KILN REFRACTORY

REFRACTORIES
REFRACTORY LAYOUT
KILN START UP & SHUT DOWN
REFRACTORY FAILURE

DALMIA REFRACTORIES
(SNCCIL)
DALMIAPURAM
REFRACTORY
Withstand High Temperature Without Getting Affected -
Softening or Fusing.
Materials Resistant to Heat and are Inorganic, Non-metallic
Substances.
SHOULD RESIST THE FOLLOWING CONDITIONS
THAT OCCUR IN SERVICE
Sudden changes in temperatures and resulting
thermal shock.
Abrasion due to moving charge.
Combined effect of load and temperature.
Reducing / Oxidizing conditions.
Chemical action of Corrosive liquids/gases
Mechanical and thermal stresses DALMIA REFRACTORIES
MATERIALS CLASSIFIED AS REFRACTORY ARE
CLASSIFIED INTO FOUR MAJOR GROUPS BASED
ON CHEMICAL CONTENT OR SPECIAL PHYSICAL
CHARACTERISTICS.

CLASSIFICATION BASED ON CHEMISTRY

BASIC
HIGH ALUMINA
FIRECLAY
SILICA

DALMIA REFRACTORIES
Properties of Refractories & their
Importance
Porosity
Cold Crushing Strength
Abrasion Resistance
Resistance to High Temperature
Resistance to Thermal Shock
Resistance to Chemical Attack
Elasticity & Insulation

DALMIA REFRACTORIES
PROPERTIES OF REFRACTORIES
1. PHYSICAL
APPARENT POROSITY
BULK DENSITY
2. THERMAL
COLD CRUSHING STRENGTH
REFRACTORINESS (P.C.E)

REFRACTORINESS UNDER LOAD(R.U.L)

PERMANENT LINEAR CHANGE(P.L.C)

THERMAL SHOCK RESISTANCE (SPALLING RESISTANCE)

THERMAL CONDUCTIVITY

REVERSIBLE THERMAL EXPANSION (R.T.E)

3. CHEMICAL COMPOSITION
DALMIA REFRACTORIES
REFRACTORY CASTABLE
COMBINATION OF REFRACTORY GRAIN AND HIGH
ALUMINA CEMENT
HYDRAULIC BONDING - AFTER ADDITION OF WATER
BECOMES RIGID DUE TO HYDRATION
SUPPLIED IN DRY POWDER FORM

TYPES OF CASTABLE

CONVENTIONAL - MIN 15%CEMENT

LOW CEMENT - MAX 5% CEMENT
ULTRA LOW CEMENT - MAX 3% CEMENT

DALMIA REFRACTORIES
CHARACTERISTICS
CONVENTIONAL CASTABLE LOSES STRENGTH AT
INTERMEDIATE TEMPERATURE AND THEN PICKS UP
DUE TO CERAMIC BOND FORMATION.

LOW CEMENT CASTABLES MAINTAINS SAME

STRENGTH THROUGH OUT.

AS FLUXES ARE LOW IN LCC AND ULCC,

REFRACTORINESS IS HIGHER.

DALMIA REFRACTORIES
REFRACTORY SHAPES
CIRCULAR BRICKS
SIDE-ARCH BRICKS
END-ARCH BRICKS
ISO STANDARD
VDZ - SERIES

DALMIA REFRACTORIES
REFRACTORY LAYOUT

DALMIA REFRACTORIES
 INTRODUCTION
THE PRODUCTION OF CEMENT CLINKER INVOLVES A
CLOSELY CONTROLLED PYROCHEMICAL PROCESS FOR
CONVERTING OXIDES OF CALCIUM, SILICA, IRON,
ALUMINIUM AND OTHER CONSTITUENTS TO THE
FORMATION OF DESIRABLE COMPOUNDS VIZ.

C3S, C2S, C3A , C4AF

THIS INVOLVES VARIOUS EQUIPMENTS IN THE TOTAL

KILN SYSTEM TO CARRY OUT VARIOUS CHEMICAL
REACTION AS LISTED BELOW.

DALMIA REFRACTORIES
CLINKER PRODUCTION LINE CONSISTS OF
VARIOUS EQUIPMENTS VIZ:
1. PREHEATER a. CYCLONES
b. RISER DUCTS
c. RAW MEAL CHUTES
2. PRECALCINER / PYROCOLON
3. INLET CHAMBER
4. ROTARY KILN
5. KILN HOOD
6. TERTIARY AIR DUCT
7. COOLER

DALMIA REFRACTORIES
TYPE OF REFRACTORY MATERIALS TO BE
USED IN VARIOUS ZONES
DEPENDS ON THE SERVICE CONDITIONS
TEMPERATURE
ATMOSPHERE
CHEMICAL REACTIONS
MECHANICAL STRESSES
THERMAL STRESSES
TEMPERATUE FLUCTUATIONS
MODE OF OPERATIONS
RAW MEAL AND PRODUCT CHARACTERISTICS

DALMIA REFRACTORIES
 SERVICE CONDITION & REFRACTORY IN
VARIOUS EQUIPMENTS IN KILN SYSTEM
CYCLONE PREHEATERS:
PROCESS CARRIED OUT:
RAW MEAL IS PREHATED & PARTIALLY CALCINED
BY MOVING COUNTER CURRENT TO HOT GASES
LEAVING THE KILN.
FIRST & SECOND STAGE
GAS TEMPERATURE - 350-400oC
CHEMICAL ATTACK - MODERATE
THERMAL SPALLING - MODERATE
ABRASION - MODERATE

REFRACTORY QUALITY:
I. INSULATION AT BACKUP
II. 40% Alumna WITH CCS OF 350 Kg/cm2
DALMIA REFRACTORIES
III, IV & VTH STAGES
SERVICE CONDITIONS:
GAS TEMPERATURE - 700-1100oC
CHEMICAL ATTACK - SEVERE FROM ALKALI, SULPHATE
& CHLORIDE
THERMAL SPALLING - MODERATE
ABRASION - SEVERE DUE TO PARTLY
CALCINED RAW MEAL

REFRACTORY QUALITY:
I. INSULATION BACK UP
II. HIGH MECHANICAL STRENGTH WITH MEDIUM ALUMINA 40-45%
WITH HIGHER PCE & LOW POROSITY.

DALMIA REFRACTORIES
 RISER DUCTS
ABRASION - SEVERE
THERMAL SPALLING - MODERATE
BUILD UP IN BENDS DUE TO ALKALI,
SULPHATES AND CHLORIDES ATTACK.
REFRACTORY:
30-40% ALUMINA IN VARIOUS STAGES WITH
LOW POROSITY,
HIGHER SPALLING RESISTANCE
HIGHER RESISTANCE TO CHEMICAL ATTACK

DALMIA REFRACTORIES
 PRECALCINER
PARTLY CALCINED RAW MEAL ENTERS THE CALCINER WITH
HOT AIR AT 700-750oC FROM THE GRATE COOLER.

FINELY GROUND COAL FED INTO THE SYSTEM TO ATTAIN

TEMPERATURE OF MAXIMUM 1000oC.

SERVICE CONDITIONS:
GAS TEMPERATURE - 800-1000oC
ABRASION - VERY SEVERE
CHEMICAL ATTACK - SEVERE AT SELECTED POINTS DUE TO
ALKALI, SULPHATE & CHLORIDE
THERMAL SPALLING - SEVERE

REFRACTORY QUALITY
I. BACKUP INSULATION
II. DENSE 70% ALUMINA IN POCKETS WHERE ABRASION IS SEVERE
III. DENSE 40-50% ALUMINA FOR ROOF & OTHER MAJOR AREAS
WITH HIGH CCS, LOWER POROSITY. DALMIA REFRACTORIES
 KILN SYSTEM

CLASSIFICATION OF ZONES
a. INLET ZONE
b. CALCINATION ZONE
c. LOWER TRANSITION ZONE
d. UPPER TRANSITION ZONE
e. BURNING OR SINTERING ZONE
f. COOLING ZONE
g. OUTLET OR DISCHARGE END

DALMIA REFRACTORIES
INLET ZONE
SERVICE CONDITIONS
a. MODERATE ABRASION DUE TO FALL OF
PARTIALLY CALCINED RAW MEAL
b. CHEMICAL ATTACK DUE TO BUILD UP
c. SPALLING

REFRACTORY QUALITY
LINED WITH 40% ALUMINA ABRASION
RESISTANCE CASTABLE TO AVOID
COMPLICATED BRICK SHAPE.

DALMIA REFRACTORIES
 CALCINATION ZONE
SERVICE CONDITIONS:
a. DECOMPOSITION OF CARBONATES
b. CHEMICAL ATTACK FROM ALKALIES
c. MODERATE ABRASION
d. TEMPERATURE FLUTUATION

REFRACTORY QUALITY:
LOW ALUMINA BRICK WITH MODERATE CCS TO
WITHSTAND ABRASION.
LOW THERMAL CONDUCTIVITY TO SAVE
ENERGY

DALMIA REFRACTORIES
 TRANSITION ZONE
SERVICE CONDTIONS
EXPOSED TO SOLID STATE CHEMICAL REACTION
BETWEEN RAW MEAL AND CHARACTERISED BY RING
FORMATION
SEVERE ABRASION
CHEMICAL ATTACK FROM ALKALI &CHLORIDE
SEVERE THERMAL& MECHANICAL STRESS

REFRACTORY QUALITY:
WITHSTAND ALKALI ATTACK, SPALLING & ABRASION.
BRICKS SHOULD HAVE LOW AP & HIGH RUL
60% AL203 BRICKS FOR SMALLER CAPACITY AND 70%
AL203 FOR LARGER CAPACITY KILNS.

DALMIA REFRACTORIES
 BURNING ZONE
SERVICE CONDTIONS
HIGH TEMERPATURE SOLID STATE REACTIONS AND LIQUID
FORMATION
STABLE COATING FORMATION BY REACTION BETWEEN BRICK
AND CLINKER
CHEMICAL ATTACK FROM LIME, ALKALI &CHLORIDE
SEVERE THERMAL& MECHANICAL STRESS
THERMAL SHOCK DUE TO LOSS OF COATING & OPERATING
CONDITIONS.

REFRACTORY QUALITY:
WITHSTAND CHEMICAL ATTACK AND ABRASION
BRICKS SHOULD HAVE GOOD SPALLING RESISTANCE & HIGH
RUL TO WITHSTAND THERMAL LOAD.
70% AL203 OR BASIC BRICKS.

DALMIA REFRACTORIES
 COOLING ZONE
SERVICE CONDTIONS
ABRASION IS VERY SEVERE DUE TO HOT CLINKER
THERMAL SPALLING IS VERY SEVERE
THERMO MECHANICAL STRESS DUE TO THERMAL
EXPANSION OF BRICKS.
THRUST EXTENDED BY TOTAL LINING OF THE KILN

REFRACTORY QUALITY:
70-80% AL203 BRICK WITH HIGH CCS TO WITHSTAND THE
ABRASION
HIGH SPALLING RESISTANCE AND STRENGTH
LOW THERMAL EXPANSION.

DALMIA REFRACTORIES
 INSTALLATION METHODS

QUALITY OF WORKMANSHIP IN INSTALLATION

HAS MARKED INFLUENCE ON PERFORMANCE
PROVEN PROCEDURES OF LINING TO BE
ADOPTED
e.g USING KEY BRICKS, EXPANSION ALLOWANCE
EXTRA TIME & EFFORT SPENT DURING LINING
RESULTS IN BETTER LIFE

DALMIA REFRACTORIES
 HANDLING & STORAGE
OF REFRACTORY
IMPORTANT TO GET BETTER LIFE
BRICKS SHOULD BE HANDLED CAREFULLY
TO AVOID DAMAGES TO EDGES / CORNERS
CASTABLES ARE DAMAGED IF THEY COME
IN CONTACT WITH WATER
REFRACTORY MATERIALS SHOULD BE STORED
IN A COVERED AREA WHERE WATER CANNOT
INTRUDE

DALMIA REFRACTORIES
 KILN START UP & STOPPAGE
PRACTICES
LIFE OF KILN REFRACTORY IS DIRECTLY RELATED
TO PROCEDURES ADOPTED FOR HEATING &
COOLING DOWN THE KILN
INCORRECT HEATING & COOLING PROCEDURES
MAY WEAKEN REFRACTORY AND CAUSE CRACKS &
SPALLING
LINING MAY BE DAMAGED BY STRESSES INDUCED
BY INTERNAL EXPANSION & CONTRACTION OF
MATERIAL DURING HEATING/COOLING
THESE STRESSES SHOULD BE MINIMISED & LINING
SHOULD BE PROTECTED FROM OVERHEATING

DALMIA REFRACTORIES
 FREQUENCY OF KILN SHUT DOWNS
LIFE OF REFRACTORY IS PROPORTIONAL TO
NUMBER OF KILN SHUT DOWNS
MORE SHUT DOWNS & STOPPAGES LESSER THE
LIFE
REFRACTORY DAMAGE IS RELATED TO THE RATE
OF COOLING OF KILN
GREATEST DANGER WHEN COOLING IS RAPID
COOLING SHOULD BE SLOW & UNIFORM DURING
KILN SHUT DOWN
COOLING TIME SHOULD BE ATLEAST 8 HRS &
PREFARBLY LONGER
FOR UNIFORM COOLING KILN HAS TO BE TURNED &
JACKED ON A REGULAR SCHEDULE AS THE FEED
BED & REFRACTORY UNDERNEATH WILL COOL
MUCH SLOWER DALMIA REFRACTORIES
FACTORS AFFECTING REFRACTORY
THERMAL
RAPID HEATING
OVER HEATING
THERMAL SHOCKS
CHEMICAL
UNIFORMITY OF FEED
IMPURITIES LIKE ALKALIES & SULPHATE
COATING & BURNABILITY OF RAW MEAL
REDUCING ATMOSPHERE
MECHANICAL
OVALITY
TYRE CONDITION
SLIPPAGE
KILN ALIGNMENT
DALMIA REFRACTORIES
 REFRACTORY FAILURE
THE REFRACTORY WEAR IS CATEGORISED AS
THERMAL
THERMO-CHEMICAL
THERMO-MECHANICAL
MECHANICAL

ALL THE ABOVE WEAR PHENOMENA ARE INDEPENDENT

AS WELL AS ASSOCIATED DURING THE OPERATION OF A
ROTARY KILN.

THE FAILURE ANALYSIS IS DISCUSSED BASED ON THE

STANDARD QUALITY OF REFRACTORIS.

DALMIA REFRACTORIES
 THERMAL WEAR
WEAR APPEARANCE CAUSE
1. MELTED SURFACE 1. EXCESSIVE
(CONCAVE WEAR) TEMPERATURE AND
2. EROSION FLAME
3. OPEN JOINTS 2. INABILITY TO INDUCE
4. SPALLING COATING
5. EXPANSION PEELING / 3. SHRINKAGE
GROOVE FORMATION 4. BURNING
6. CARBONISED POROUS INTERRUPTION
BRICKS 5. UNSTABLE COATING /
RAPID HEATING
6. RAPID HEATING /
REDUCING
ATMOSPHERE
DALMIA REFRACTORIES
 THERMO - CHEMICAL
WEAR APPEARANCE CAUSE
1. REACTED, PITTED 1. HIGH BURNABILITY
SURFACE
2. DENSIFICATION OF 2. ALKALI, CHLORIDE AND
BRICKS SULPHATE PENETRATION
3. NETWORK OF CRACKS 3. CHEMICAL ATTACK / QUALITY
OF COAL
4. SHELL CORROSION AND 4. INFILTRATION OF ALKALI
DISCLOLOURATION SALTS
5. CHEMICAL EROSION 5. VARIATION IN RM LOW
MELTING FLUXES.

DALMIA REFRACTORIES
 THERMO - MECHANICAL

WEAR APPEARANCE CAUSE

1. PINCH SPALLING 1. SUDDEN THERMAL
EXPANSION DUE TO
RAPID HEATING OR
SUDDEN EXPOSURE TO
HIGH TEMPERATURE DUE
TO UNSTABLE COATING)

2. CRACKING AND FALLING OF 2. TORSIONAL FORCES /

BRICKS SUDDEN COOLING OF
SHELL

3. SKEWING 3. LOOSE LINING /

DIFFERENTIAL EXPANSION

DALMIA REFRACTORIES
 MECHANICAL
WEAR APPEARANCE CAUSE
1. DISPLACEMENT OF RINGS 1. DEFORMATION OF SHELL
AND SPIRALLING
2. OVALITY
2. UNSTABLE LINING (PERMANENT/INCIDENTAL)

3. DAMAGE OF BRICK AT 3. EXPANSION AT THRUST

RETAINERS RING
4. STRESS SPALLING AT 4. MECHANICAL STRESS
TYRES DURING ROLL BACK AND
STOPPAGE OF TYRES
5. FAULTY LINING / RELATIVE
MOVEMENT

DALMIA REFRACTORIES
 INSPECTION & MAINTENANCE OF
KILN LINING
COATING & LINING THICKNESS TO BE MEASURED
WHENEVER KILN INSIDE IS ACCESSIBLE
MAINTENANCE OF PROPER LINING RECORD
HELPS TO
a. UNDERSTAND THE RATE OF WEAR OF
REFRACTORY OVER A PERIOD OF TIME IN
DIFFERENT ZONES
b. MONITOR REFRACTORY PERFORMANCE &
SCHEDULE REPAIRS
c. PLAN SYSTEMATIC REPLACEMENT
PROGRAMME
DALMIA REFRACTORIES