Cement Kiln Refractory Heat Up.pdf

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Drying out and Heating up of refractory installations in the cement industry Dirk Basten Refratechnik Cement Supervisor Training Course 2012

Refractory installation of a complete plant

Scheme of the refractory installation of a complete plant

static predominantly castable

dynamic predominantly bricks

static predominantly castable

Water sources – physically bonded water Installation of wet bricks

Strictly follow guidelines

Avoid leaking water

Anme rkunge n: 1* 2* 3* *

Ge ne re ll sollt e vor de m Be ginn de r Trocknung und de s Aufhe ize ns e in minde st e ns 24 st ündige s Aushärt e n de r Masse st at t ge funde n habe n! > Ofe ndre hung 180° a lle 45 minut e s - Re fe re nzmante lt e mpe ra tur in de r Bre nnzone ca . 100 - 150°C > Ofe ndre hung 90° alle 30 minut e s - Re fe re nzma nt e lt e mpe rat ur burning zone ca.. 200 - 235°C > Ofe ndre hung kont inuie rlich - Re fe re nzmant e lt e mpe rat ur burning zone ca . 260 - 310°C t he ore t ical calculat e d she ll t e mpe rat ure - de pe nds on e nvironme nt condit ions

T [°C] 1400

Trocknung

1300

Aufheizen

1200 1100

850°C -1000°C Inbetriebnahme

1000 900 800

3* 700

approx 30 K/h

600

2* 500 400

1* approx 10 K/h

300

approx 13 K/h

200

Entfernen der Abdichtungen / Start des Hauptbrenners

approx 10 K/h

100 0 0

12

24

36

48

60

72

84

96

108

120

132

144

156

168 t [h]

Typical dry out curve for complete new plant

Heating diagram of refractory concretes 1500

Aufheizdiagramm feuerfester Massen (LCC, MCC, SC, JC) Heating diagram of refractory concretes (AR, LCC, SC, JC, G, diagramm of refractory concretes (LCC, MCC, SC, JC) MCG, Heating LCG) Stationary areas wall thickness 5050- 300 mm

1400 1300 1200 1100

Temperatur / °C Temperature / °C

1000 900 30 °C/h bis zur Einsatztemperatur up to temp. of application

800 700 600

Heating Up

10 h / 500 °C

500 400

Drying

25 °C/h

300 20 h / 110 - 150 °C

200 min. 24 h Erhärtungsdauer min. 24 hrs setting time

100

15 °C/h

0 0

10

20

30

40

50

60

Time after installation / h

70

80

90

100

Zeit nach Einbau / h Time after installation / hrs

110

Drying

Behaviour of drying rate rate a function of time as as a function of drying time

100

Phase 1

90

Phase 2

80

Low vapour pressurelow drying rate

Drying rate

Drying rate [quantity/h]

70 60 50

continous drying rate

Decreasing drying rate

40 30 20 10 0 1

2

3

4

5

6 tkn

7

8

Dryiing time

Drying time [h]

9

10

11

12

13

Phase 1: Pmeniskus > Ppore opening air

Inlet

outlet

T [°C] 100° 100°C /1 bar

Ppore opening

Pmeniskus

20° 20°C /0.02 bar

Pcapillary

Low temperatur, continous airstream with high ventilation

∆P≈ 1 bar

Phase 2: PMeniskus < Ppore opening Inlet

Air stream

Outlet

T [°C] 350° 350°C /165 bar

Ppore opening

∆P≈ 164 bar

Pmeniscus

100° 100°C /1 bar

High temperature, low ventilation and airstream

Pcapillary

Pressure- and temperatur gradient in a to be dried refractory body (Dissertation: Modell zur Beschreibung der Trocknung von Feuerbetonen, Ingo Großwendt, 2007, p.25) S a tu r a tio n v a p o u r p r e s s u r e (b a r)

250 200 150 100 50 0 0

50

100

150

200

250

300

350

400

Temperature (°C)

1500

Aufheizdiagramm feuerfester Massen (LCC, MCC, SC, JC) Heating diagramm of refractory concretes (LCC, MCC, SC, JC)

1400 1300 1200

Temperatur / °C Temperature / °C

1100 1000 900 30 °C/h bis zur Einsatztemperatur up to temp. of application

800 700 600 10 h / 500 °C

500 400 25 °C/h

300 20 h / 110 - 150 °C

200 min. 24 h Erhärtungsdauer min. 24 hrs setting time

100

15 °C/h

0 0

10

20

30

40

50

60

70

80

90

100

Zeit nach Einbau / h Time after installation / hrs

110

Explosive spalling of castable surface (satellite cooler)

Dry out - surface cracking

Typical view on a badly predried castable , cooler sidewalls

Explosive spalling of Castable

Spalling of wet LCC castable on burner

Optimized drying schedule

Exhaust gas – sealing of kiln and ducts

Protection against humid exhaust gases (filter, basic bricks)

Evaporation holes in the cycloneroof lockable socket for controled evaporation

Heating up of kiln

Limiting mechanical components

Contraction at tyre

Temperaturedistribution in brick and kiln shell during heating up In 8h to 1000°C

Too slowly heating up, too early turning of kiln

Loose lining  migration, relativ movement

Too fast heating up

Axial and radial pressure  Spalling , cobblestone surface

Done: Drying and heating successfully finished first clinker in cooler Typical timing: 78 h – 120 h

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