GENERAL PROCEDURE FOR

REFRACTORY DRYOUT

Refractory dryout procedure is carried out whenever new Bricklining is carried out, or after major
repairs in B/Lining or if the furnace is unoperated during plant shutdown for long time. The property of
insulating and refractory material and the mortar joints are such that under cold condition it will absorb
moisture. New brickwork shall be Air Dried for at least 2 days before heating. This dryout procedure is a
slow heating process, carried out over a period of about 2 days. The excess moisture is removed by slow
heating of the furnace either by burning wood directly inside the furnace. An alternative method of
heating is by oil firing system by which temperature control of low magnitude is possible. Gradual
heating with low temperature rise is absolutely necessary while heating. With a fast rate of heating the
sudden expansion of the refractory may spall the lining.

Ensure all thermocouples / temperature Indicators are located and assembled at proper
locations. Keep manholes open as required and dummies in position.

Refer the heating and cooling cycle shown in the Annexure.

Operate on low flame for the first few hours. Be sure there is sufficient combustion air entering
around the start-up burner at all times to avoid local overheating of the brickwork.

If the flame is accidentally or purposely extinguished, it is absolutely necessary to purge the

system before lighting. Do not attempt to light the burner again until the furnace is purged of the
unburnt fuel, by operating combustion air fan or startup blower for about 15 minutes.

Raise the temperature at the rate of 25 to 30 deg. / hr. upto approx. 110 deg. C. Hold at this
temperature for about six to eight hours. Raise the temperature again at the same rate from 120 deg. C
to about 200 deg. C and hold for six to eight hours. Raise the temperature again at the same rate from
200 deg. C to about 300 deg. C and hold for six to eight hours.

Cooling is then done @ 50 deg. C / hr. till the temperature reaches to about 110 deg. C. Box upto
furnace until plant is taken up for heating.

Normally dry out and boil-out operations are combined to save time and fuel cost. In case the
plant is ready for start-up, further heating can be continued as per process requirement using the oil
burner. The temperatures are to be periodically measured and recorded.

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