PREHEATER INSPECTION REPORT

09.01.2015
Note: Pictures were not taken because the cyclones were dusty.

Cyclon
e

Problem

Impact

Stage 4 East

1. Missing bricks at cone

bottom
2. Missing castable at the
intersection of cone
and feed pipe
3. Damaged diptube

Causes the cyclone

metal body to be
damaged due to
high temperatures
Increased heat loss
from the walls
Reduced cyclone
collecting efficiency

Stage 4 West

Stage 3

Missing bricks at the cone

(south side just below
small circular door)
Damaged dip tube

Worn out castable around

the diptube

Causes the cyclone

metal body to be
damaged due to
high temperatures
Increased heat loss
loss from the walls
Reduced cyclone
collecting efficiency
Causes the cyclone
metal roof top to be
damaged due to
high temperatures

Action

Who

When

1. Lay refractory
bricks around
the cone bottom
2. Cast the
intersection of
the cone and
feed pipe
3. Replace the
diptube
1. Lay refractory
bricks around
the cone
2. Replace the dip
tube

Production

KSD

Production

KSD

Methods

KSD

Production

KSD

Methods

KSD

1. Put castable
around the dip
tube

Production

KSD

Increased heat loss

from the walls
Stage 2 West

Worn out castable around

the diptube

Causes the cyclone

metal roof top to be
damaged due to
high temperatures
Increased heat loss
from the walls

1. Put castable
around the dip
tube

Production

KSD

Stage 2 East

Worn out castable around

the diptube

Causes the cyclone

metal roof top to be
damaged due to
high temperatures
Increased heat loss
from the walls

1. Put castable
around the dip
tube

Production

KSD

Stage 1
South

Inleaks around cone

cylinder intersection
Damaged diptube
Metal rod at the cone
bottom

Reduced
temperature hence
increase fuel
consumption
Reduced cyclone
collecting efficiency
Can lead to a
cyclone blockage
Reduced cyclone
collecting efficiency

1. Weld the cracked

intersection
2. Replace the
diptube

Methods

KSD

Methods

Advice
after KSD

Stage 1
North

Damaged diptube

Production
3. Remove the
metal rod
1. Replace the
diptube

Methods

Advice
after KSD