Академический Документы
Профессиональный Документы
Культура Документы
Objective:
To describe the process of installing refractory at kiln outlet section
Domain of application:
Production Department Rotary Kilns
Document date: August 2016
Emergency numbers:
Shift Coordinator +254 720 627 023
CCR ext. 3233
Contents:
OBJECTIVE: ................................................................................................................................................................. 1
CONTENTS: .................................................................................................................................................................... 2
OBJECTIVE: ................................................................................................................................................................. 2
1. INTRODUCTION ................................................................................................................................................. 3
1.1. EQUIPMENT & TOOLS REQUIRED ...................................................................................................................... 3
1.2. PERSONNEL REQUIRED ..................................................................................................................................... 3
1.3. MATERIALS REQUIRED ..................................................................................................................................... 3
2. SAFETY ................................................................................................................................................................. 4
2.1. SAFETY DOCUMENTS ........................................................................................................................................ 4
2.2. PPE REQUIREMENTS......................................................................................................................................... 4
2.3. SAFETY ASPECTS .............................................................................................................................................. 4
3. INSTALLATION OF ANCHORS ....................................................................................................................... 5
3.1. MATERIAL SELECTION ...................................................................................................................................... 5
3.2. WELDING PREPARATION................................................................................................................................... 5
3.3. WELDING OF ANCHORS .................................................................................................................................... 5
3.4. ANCHOR DENSITY ............................................................................................................................................ 5
4. CASTING ............................................................................................................................................................... 6
4.1. SHUTTERING ..................................................................................................................................................... 6
4.2. EXPANSION ....................................................................................................................................................... 6
4.3. MIXING ............................................................................................................................................................. 6
4.4. BALL-HAND TEST ............................................................................................................................................ 6
4.5. POURING ........................................................................................................................................................... 7
Specific Definitions:
Distribution list:
Production Manager
Production Superintendent
Production Coach
Refractory Champion
Process/Production Engineer - CIP
Objective:
To describe process of installing refractory lining at kiln outlet section
1. Introduction
The kiln outlet section is subjected to significant thermal and mechanical stresses. In MOM RK2, the kiln
outlet is lined using monolithic castable from the nose ring segments up to the retainer. The castable length
is 1.1m.
2. Safety
2.1. Safety Documents
1. Job Safety Analysis form
2. Permit to Work
3. Confined Space Entry Permit
4. LOTOTO Checklist
5. Hot Work Permit
6. Emergency Response Plan
3. Installation of Anchors
3.1. Material Selection
Anchors used are floating Omega type of anchors AISI 310, 10mm diameter.
The omega support diameter should be 2mm larger than the anchor diameter.
The anchors must have the same mechanical properties as the castable intended for use
The welding rods used must be compatible with the kiln shell (mild steel) and anchors (heat
resistant stainless steel).
4. Casting
The casting is done by working clockwise as the kiln moves in an anti-clockwise sense.
4.1. Shuttering
Shuttering is made by use of plywood to secure the poured castable mix in a box
The box dimension should follow the width of the nose ring segments.
Thus each box is 300mm wide by 600mm long.
4.2. Expansion
6mm expansion fiber (ceramic fiber or mansonite board rated 1600 degC) is placed on the edges
of each box.
4.3. Mixing
The castable is mixed in a motorized rotary cement mixer.
WARNING! Water content of the mixture is important since too much water adversely affects the
castable porosity and cold crushing strength. Follow the manufacturers instruction.
Place 5 to 6 bags in the mixer and rotate for about 1 minute.
Add about 80% of the required water content and mix for about 2 minutes.
Stop the mixer and let it rest for about a minute and test for consistency using ball-hand test.
If necessary, add the remaining 20% of the water, mix then repeat the ball-hand test
Vibration should not exceed 5 minutes on each area to avoid segregation of particles. When
complete, the surface of the refractory should appear shiny.
Carefully withdraw the vibrating needle to prevent formation of an air bubble
Pierce a steam escape hole using a steel needle and leave to set for 30 45 minutes
4.6. Curing
Every casted segment must be left to cure for 30 to 45 minutes
Rotation of the tube can be done only when the surface is firm
4.7. Drying
At the kiln outlet, drying is done by the main burner during warming
Rapid increase of surface temperature from flame radiation can be controlled by covering the nose
ring area with 3 mm mineral fiber blankets.