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Stefan Thomas
Drying out and heating-up diagramm of refractory castables/concretes (RCC, MCC, LCC, SC, JC)
Two different kinds of water are found in the refractory lining: 1. Physically bonded water (free water): removed at 100-150C
Conversion of physical and chemical bonded water to the vapour phase by evaporation or vaporisation. Evaporating already during setting process at room temperatures and normally vaporising at 100C
Acc.V Spot Magn Det WD Exp 25.0 kV 4.0 540x SE 9.8 17 CRB Analyse Service GmbH
Acc.V Spot Magn Det WD Exp 25.0 kV 4.0 10000x SE 9.9 13 CRB Analyse Service GmbH
Acc.V Spot Magn Det WD Exp 25.0 kV 4.0 7800x SE 9.6 17 CRB Analyse Service GmbH
Phase 1
Phase 2
Low vapour pressure Low drying rate
10
11
12
13
Drying tim e
Drying out and heating-up diagramm of refractory concretes/castables (RCC, MCC, LCC, SC, JC)
Phase 1: Initial phase: Evaporation of physical bonded water is relevant Evaporation commences already during setting process at T < 100C: Water is partly incorporated into the mineral lattice structure > 24 h in room temperature! The longer, the better! Vaporisation of free water at 100C Physical bonded water can be found in very fine capillaries Higher temperatures are necessary to overcome capillary forces Vaporisation of capillary water at >100C (100-150C)
Phase 1
20 50
Phase 1
Cold Face
Hot Face
Outlet
Pmeniscus
P 1 bar
Pcapillary
Outlet
P 164 bar
Pmeniscus
100C /1 bar
Pcapillary
Desteaming holes are only necessary on the top of the cyclone roofs to control the desteaming progress
As they dry, LC castables cause more problems due to: Lower proportion of water Lower water vapour pressure
Lower porosity
Lower water content of castable does not mean faster drying out and heating up!
Kiln Shell
Time in hrs
thermal expansion of the kiln shell thermal expansion of magnesia spinel bricks 0 100 50 0 1 2 % relative expansion
-1 N/mm2
Girth Gear
Before drying, at least 24h conditioning time for all masses Closing kiln inlet and cooler outletopening (Ytong o.a.) Adjustment of air flow with TAD slider. Configuration of multiple high velocity burners and thermal elements Fuel, ideally gas or light fuel-oil
R Steigi schacht T1 s e r
Riser
Cooler
FLS Kuwait
Raw meal feeding is started in KHD and Polysius plants if the inlet chamber temperature exceeds 850 C.
In case of FLS plants, raw meel feeding commences once a temperature of 920 C is reached in the lower cyclones.
Theoretically possible and easily to be managed at first glance, but: calciner burners are not designed for small quantities of fuel
danger of overheating of the brickwork opposite the burners sufficient heat distribution up to the cooler benches not possible
2. Drying out and heating-up using exclusively the calciner burner Expected temperatures at Kuwait Cement Co., (FLS)
2. Drying out and heating up using exclusively the calciner burners Actual temperatures at Kuwait Cement Co., (FLS)
3. Drying out and heating-up using the central burner and calciner burner (no auxiliary burners)
Theoretically possible, but: Drying out and heating-up time is limited (see process with central burner) Early turning of rotary kiln is required. Temperatures in rotary kiln do rise very fast Danger of squeezing
Too fast drying of castables/wear benches in the cooler as drying only commences after first clinker has arrived.
Temperatur in C
29 30 .0 5. 20 03 17 :0 20 .0 5. 7:
100
200
300
400
500
600
30 31 01 01 02 02 03 04 .0 6. 20 03 03 :5 3: :3 6: 00 03 12 03 28 1: .0 6. 20 :3 22 03 18 5: .0 6. 20 :1 08 03 18 5: .0 6. 20 :1 18 03 54 3: .0 6. 20 :3 03 03 39 1: .0 6. 20 :2 12 03 39 1: .0 5. 20 :2 22 03 03 7: .0 5. 03
20 :0
07
48
Sollwert
Drying out curve with actual temperatures measured during the process
TC 5 Mestelle 5
TC 4 Mestelle 4
TC 3 Mestelle 3
TC 2 Mestelle 2
TC 1 Mestelle 1
Burner Drying
Burner Drying
Burner Drying
Clinker for protection of the grate plates Lower part fo wearbanks have been cleared again to ensure temperature access during dry out Prevention of thermal shock
Support burner
Lightoil burner in action
Temperatur in C
100
200
300
400
500
600
Positioning of support burner at cooler side wall Burner pointing into the cooler but not at the roof
Thermal shock at castable surface causes cracks. Typical in cooler section Hot clinker in direct contact to thick castable layer. Explosive mixture