Rhi Rotary Kiln 2

REFRACTORIES
INSTALLATION GUIDE
REFRACTORY BRICKS
IN ROTARY KILNS
1. INTRODUCTION
2. LINING GEOMETRY
3. GENERAL LINING INSTRUCTIONS
4. JOINTS
5. LINING METHODS
6. SPECIFIC LINING SITUATIONS
Installation Kiln Bricks engl.DOC 1/40 Rev. 00 16.12.03/

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REFRACTORIES
l. INTRODUCTION 3
1.lSTORAGE 3
1.2 HYDRATATION 5
1.3 IMPORTANT LINING FACTORS 5
2. LINING GEOMETRY 7
2.1 POSITIONING OF THE LINING 7
2.2 ARRANGEMENT OF THE RING JOINTS 7
2.3 ARRANGEMENT OF THE RADIAL JOINTS 7
2.4 KILN SHELL DEFORMATIONS 8
í 2.5 LINING OVER TOO HIGH WELD SEAMS 8
2.6 KEY (CLOSURE) BRICK BRICKWORK 8
2. 7 FIT TO OLD BRICKWORK 8
3. GENERAL LINING INSTRUCTIONS 9
4. JOINTS 9
4.1 RADIAL JOINTS 9
4.2 RING JOINTS 9
5. LINING METHODS 10
) 5.1 SCREW JACKMETHOD 10
5.2 DAT KILN RIG 10
5.3 GLUE METHOD 10
5.4 BOLTED METHOD 10
6. SPECIFIC LINING SITUATIONS 11

6.1 KILN OUTLETS WITH NOSE RING 11
6.2 LINING IN THE AREA OF RETAINING RINGS 11
6.3 LINING OF CONES 11
6.4 LINING OF ZONES WITH METALLIC PARTS ·-·----------------------------
(LIFTING REVERSE, CHAINS, ETC.) 12

6.5 INLET ZONES 12
Installation Kiln Bricks engl.DOC 2140 Rev. 00 16.12.03/

REFRACTORIES
l. Introduction
1.1 Transport and storage instructions for refractory materials

Transport
Ali lining materials have to be protected against moisture and mechanical stress - container
transportation is recommended.
When arriving at job site all packages have to be checked in view of any damages. Any damages
occurring during transport have to be notified to the carrier and supplier immediately.
Storage
Refractory materials must generally be stored in ventilated, covered, and dry rooms with protection
against weather conditions (snow, rain, splashing water, etc.) from all sides. The floor must provide
sufficient support and be dry.
Basic products, such as magnesia-, magnesia-chromite- and magnesia-spinel-bricks, as well as

dolomite materials, are sensitive to hydration, and can be damaged if stored improperly.
If indoor storage space is not available to the extent needed, it is possible (in sorne cases) to store
fireclay and high-alumina bricks outdoors, these bricks being not so sensitive to moisture. Of course
specific protective measures must be taken in such cases.
Storage Type 1 - Outside storage with tarpaulin cover
Valid for: fireclay bricks, high alumina bricks, light weight bricks, insulating bricks and metallic
anchors
If the transport packing and an additional tarpaulin cover guarantees the required protection against
wetness, it is allowed to store the above mentioned materials outside.
The ground should be dry, plan and compacted to ensure the necessary load bearing capacity and the
possibility to transport materials by fork-lift truck.
'í Furthermore it is necessary to ensure that rain water can easily drain away.
Frozen materials have to be warmed up sufficiently (material temperature at least + lüºC).
Storage Type 11 - Inside storage in closed rooms
Valid for: magnesia bricks, unburned chemical bonded high alumina and light weight bricks,
mortars, insulating and auxiliary material
All above mentioned materials have to be stored dry and free of frost in ventilated, closed rooms (ideal
temperature +1OºC to +30ºC).
Unshaped products generally have a limited storage life, indicated in the respective data sheets.
Especially already opened packages of monolithic materials have to be stored as mentioned above and
to be used as soon as possible.

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Tropical climatic zones - i.e. extremely high humidity and strong sun radiation
If it is not possible to avoid the formation of condensation water under the shrink wrapping despite
ventilation, the shrink wrapping should be opened.
Because of expected formation of condensation water, it is forbidden to store the material in the
transport containers.
Already lined magnesia bricks
Basic bricks have to be installed as late as possible, i.e. immediately before heating up (maximum 4
weeks).
Take care of well ventilation and protection of lining against wetness in the period between completion
of installation and first heat up.
Effect of wetness
If refractory materials have become wet despite protective measures they have to be stored free of frost
(i.e. above +1OºC), furthermore the following instructions have to be considered:
Fireclay bricks, high alumina bricks, light weight bricks and insulating bricks:
These materials have to be dried carefully before use.
Magnesia bricks: They have to be checked in view of damages by hydration (see chapter
1.2 Hydration of basic bricks), characterised by cracks on the surface and increase
in volume.
Damaged bricks cannot be used anymore!
Magnesia bricks shall be dried at ,,room temperature" (i.e. no hot air).
Refractory mortars: Unshaped materials cannot be used after becoming wet.
Unburned chemical bonded high alumina and light weight bricks:

These special products tend to absorb moisture from the air even when
properly stored, but in that case they need not to be dried before installation.
Permitted shelf height of pallets if the load bearing capacity of the ground is sufficieut:
Storage Type I: Bricks: 4 pallets

Light weight and insulating bricks: 2 pallets
Storage Type II: Bricks: 4 pallets
Unshaped materials (castable, mortar, etc.): 3 pallets
Management of stock
If larger amounts of refractories are delivered, the storing in accordance to the construction schedule is
recommended.
It should be possible for a fork-lift truck to reach each block directly.
Furthermore take care that the marking is clearly visible.
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1.2 Hydration
Test of the degree of hydration of magnesia-chromite, magnesia-spinel and dolomite bricks -

outer appearance of hydrated bricks
The suspicion of hydration is given if magnesia-containing bricks show an externa! white coating
connected with commencing brittleness, loose structure and cracking. J ust an outside whitish coating
may not be of influence to the serviceability of the bricks if there are no other damages. If the white
magnesium hydroxide continues to the inside of the brick, which can be checked by breaking the brick
in two halves, the degree of hydration may be too advanced.
The hydration process
Magnesia (Mgü) reacts with water (H20), forming magnesium hydroxide (Mg(OH) 2). In case of
dolomite an additional lime componen! (Caü) is involved, which can be hydrated to calcium hydroxide
Ca(OH)2 . The reaction time oflime is much shorter than that of magnesia.
This is connected with a disintegration because the magnesium hydroxide (brucite) consists of a
powder which additionally has a bigger volume compared to the original magnesia (periclase).
The speed of hydration depends on the contents of magnesia in the brick, its structure, and to a great
extent on the temperature. Under water, for example, the hydration is not fast but as soon as the water
penetrates in its evaporated form hydration becomes faster. Magnesia bricks are therefore particularly
endangered in humid hot climate and during heating-up in the kiln in case wet bricks have been
installed until the water has evaporated.
Site test of the degree of hydration
Tested is the ignition loss (LO!).

This test can easily be done in your plant Laboratory.
Brick pieces of 2 to 3 kg have to be dried at 11 O ºC for 4 hours and after that the weight is taken. The
dry specimen is then furnace-heated for 12 hours at 1.050 ºC. To avoid contact reactions the specimen
has to be placed on a split of the same material. After cooling the weight has to be taken again and the
weight difference between the dry specimen and the heat-treated specimen is an indication of the
degree ofhydration:
- lgnition loss of a not hydrated (new) magnesia brick is approx. 0,2 %.

- Bricks with an ignition loss up to 0.6 % are not damaged during heating-up when referring to the
heat-up instructions (24 hours for approx. 1.200 ºC).
- With 0.6 to 1 % ignition loss there is an increased danger of destruction during heating-up.
- With more than 1 % ignition loss the serviceability ofbricks is restricted.
- Brittle and cracked bricks - due to hydration - must not be used.
1.3 Important Lining factors
There are a multitude of factors responsible for the wear of a refractory lining. A loosening of the brick
lining_is O_ll~_Q[!hese factO!~J'."~jch _Q_fte11_¡:>lay an im129.i:tant rol~¡!.f\Q_greatly depend Qll_1@_gl.l_ali!)'.9_f_ mm _ • _
the work done when installing the brickwork. A loosening of the lining effects relative movements and
spiral twisting resulting in a mechanical destruction ofthe brick.

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The objectives of experts dealing with the installation ofthe brick lining are:
1. Brickwork rings as tight as possible

2. Correct geometrical alignment of ali bricks taking the following into consideration
• toleran ces of the bricks
• Kiln shell deformation
• too high weld seams
• arrangement of the key bricks
• adjacent brickwork
3. Installation of bricks without damages and the prevention of damage to the bricks during
installation
4. Corree! arrangement ofthe joints
5. The quality of a lining according to the 4 points mentioned abo ve is also dependen! on the
selected lining method. The choice of the lining method depends on:
• technical condition of the Kiln shell
• working safety aspects
• expert installation
• required lining time
• operational handling of the required lining equipment
These criteria provide an evaluation base according to figure 1 for the lining method:
1. Pneumatic centers (DAT Kiln rig)
2. Screw jacks
3. Glue
4. Bolted
Figure 1: Table - Evaluation criteria for various lining methods

Screw jacks DAT kiln rig Glue Bolted
Working Safety ++* +++ + ++
Expert Installation ++ +++ ++ +
Lining Time + +++ +++ ++
Handling/Operation + ++ ++ ++
Total 6+ 11+ 8+ 7+
* on smaller kilns +++ diameter < ~ 3.60 m
on larger kilns + diameter > ~ 4.60 m
A mixed brickwork with 2 shapes is recommended with different wedges. By varying the mixing ratio
the arch of the rings will be precisely in line with the curvature radius of the Kiln shell. Brick
tolerances can also be compensated. The wedge bricks according to ISO (International Standardization
Organization) or VDZ (Association of German Cernen! Plants) series are generally used worldwide
with the corresponding key bricks. For the calculation of the amount of bricks needed one subtracts 2
from the theoretical amount per ring and then adds 2 key (closure) bricks each of the 2 different key
....----brick-types..-Ihese-guidelines-apply-for-cases--where.no-Specific-installation-.drawings.are-available.--
Installation drawings are generally an integrated part of these guidelines and are of preliminary
importance.

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l 2. Lining Geometry
2.1 Position of Lining
For all lining methods one starts in the lower area of the kiln shell. The first brick row is aligned axially
according to figure group 1 and 2. This automatically effects the very important right angle alignment
of the bricks to the kiln axis. Furthermore, it is very important that this right angle is maintained over
the entire brickwork ring. In other words, the brickwork rings must be positioned absolutely
concentrically and axially. For this, it will be required to draw marking lines in a distance of approx. 1
m (5 rings). The continuous weld seams ofthe kiln shell sections will be of assistance for orientation.
At the start of the retention rings the alignment of the bricks with the corree! angle is given
automatically. Bricklaying is done generally ring by ring with the exception of specific lay-up work
next to old brickwork ( refer to point 2. 7) The lay-up is done ring by ring as shown in picture group l.
The disadvantage is that in case of relative movements it is possible that neighboring rings hook up
with one another causing mechanical damage (picture 1.3). Consequently, a staggered arrangement
according to picture group 2 is recommended even if this calls for more work by inserting cardboard
spacers or placing mortar. The staggered arrangement must be chosen if there is proven spiral twisting.
Bricklaying is always in upward direction, that is from the bottom side in direction feed end chamber.
2.2 Arrangement of Ring Joints
The staggered arrangement of the bricks ensures best that the brick rings are laid individually, that
means will not hook with one another. This danger exists with a row by row arrangement and can be
avoided if possibly required cardboard spacers in the ring joints overlap severa] bricks (picture 1.2) so
that "toothing" of adjacent rings becomes impossible. It becomes difficult if, for example, 3 shapes are
being used and there are big tolerances in the brick length. Consequently, before the start of any lay-up
work it will be necessary to take brick samples and measure them. If one of the 2 shapes has a different
length, then it is necessary to start with the longer brick. this will ensure that the remaining bricks will
stay within the ring width given by the longer bricks. If done otherwise, a too short ring width exists
and the longer bricks will not fit in between. Differences in length of more than 3 mm (ISO tolerance)
between adjacent bricks require that the recesses will be filled with mortar.
2.3 Arrangement of Radial Joints
For a mixed brickwork a specific mixing ratio is given. Ifthere are tolerances regarding the taper ofthe
bricks there will be a low or high step alignment of the brickwork. A wedge joint of +!- 1 mm (113
resp. 311) can be tolerated with mortar lay-up. The permissible tolerances according to ISO can be
compensated. The standard joint is 2 mm for non-basic and !mm for basic bricks. With a clench or
steel shim installation it is possible to make a correction by changing the mixing ratio. This is often not
accepted in cases where given zone lengths must be lined with a given number of bricks. If necessary,
any corrections must subsequently be done with mortar. This means that here and there wedge-shaped
joints with mortar have to be constructed in order to observe the given mixing ratio. A correction with
steel shims should not be done because hollow spots form and, as a result, bending stress will occur.
The steel shim edges can also cut. In such cases it is better to insert 2 mm Pyrostop Papier. The total
number of such spacers should not exceed 1 per 8 bricks (ISO shapes) and 1 per 1O bricks (VDZ
shapes) in order to avoid a loosening of the lining. Deviations of radial joints from the Kiln axis can
also be corrected in this manner. Here, too, compensation mortar should be preferred. It will often be
--- ------ possil5le-roturn~over tlieb-rtCkStrr-oraer-10-cotre-cr111esiluaflon-if-tl1erearea:eviatio-ns,_or-tlié--radial- - · ----- ---- ----
joints from the Kiln axis. The conicality in axial direction is compensated by that. With pre-attached
steel shims on the bricks it will be necessary to remove them if changing the installation direction.

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2.4 Kilo Shell Deformations
In the vicinity of Kiln shell deformations the radial and axial alignment of the bricks must be strictly
observed. Bigger deformations must be compensated with a fine grain refractory castable (O - 3 or O - 6
mm). The brickwork rings can then be installed corresponding to the theoretical Kiln curvature (figure
4). The radial and axial alignment must also be observed ifthere are convex dents (figure 4.1). Convex
dents are often the cause of shorter service lives of the lining since they are an obstruction in case of
relative movements effecting damage to the lining on the rear side.
2.5 Lining Over Too High Weld Seams
Generally the weld seams should be ground to a maximum 2 mm excess height. If this is not the case
or if there is a displacement of Kiln points, then difficulties will arise again and again as shown in
figure 5. A correction ofthe position ofthe bricks is possible. However, this is little more than a small
degree of assistance for the lay-up of the bricks. Axial expansion movements and radial drifting of the
bricks can, nevertheless, cause damage on the rear si de of the lining.
2.6 Key (Closure) Brick Brickwork
The arrangement of the key (closure) bricks is shown in figure group 8. With nonparallel key brick
joints there will be edge pinching and there is also the danger of individual key bricks falling out.
Parallel joints are obtained by corrective measures in the vicinity of the key brick brickwork with
compensation mortar, insertion of spacers as mentioned above, but preferably by changing the mixing
ratio. The key brick combination arises from the brickwork gap which exists at the end. If cutting the
key brick cannot be avoided it is importan! that the key brick in the ring is cut without taper (one cut
through the entire brick). Key bricks should not be cut thinner than 70 mm. Ifthe gap is below 70 mm
it is recommended to cut 2 key bricks. The key brick should not be driven in last but must be bricked
beforehand. If the cutting surface is not leve! then mortar must be used. The closure is done with a
standard full size brick. This also applies for delivered key bricks if they are thinner than the standard
full size bricks. For driving in the last brick only plastic or rubber mallets shall be used. Steel hammers
can only be used with great care and after placement of large size hard wood pieces buffer. Only 1
shim with a 2 mm thickness can be used per joint. The shims are sharpened on 1 or 2 edges (figure 8.3)
They can be inserted with a steel hammer but great care is required. Under no circumstances may
bricks be hit. It is advantageous to use a too! (refer to figure 8.4) for inserting the shims in connection
with a pneumatic hammer. The use of closure shims must be avoided if installing silicon carbide
bricks, high-alumina bricks, fireclay bricks, and insulating refractory bricks. These brick grades are
usually installed with mortar. By varying the joint width it is possible to position the key brick
combination without using shims so that a safe fit of the lining is guaranteed. In the vicinity of the key
brick brickwork the mortar joints should be thin so that the highest degree of ring stability 1s
guaranteed. With thickjoints mortar can flow out and the brickwork can slide.
2. 7 Fit to Old Brickwork
As described above, the first brick ring must be installed absolutely axially. If old brickwork deviates
from the axis it must be realigned as shown in figure 6. It is important that the ring width is not below
100 mm. If the brickwork gap is smaller, then a lining system must be selected as is shown in figure
6.1. With greater deviations of the old brickwork from the axis, one must consider the procedure as
....------shown.in.figure_62,.and.use.of.a.refractory-mix...-..........--.-.-----------..--- ..................... ..

REFRACTORIES
l 3. General Lining Instructions

As mentioned above, it is very importan! that the brickwork rings sit tight in the Kiln shell.
Consequently, each brick must be hit with a rubber hammer independent ofthe mortar, shim or clench
installation. The installation of damaged bricks should be avoided. Any damaged bricks, which are
within the tolerated damage limits, should be distributed over a larger area. This means that they may
not be installed next to one another. If damages occur during installation work, which may occasionally
be the case with key (closure) bricks, it is absolutely necessary to replace the damaged refractories.
Hydrated bricks may likewise not be installed. They can be noticed by a white coating, cracking, soft
edges and corners. The Kiln shell must always be kept very clean. Clinker grains, brick chips, and dust
on the Kiln shell act as "ball bearings" and intensify the relative movement and also act as grinding
agents causing damage on the rear side of the bricks. After the lining has been installed the Kiln must
not be turned. During lining work the rotation of the Kiln must be kept to a minimum in order to avo id
a loosening of the lining. For the same reason the Kiln must not be turned when it is shut down. The
attempt to "rotate out" coatings, which have fallen off, or old lining, which is to be replaced, can cause
a caving in of other lining sections which are to remain in the Kiln. The lining work always
commences at the lower side in direction of the Kiln inlet. Old lining remaining in the Kiln must be
supported at the up-Kiln side (refer to figure 6).
BE INFORMED THAT THE INSTALLATION COULD ONL Y BE DONE ATA TEMPERATURE

OVER 10 ºC WHICH INCLUDES THE TEMPERATURE OF THE REFRACTORIES TOO.
THE LINING HAS TO BE KEPT ATA TEMPERATURE ABOVE IOºC UNTIL DRYING OR
HEATING-UP OF THE LINING.
14. Joints
One differentiates between radial and ringjoints (figures 1.1). The joints may remain empty in order to
increase the flexibility of a brickwork. A brick-bonding joint medium can be used, for example mortar
or steel shims for basic bricks. The joints can also be designed as expansion joints and filled with
spacers of inflammable material that give or burnout materials which provide space for thermal
expansion after heating-up. Mortar on the Kiln shell side is no longer standard today. The thickness of
mortar joints is generally 2 mm for non-basic and 1mm for basic bricks.
(
4.1 Radial Joints
The tension in the ring depends on the radial joints. The radial joints must not give at the colder brick
foot ( shell si de). With basic bricks the expansion of the Kiln shell and cooler rear si de brick part is
about equal so that no tension occurs as a result of subdued expansion. At the hot side such tension
occurs due to excessive expansion. Here the brick material or the joint medium must give in order to
avoid spalling. High-alumina bricks, fireclay bricks and insulating refractory bricks should preferably
be laid with mortar. The clench lining is sometimes selected. However, the brickwork will loosen
easier and if the brick surfaces are not leve! bending stress will arise in the bricks. Mortar will bond the
bricks over large surfaces. Excessive expansion is compensated by the mortar being able to give. An
installation without mortar is possible for ali bricks. For basic brick grades in specific cases glued on
shims are used. A mortar installation shall not be used for dolomite bricks.

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4.2 Ring joints
With a mortar installation of high-alumina bricks, fireclay bricks, and insulating refractory bricks the
ring joints are filled with mortar. No mortar is used if a clench lining is selected. Ali basic bricks
require cardboard spacers in the expansion joint. These cardboard spacers can be glued on the bricks or
supplied separately. For mortar installation the cardboard spacers have to be positioned during lining
work as shown in figure group 1 and 2. The cardboards must cover the radial joints in order to avoid
mortar flowing from the radial joints into the ring joints and them being blocked. If rotary Kiln bricks
are laid as shown in figure group 1 and the mortar has been spread on the entire row of bricks, the
cardboard must then be shoved from above - exactly in the middle of the joint - into the mortar bed.
The mortar in the ring joint is, consequently, pushed downwards and the joint remains free. This also
applies for all mortar installations of basic bricks.

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f s. Lining Methods
5.1 Screw Jack Method
Starting from the Kiln bottom the lining is installed conventionally up to the height of the horizontal
Kiln axis. One attempts to maintain equilibrium. It will sometimes be necessary to use pedestal centers.
Next horizontal screw jacks are installed in a distance of O. 75 to 1.25 m depending on the Kiln
diameter. The lower half of the lining will sit tight on the Kiln shell with the assistance of these screw
jacks. In order to distribute the pressure over a large area, it is necessary to install wooden planks as an
intermediate !ayer. The work procedures are shown in figure 10.A useable screw jack is shown in
figure 1O. l. Usually larger sections are lined with the assistance of screw jacks, e.g. 6 m or more.
Corresponding to the distance of the screw jacks to be positioned crosswise, 12 or more screw jacks
will be required. During lining work and rotation of the Kiln, ali screw jacks must be repeatedly
checked to see if they sil light. The degree of tension in the Kiln shell can greatly depend on the
position of the lining and temperature differences between day and night. Extreme care is called for
with very thin Kiln shells because they can be permanently deformed by the pressure exerted by the
screw jack. In larger kilns having a diameter of 5 m and more the use of screw jacks becomes
dangerous since they can slide off. In such cases the screw jack method is no longer recommended or
should only be used for individual rings or very short sections. A closure ring is positioned at the Kiln
bottom.
5.2 DAT Kilo Rig
The Kiln is not rotated if using the Kiln rig. As with the screw jack method, the lower half is lined
conventionally and the Kiln rig only used for the upper half The ring is closed at the apex of the Kiln.
The staggered arrangement of the brick rings is easily done with centers. Ali types of linings with
differentjoint designs, nose rings, and eones can be efficiently installed with DAT Kiln rigs. Setup and
working procedures are described in a special brochure which is made available when working with
the DAT Kiln rig. See also figure 9. According to the evaluation table in chapter 1 the center method
(DAT Kiln rig) should be preferred.
5.3 Glue Method ·
When applying glue it is importan! to follow the instructions of the manufacturer. A number of bricks
per ring should be glued to the Kiln shell as illustrated in figure 11. Work starts at the Kiln bottom and
the Kiln is rotated as work progresses. At the beginning it is importan! that there is an equilibrium of
the bricks laid right and left of the Kiln bottom. This prevents premature stress on the spots glued
which need at least 2 hours to dry completely (depending on temperature). lt is importan! to observe
the manufacturer instructions. The spots glued must be dry, without dust, and not lubricated (clean in a
metallic sense). Great care is required. Glue, which has been in storage too long, should not be used or
at own risk after positive gluing test before installation work. With the glue method one also works
with larger sections. The size of the sections will depend on the hardening time of the glue used. Ali
bricks must be positioned in the glue before the hardening time ends.
A ring is closed at the Kiln bottom.
Impregnated bricks cannot be glued.
5.4 Bolted Method
Figure 12 illustrates this method. The nuts welded to the Kiln shell cause damages on the rear side
once there are relative movements of the lining. Consequently, this method should be rejected even if
only one bolt row is used to secure the first brick row with the glued method.

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J 6. Specific Lining Situations

These are, for example, linings with unshaped (monolithic) refractories in Kiln outlets, nose rings,
retention rings, eones of the Kiln inlet, as well as zones containing metallic and ceramic installations
and patch repairs.
6.1 Kiln Outlets with Nose Ring
The design of the outlet is specific to the company having designed the Kiln. Sometimes Cement
plants have their own design so that it is necessary to request the special lining drawings. The
following is importan!:
- Generally the radial joints should be mortared.

- Mortar is also to be used on the nose ring segment.
- The expansion of bricks between nose ring sector and the next retention ring must be compensated
by expansion joints - PYROSTOP PAPER/FELT (no asbestos) or cardboard.
- Mortar in the ringjoint between brick and retention ring (skew brick) acts as a "grinding agent" and
may - in case of relative movements - destroy the brick foot.
- The retention ring may not have a filie! joint on the inlet side.
- The entire surface of the brick must have contact. It is importan! that the retention ring is vertical to
the steel shell. It must be replaced as soon as wear is noticed (scaling, oxidizing).
- Nose rings should be 250 to 350 mm long. Depending on the design of the outlet, standard brick
shapes should be used (ISO or VDZ arch brick), ifpossible.
- Kiln outlets with bigger deformations are best lined with castables. For the precise lining drawings
will be required.
6.2. Lining in the area of retaining rings
The same applies as for the retention rings in the Kiln outlet. Flat rings, on which a standard brick can
be placed, are preferred instead ofretention rings. For vertical retention rings special shaped bricks are
preferred. If standard brick have to be cut it is important that the cut made with the brick cutting saw
only extends to the comer and not further in order to prevent notch effects. Cut bricks are always to be
placed at the outlet side. Bricks at the outlet side must never be shorter than 200 (198) mm.
6.3. Lining of eones
Very flat eones with an inclination of not more than 1:20 (incline of a brick row) can be lined with
standard bricks if mortar is used. So-called confining joints form. These are radial joints which are not
surface-parallel but wedge-shaped. The joint difference may deviate +/- 1 mm from the average
measurement. If using standard bricks the outlet and inlet side brick must be fitted to the cylinder
brickwork (figure 13) by a vertical inclined cut. For eones with greater inclines shaped bricks will be
required. Usually 2 shaped bricks are installed which fit in a smaller and a bigger diameter. The
intermediate brick rings are lined with a mixed brickwork. With shaped bricks a shim installation (only
basic bricks) and clench lining is possible. In any case a mortar installation should be preferred. It is
best to request special sketches of the cone linings. In regard to the ring joints and expans10n
compensation the same applies as stated in the chapter on joints.

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6.4. Lining of zones with metallic parts (lifting reverse, chains, etc.)
In any case special lining drawings will be required, especially if shaped bricks are being considered
for the lining. For a castable lining the special instructions apply. The application of mortar with bricks
in the preheating zones of long dry and wet rotary kilns is very critica!. For the wet zones it is not
possible to use a chemically-bonded water glass mortar. Here special hydraulic setting mortars
(COMPRIMUR) must be used.
6.5. Inlet zones
Castables or special shaped bricks are used for the inlet zones. Here, too, special drawings will be
required. With shaped bricks it is importan! that a metallic retention ring is installed at the foot of the
inlet cone so that the cone will not get loose upon a downward drifting of the cylinder brickwork
(figure 14).
For a castable lining the instructions apply. The castable lining is to be implemented segment by
segment. These segments should not have a chord measurement above 600 mm in the vicinity of the
Kiln cylinder. The segments are to be divided by working joints. Expansion joints are not required.
****

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fixing of the kiln axis
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axial joints
ki In axis
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1.1 row by row installation of rotary kiln bricks
Installation Kiln Bricks engl. DOC 15/40 Rev. 00 16.12.03/

REFRACTORIES
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ircor 1 -ect. the cardJoa'-d
nust ccver the jo i nt
befcr-e placing the
~scr~off
eny sq eezed out mcrtfr
1.2 alignment of separate expansion cardboards row by row

lining

RÍfl)
REFRACTORIES
, ki ln axis
···-'-- - - ---------.
X
1
L___
------~------
A increasecl presgre dJe to spiral l ing

B N.ptLre stress
X hook.ing of 1 ining
1.3 hooking of adjacent rings with row by row installation of

rotary kilo bricks

RW
REFRACTORIES
fixing of the ki ln axis
. plult>
V
1/2 1/2
me:rk.er 1 ines
¿' ki In axis
2 radial and axial alignment of a rotary kiln lining
Installation Kiln Bricks engLDOC 18/40 Rev. 00 16.12.03/

IÚii)
REFRACTORIES
axial joints
--- ---- ---- ---

1
1 1 ki In axis
------ ---- -----
1
1
1
--- ---- ---
radial joints
2.1 staggered alignment of rotary kilo bricks

REFRACTORIES
í
1
.> ' ,>

1 !
.~ ,>
!
1
l
'
1
preettached ctrd:lofrd
1
befcre pleclng e rew trick row

scrape off eny ~ ieezed out mortar
2.2 mortar lining of bricks with preattached expansion

cardboards
·------------·-·-·---- --------·-------·-- -------------- --- --

RffiJ
REFRACTORIES
• .>
.~
'
.>
1
1
ca 1 ect V
1
lncorrect, the ~
nust cover the Jo i nt
before placing the
ca-cboerds ~ off
frt>/ SQ eezed out mcrtar
2.3 alignment of separate expansion cardboards in a staggered

lining
·---··-·-~--~-· ·---- -·----------·------·----------·--- -----------·- - -----

iíiW
REFRACTO Al ES
'"
. \,.
< ..
\
\. • • .
\V v V Y •
Lter with S>3mn
wi th tri ck 1ength tolera ces use the

l01ger tricks far the first NYN
3 alignment of brick rows witb length tolerances

w
REFRACTORIES
, J
weEk ctefonnetion
( s :;. 8rrm )
---- ----- 1
1
1
- --- - '
~
!' \
a:::I i ust i ro morta-
, .
1 heavy defcrmat1on
e St-52 > 8rnn >
1 ·.·.·.·.·.·.·.·.·.·.·.· .. 1
L with refractcrv casteble
filled with refract casteble
4 installation in case of concave shell deformation

REFRACTORIES
kl Ln center
adiUSting mor"Ur
4.1 iostallatioo in case of coovex shell deformations

REFRACTORIES
lf s > 2 mn i t is reconmended
to grincl off the weld seams
I B \
inclined radial joint
5 installation in case of high weld seams

REFRACTORIES
old brickwcrk
IOOxlOO. lei:-91t 150

welded
6 fixing of old brickwork

iiíW
REFRACTORIES
Kl ln exrs
Y«Tl<.ing directlon
.¡;¡¡¡z I !!>
(stu1; cr O(d brickwork
A
198 ;
open joints fil led

With lllCJrt¿r
ex 1st1 br ¡ ckwork
)
8
160 1
ex i st i br i ckwork 260 198
e
- _130- 1
19~
6.1 adapting the new lining to the old brickwork

REFRACTORIES
Y-a IChOI IN
8 PYRJSICP .,
i:>! Cl03U'e ri
1
steet shim
old brlckwork 120x220x2 nm
mortar ·o i nts
ranrni mlx
,/\ºQI 1
1 Jmorta- 1
!J?q ;!¡!-lck.work • 1, sUrodfrd brick.work
5 10- Y-ado lN 1
o
Ul / I>1
"':; 8
,.
.·'
r··
"'
...
..
'~'stee 1 sh i m
'...!.&
1"20x220x2 rrm
A-A PYROSTCP
8-8
6.2 adapting the new Jining to the old brickwork

RW
REFRACTORIES
workina steos
l.
''(do3 rirgs
not
et
open mere ttH1
on::e
4. 5. 6.
3.
view "A" ..A"

;rsert of last t:rid<.
iS shoY.rl In f i 26
7 patcb work

w
REFRACTORIES
e 1OSU'e sh lms th i d<.ness 2 11111

mex:. 1 shim ea::h Joint
e 1OSlJ'"'e br i 70 nm
e 1QSlJ"'e br i bricks
ClOSlre bricks
ClOSl.l"'e bricks
8.1 alignment of closure bricks

REFRACTORIES
l osu-e br j ck
~
~
eles.re br-ick
cor rectim ·s· wi th steel shims thickness of 2 11111

distributed over severa! joints
8.2 insertion of an individual brick
" - - - - - - - - - - - " - - - - - ---·----·-·-----"--------
Installation Kiln Bricks engl.DOC 31140

RiW
REFRACTORIES
y to,I
., 065 -o.z
/
1
l l.
. '"'
2
~
X
no bevel l irg with 200 nrn
Llnlrg thickness et this
edge
material: mi ld steel
thi~ of 160 180 200 220 250 300
X= 150 170 190 210 240 290

y = 190
weig'tt Ckgi O, 44 o. 51 0,56 O, 62 O. 71O,86

REFRACTORIES
¡·30,..1 si 1 crownec.t
i~!
l. /! ¡
u
o
ICI
..,o
C>
"'-25
- =
--~
8.4 tools for driving in tbe shims
33/40 Rev. 00 16.12.03/

Installation Kiln Bricks engl.DOC
REFRACTORIES
1. step
Ccnvent i anal l in ¡ i:ig
of the 1ower she l t
2. step
Insta! lation
of 1 ining rig
3. step
lining of Lpper shel 1
from ooth s; des by
l ining rig
9 installation witb DAT lining rig

REFRACTORIES
4_ step
A"'essing of trick ring
by hycraJ 1 i e puip_
5. step
CIOSl.re of t:rick ring
by ctos...re tricks.
9.1 installation with DAT lining rig

REFRACTORIES
1 L min
-~---------------:d-
-Jf
lc----·---"L"-'-----o.I
·~
L mex
::: :: -
:a_
bolt w;tn sofetv o;n
&~~~=~~==-::-=:='==~;··:f:·~Jj/E:::::=~~~:::==:::::==:=-+-- - _s .
i ~
--¡-- icn L2
1 MN<>lv;nq bolt fer 5 Jacks

600
X
111/56
l 1 l/54
4750
4550
5600
5400 . * 100. - 700.
7 32
. .
3900
111/52 4350 . . . . .
111/50 4150
5200
. . . . .
111/48 3950
5000
4800 . . . . .
11 /46 3850
11 /44 3650
4600
4400 . * 100. - 600.
6 20
. 2500
.
11 /42 3450 4200 . . . . .
11 /40 3250 . . . . .
11 /38 3050
4000
3800 - - . . .
1 /36 ~50 5 • 100 - 500 18 2000
-. .
3600
1 /34 2750 3400 . . .
1 /32 2550 - . . .
1 /30 2350
3200
3000 .. . . . .
Typ L min
L """' Ll L2 """'·
loed
material:
eluninie
10.1 screw jack

RfW
REFRACTORIES
si:trtl
gluing Jolnt
. _,¡'\
~~(,,_'/'<·,--------------_/'/ A'<,._
positicn at e'ld of
· ···--1-1--gluing-procedure-with-gluing-method----------·---·-·········-- ··· ······· ·······-··-· · ·- · ·· -

REFRACTO BIES
detai l "A"
1
. 11111 /·1 rnrr t·nrntrnrrt·rn·nt
---.12-SCl".e:w-installation.method---------·----------·---·-----.... ......... . .. . .. . .....
Installation Kiln Bricks engLDOC 38140 Rev. 00 16. 12.03/

REFRACTORIES
fcn11Jla fer rnorur instal lation <wedge-~ radial joints

with average m 2 nm. max'- - deviat ion from Bllerage: V = <-0. 5 11111)
Z • pieces per ring

lfcr ri"9 ro. 1)
for V >
cerne- m.JSt be
f' i t. ted si te
O"'I
13 lining of eones

iíiIV
REFRACTORIES
shéped bricks
"'IChor.
A 1
~
refractor castable
A
~1 retenticn ri
( )
bed joints without

i nsert on stee L
dista-lee mex.600 mn section A-A
14 inlet cone lining
·-- --------·---------------------------------- ·- -- -- - -- - -- - --

Rhi Rotary Kiln 2

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Rhi Rotary Kiln 2

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REFRACTORIES

3. GENERAL LINING INSTRUCTIONS

6. SPECIFIC LINING SITUATIONS

Installation Kiln Bricks engl.DOC 1/40 Rev. 00 16.12.03/

3. GENERAL LINING INSTRUCTIONS 9

6. SPECIFIC LINING SITUATIONS 11

(LIFTING REVERSE, CHAINS, ETC.) 12

Installation Kiln Bricks engl.DOC 2140 Rev. 00 16.12.03/

1.1 Transport and storage instructions for refractory materials

Basic products, such as magnesia-, magnesia-chromite- and magnesia-spinel-bricks, as well as

Storage Type 1 - Outside storage with tarpaulin cover

Frozen materials have to be warmed up sufficiently (material temperature at least + lüºC).

Storage Type 11 - Inside storage in closed rooms

Installation Kiln Bricks engl.DOC 3140 Rev. 00 16.12.03/

Already lined magnesia bricks

Refractory mortars: Unshaped materials cannot be used after becoming wet.

Unburned chemical bonded high alumina and light weight bricks:

Storage Type I: Bricks: 4 pallets

-- -~~-- ---- --------------~

Installation Kiln Bricks engl.DOC 4/40 Rev. 00 16.12.03/

Test of the degree of hydration of magnesia-chromite, magnesia-spinel and dolomite bricks -

The hydration process

Site test of the degree of hydration

Tested is the ignition loss (LO!).

- lgnition loss of a not hydrated (new) magnesia brick is approx. 0,2 %.

1.3 Important Lining factors

Installation Kiln Bricks engl.DOC 5140 Rev. 00 16.12.03/

1. Brickwork rings as tight as possible

Figure 1: Table - Evaluation criteria for various lining methods

Working Safety ++* +++ + ++

Expert Installation ++ +++ ++ +

Lining Time + +++ +++ ++

Installation Kiln Bricks engl.DOC 6/40 Rev. 00 16.12.03/

2.2 Arrangement of Ring Joints

2.3 Arrangement of Radial Joints

Installation Kiln Bricks engl.DOC 7/40 Rev. 00 16.12.03/

2.4 Kilo Shell Deformations

2.5 Lining Over Too High Weld Seams

2.6 Key (Closure) Brick Brickwork

2. 7 Fit to Old Brickwork

Installation Kiln Bricks engl.DOC 8/40 Rev. 00 16.12.03/

l 3. General Lining Instructions

BE INFORMED THAT THE INSTALLATION COULD ONL Y BE DONE ATA TEMPERATURE

Installation Kiln Bricks engl.DOC 9140 Rev. 00 16.12.03/

4.2 Ring joints

Installation Kiln Bricks engl.DOC 10/40 Rev. 00 16.12.03/

5.2 DAT Kilo Rig

5.3 Glue Method ·

5.4 Bolted Method

Installation Kiln Bricks engl.DOC 11/40 Rev. 00 16.12.03/

J 6. Specific Lining Situations

6.1 Kiln Outlets with Nose Ring

- Generally the radial joints should be mortared.

6.2. Lining in the area of retaining rings

6.3. Lining of eones

Installation Kiln Bricks engl.DOC 12/40 Rev. 00 16.12.03/

6.5. Inlet zones

Installation Kiln Bricks engl.DOC 13/40 Rev. 00 16.12.03/

fixing of the kiln axis

- -- ------ - ---- t- ---- ----

Installation Kiln Bricks engl.DOC 14140 Rev. 00 16.12.03/

1.1 row by row installation of rotary kiln bricks

Installation Kiln Bricks engl. DOC 15/40 Rev. 00 16.12.03/

1.2 alignment of separate expansion cardboards row by row