Refractory

RefractoryInstallation
Installation

Installation of refractory
bricks in rotary kilns for
the cement clinker
process

Refractory
RefractoryInstallation
Installation
Content
1.

Comparison single shape lining mix lining

2.

Calculation of necessary numbers of bricks for mixed lining

3.

Comparison of common kiln brick systems

4.

Recommendation for lining thickness and brick mix

5.

Installation guide step by step

6.

Comparison of various lining methods

Screw jack method

Glue method

Bolt method

Kiln rig method

Refractory
RefractoryInstallation
Installation

1. Comparison single shape lining mix lining

Determination

Advantage

Disadvantage

Only one shape

Quick installation

Correction of the lining is not possible

Every kiln diameter needs its own shape
Exchange of bricks with other plants is
difficult
Less flexibility in the brick rings
Forced to be dependent on producer /
supplier

Good correction of the lining

Kiln diameter in a range up to 1,5m can be
lined by the same brick shapes
Exchange of bricks with other plants
possible
Improved flexibility in the brick rings
World wide producer / supplier available
High flexibility in terms of delivery from
supplier

Two shapes necessary

Higher number of brick per ring

Single Shape
Lining

Mix lining
(two shapes)

Refractory
RefractoryInstallation
Installation

2. Calculation of necessary numbers of bricks for mixed lining

Shape N1

Shape N2

A1

A2

Formula
D = D2*h
N11 =

B1

N22 =

B2

( D * B2 d * A2 )
A1 * B2 B1 * A2
( D * B1 d * A1 )
B1 * A2 A1 * B2

If one of the results N1 or N2 is negative a

installation
of the chosen bricks is impossible!

A1, A2, B1, B2 - Dimension of brick, including the thickness of the mortar joint
D
h
d
N1
N2

=
=
=
=
=

Kiln diameter (inner kiln shell)

lining thickness (brick thickness)
lining diameter (inner diameter)
number of pieces of SHAPE 1
number of pieces of SHAPE 2
4

Refractory
RefractoryInstallation
Installation

3. Comparison of common kiln brick systems ISO (/3) shaped

bricks POS.
Dimension [mm]
POS.
Vol.
a
216
316
416
516
716
218
318
418
518
618
718
ISO

220
320
420
520
620
720
820
222
322
422
522
622
722
822

b
86,0
92,0
94,5
96,5
98,2

103

84,0
90,5
93,5
95,5
97,0
97,7

103

82,0
89,0
92,5
94,7
96,2
97,0
97,8

103

80,0
88,0
91,5
94,0
95,5
96,5
97,3

103

160

180

200

220

198

198

198

198

Dimension [mm]
b
h
77,0
85,5
90,0
92,7
250
94,5
95,5
96,5

dm
2,99
3,09
3,13
3,16
3,19

225
325
425
525
625
725
825

3,33
3,45
3,50
3,54
3,56
3,58

103

198

Vol.
dm 3
4,46
4,67
4,78
4,84
4,89
4,91
4,94

ISO
230
330
430
630
830

71,6
82,0
87,3
92,5
95,0

103

300

198

5,19
5,49
5,65
5,81
5,88

3,66
3,80
3,87
3,91
3,94
3,96
3,98

A = 103mm = constant

B = variable
Wedge (A + B)/2 = variable
h

3,99
4,16
4,24
4,29
4,32
4,35
4,36

L
b
5

Refractory
RefractoryInstallation
Installation

3. Comparison of common kiln brick systems VDZ shaped bricks

POS.

VDZ

Dimension [mm]
b
h
65,0
68,0
160
69,0
70,0

B 216
B 416
B 616
B 716

a
78,0
75,0
74,0
73,0

B 218
B 318
B 418
B 518
B 618

78,0
76,5
75,0
74,5
74,0

65,0
66,5
68,0
68,5
69,0

B 220
B 320
B 420
B 520
B 620

78,0
76,5
75,0
74,5
74,0

65,0
66,5
68,0
68,5
69,0

B 122
B 222
B 322
B 422
B 522
B 622
B 822

81,5
78,0
76,5
75,0
74,5
74,0
73,5

61,5
65,0
66,5
68,0
68,5
69,0
69,5

180

l
198

Vol.
dm3

POS.

2,27
VDZ

198

a
82,0
78,0
76,5
75,0
74,5
74,0
73,5

B 225
B 325
B 425
B 525
B 625
B 725
B 825

2,55

Dimension [mm]
b
h
61,0
65,0
66,5
68,0
250
68,5
69,0
69,5

Vol.
dm3

198

3,54

A = variable
B = variable
Wedge (A + B)/2 = constant = 71,5mm

a
200

198

2,83

220

198

3,11

L
b

Refractory
RefractoryInstallation
Installation

3. Comparison of common kiln brick systems key / closure bricks

KEY BRICKS

POS.
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P

161
162
164
165
181
182
184
185
201
202
204
205
221
222
224
225
231
232
254
255
251
252
304
305

a
71,0
78,0
58,0
65,0
71,0
78,0
58,0
65,0
71,0
78,0
58,0
65,0
71,0
78,0
58,0
65,0
71,0
78,0
58,0
65,0
71,0
78,0
58,0
65,0

Dimension [mm]
b
h
63,0
160
70,0
160
51,0
160
58,0
160
65,0
180
71,0
180
53,0
180
60,0
180
65,0
200
71,0
200
53,0
200
60,0
200
65,0
220
71,0
220
53,0
220
60,0
220
65,0
230
71,0
230
53,0
250
60,0
250
65,0
250
71,0
250
53,0
300
60,0
300

198

Vol.
dm3
2,12
2,34
1,73
1,95
2,42
2,66
1,98
2,23
2,69
2,95
2,20
2,48
2,96
3,25
2,42
2,72
3,10
3,39
2,75
3,09
3,37
3,69
3,30
3,71

L
b

Refractory
RefractoryInstallation
Installation

4. Recommendation for lining thickness and brick mix

Kiln diameter
[m]*

Lining thickness
[mm]

ISO Mix

VDZ - Mix

< 3,6

180

218 / 618

B218 / B618

3,6 4,2

200

320 / 620

B320 / B620

4,2 5,2

220

322 / 822

B322 / B622

> 5,2

250

425 / 825

B425 / B825

* Inner shell diameter

Kiln
Kiln diameter
diameter

Refractory
RefractoryInstallation
Installation

5. Installation guide step by step

(lining method: kiln rig)

1.

Measure and mark the kiln axis

2.

Align the kiln bricks along the kiln axis

3.

Proceed on either directions

4.

Install the bricks up to the kiln centre

5.

Erect the kiln rig

6.

Continue installation on either sites

7.

Close of the remain gap of the brick ring

8.

Check finally the lining

9.

Start kiln in accordance to the heating-up procedure

Refractory
RefractoryInstallation
Installation

5. Installation guide step by step

1. Measure and mark the kiln axis

2. Align the kiln bricks along the kiln axis

3. Proceed on either directions

4. Install the bricks up to the kiln centre

10

Refractory
RefractoryInstallation
Installation

5. Installation guide step by step

5. Erection of the Kiln Rig

6. Continue installation on either site

7. Keying of the Brick Ring

8. Final check of the lining

11

Refractory
RefractoryInstallation
Installation

5. Installation guide step by step

10. Start kiln in accordance to the heating-up
procedure

12

Refractory
RefractoryInstallation
Installation

5. Installation guide step by step - Patchwork

Step 1

Step 3

Step 2

Step 4

13

Refractory
RefractoryInstallation
Installation

5. Installation guide step by step - Insertion of an individual Brick

14

Refractory
RefractoryInstallation
Installation
6. Comparison of various lining methods screw jack method

turning direction

wooden plank

closure bricks
turning direction
working
direction

15
turning direction

Refractory
RefractoryInstallation
Installation
6. Comparison of various lining methods glue method

15
3

3
detail "A"

15

15

15

"A"

12
3

closure bricks

3
10

working
direction

turning
direction

8
4

gluing joint

starting position
16

Refractory
RefractoryInstallation
Installation
6. Comparison of various lining methods bolt method

"A"

wooden plank

detail"A"

welded nut
17

Refractory
RefractoryInstallation
Installation
6. Comparison of various lining methods kiln rig method

18

Refractory
RefractoryInstallation
Installation
6. Comparison of various lining methods kiln rig method

19