2 3 4 5 6 7 8 9
mesons:
Center line marked: Radial lined marked @ 2m interval: Axial lines marked @ 2m interval:

Bricks lining details

Bottom half lining rings in nos: From: To: Total no. of bottom half rings: 0
Bottom rings Skew in Right end Right end
Shift start: Shift end:
mm Left end Left end
Machine lining (Top half rings) in nos. From: To: Total no. top half rings completed:
Right end Right end
Top rings Skew in mm Shift start: Shift end:
Left end Left end
Other details during lining work Remarks
Compressed air pressure at bricks laying machine, bar:
Bricks mixing ratio:
No. of Key bricks installed per ring
No. of sims installed per ring
Step formation inf the hot surface:
Mortar Application
Shell welding joints height, mm:

Shift Remarks:

Signatures of site spervisors

Contractor Bricks supplier Plant

56
Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
2019 Kiln refractory performance at a glance (ACC)

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
 2019 Kiln refractory performance at a glance (ACL)

Surma- Bangladesh: Entire kiln refractory bricks performed 12 month against earlier life
9-10 months.
Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
ACC – Plants Refractory materials performance
(3 yrs Rolling – 2017 to 2019)

1200

1000

Sp. Refr (Basic) cons Sp. Refr (Alumina) cons

(g/MT of cli) 3 Yrs rolling (g/MT of cli) 3 Yr Rolling
800
686

600

429 425415 442444

400 354
344 346
307
273
234 247 244
204 207 209194 220
200 159 171
146

0
W2 W1 MK LK KY JP G2 G1 BG GG JL-4

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
ACL – Plants Refractory materials performance (3 yrs
Rolling 2017 to 2019)

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Kiln refractory performance expectation in 2020

Kiln refractory may not performance to full of its potential due to following
reasons
● In some kilns, we may extend the life of the kiln bricks beyond 12 months
● There will be unforeseen kiln stops
● There will be more no. of kiln stops other than refractory related which may
influence negative impact on kiln refractory
● Operating kilns with low PRI due to lack of market demand may have impact
on kiln refractories performance.

Preparatory actions:

Plant to keep sufficient stock on kiln bricks (~5m each Basic and
Alumina bricks), castables (~ 5-10 MT of LC Castable and 5-10MT of
Conventional castable) to handle the kiln stops due to refractory
failures.

Plant to keep informed manpower for attending refractory failures

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
 ACC- Kilns Refractory failures in 2019

2018 Refractory performance 2019 Refractory performance

Refractory Incidents Freq, Hours Clk lost, Freq, Hours Clk lost,
Plants Plants
nos. Lost MT nos. Lost MT
Kiln Refractory replacement due to poor
process controlling, installation, bricks
W2, W1,
quality & Mechanical reasons (RCFA done, 2 156 35983 BG, W2 3 348 130076
JL
Actions defined, actions not yet
implemented)

Kiln refractory failed due to stretching life KY-1 (3),

beyond 12 months of bricks and poor shut 4 192 33069 KY, JP 6 290 64031 W2, BG,
planning (avoidable) MK

LK, W2,
Burner pipe refractory replacement 1 27 13359 W2 4 82 15870
GL2, MK

MK,
Kiln tip casting refractory replacement 2 258 31000 1 187 31000 JP
KY2
Cooler Bull nose / arch and Other areas
2 149 18693 BG, KY 1 22 4486 GL2
refractory replacement

Preheater Refractory failure 3 179 18161 MK 2 27 5424 JL, MK

Total 14 961 132105 17 955 245463

62
Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
 ACL- Kilns Refractory failures in 2019
2018 Refractory performance 2019 Refractory performance
Refractory Incidents Freq, Hours Clk lost, Freq, Hours Clk lost,
Plants Plants
nos. Lost MT nos. Lost MT
Kiln Refractory replacement due to Process,
poor installation, bricks quality & A1(2),
BT-1, RB,
Mechanical reasons (RCFA done, Actions 6 806 206707 11 1228 399764 RB(5), DL,
RU
defined, actions implemeted and yet to be BT-2 (3)
implemented)

Kiln refractory failed due to stretching life

beyond 12 months of bricks and poor shut 1 104 19847 A1 0 0 0 -
planning (avoidable)

A1, RB,
Burner pipe refractory replacement 0 0 0 3 141 39435
MT

Kiln tip casting refractory replacement 1 101 31743 MT 1 133 37785 RB

Cooler Bull nose / arch and Other areas

0 0 0 1 81 13331 A2
refractory replacement

Preheater Refractory failure 0 0 0 0 0 0

Total 8 1011 258297 16 1583 490316

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
63
 ACC & ACL Year-wise Refractory Consumption pattern

ACC ACL
Particulars UoM
2016 2017 2018 2019 2016 2017 2018 2019
Purchase Lacs INR 3893 4394 3745 4179 2525 4405 4706 3815

Clk Produced Lacs MT Clk 150 187 187 176 143 155 157 153

Total Ref. Consumed MT 9772 8549 10029 10076 8492 6538 8363 8837
Total Sp. Ref Consumed gm/MT Clk 654 456 535 573 594 421 533 577

Sp. Spend INR/MT Clk 26.0 25.3 21.6 24.9 17.6 28.4 30.0 24.9

INR/MT Clk 23 25
Avg. Sp. Spend
CHF/MT Clk 0.31 0.34

64
Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
ACC & ACL Year-wise Refractory Consumption pattern

65
Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018
Summary

● Types of refractory materials

● Alumina based refractory materials are used in the colder zones of
the kiln system whereas basic refractory bricks are used in the
hottest parts of the rotary kiln

● Refractory wear
● Today, mainly the chemical load destroys our refractory linings

● Holcim standard refractory concept

● The successful concept for the static kiln section is based on three
pillars

● Systematic procedure for analyzing refractory failures

● A systematic root cause analyses facilitates a better refractory
performance

Monthly Operational Performance Report - Month 2018 For Internal use only © LafargeHolcim 2018