Drying out and Heating up of refractory installations in the cement
industry
Dirk Basten
Refratechnik Cement Supervisor Training Course 2012
Refractory installation
of a complete plant
static
predominantly castable
dynamic
predominantly bricks
Scheme of the refractory installation of a complete plant
static
predominantly castable
Water sources physically bonded water
Installation of wet bricks Strictly follow guidelines
Avoid leaking water
0100
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500
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800
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1000
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1200
1300
1400
0 12 24 36 48 60 72 84 96 108 120 132 144 156 168
t [h]
T [C]
approx 13 K/h
approx 10 K/h
approx 30 K/h
approx 10 K/h
TrocknungTrocknungTrocknungTrocknung AufheizenAufheizenAufheizenAufheizen
Anmerkungen: Genere ll sollt e vor dem Beginn de r Trocknung und des Aufhe izens e in mindestens 24 stndiges Aushrten der Masse stat tgefunden haben!
1* > Ofendrehung 180 a lle 45 minutes - Re fe renzmante lt empera tur in de r Brennzone ca . 100 - 150C
2* > Ofendrehung 90 a lle 30 minutes - Referenzmante lt emperatur burning zone ca .. 200 - 235C
3* > Ofendrehung kont inuie rlich - Referenzmante lt empe ratur burning zone ca . 260 - 310C
* t heoret ica l ca lculated she ll t emperature - depends on environment condit ions
1*
2*
3*
Entfernen der
Abdichtungen / Start des
Hauptbrenners
850C -1000C
Inbetriebnahme
Typical dry out curve for complete new plant
Aufheizdiagramm feuerfester Massen (LCC, MCC, SC, JC)
Heating diagramm of refractory concretes (LCC, MCC, SC, JC)
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0 10 20 30 40 50 60 70 80 90 100 110
Zeit nach Einbau / h
Time after installation / hrs
T
e
m
p
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C
T
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a
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10 h / 500 C
min. 24 h Erhrtungsdauer
min. 24 hrs setting time
20 h / 110 - 150 C
15 C/h
25 C/h
30 C/h
bis zur Einsatztemperatur
up to temp. of application
Heating Up
Drying
Time after installation / hTime after installation / hTime after installation / hTime after installation / h
Heating diagram of refractory concretesHeating diagram of refractory concretesHeating diagram of refractory concretesHeating diagram of refractory concretes
Heating diagram of refractory concretes (AR, LCC, SC, JC, G, Heating diagram of refractory concretes (AR, LCC, SC, JC, G, Heating diagram of refractory concretes (AR, LCC, SC, JC, G, Heating diagram of refractory concretes (AR, LCC, SC, JC, G,
MCG, LCG) Stationary areas wall thickness 50MCG, LCG) Stationary areas wall thickness 50MCG, LCG) Stationary areas wall thickness 50MCG, LCG) Stationary areas wall thickness 50---- 300 mm300 mm300 mm300 mm
Behaviour of drying rate
as a function of drying time
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1 2 3 4 5 6 7 8 9 10 11 12 13
Dryiing time
D
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g
r
a
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Drying time [h]Drying time [h]Drying time [h]Drying time [h]
D
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Drying rate as a function of timeDrying rate as a function of timeDrying rate as a function of timeDrying rate as a function of time
tkn
Phase 1Phase 1Phase 1Phase 1
continous drying
rate
Phase 2Phase 2Phase 2Phase 2
Decreasing drying rate
Low vapour pressurelow drying rate
Ppore openingPmeniskus >Phase 1:
outletInletair
100100100100CCCC
/1 bar/1 bar/1 bar/1 bar
20202020CCCC
/0.02 bar/0.02 bar/0.02 bar/0.02 bar
T [C]
Ppore opening
Pcapillary
PmeniskusP 1 bar
Low temperatur, continous airstream with high ventilation
Ppore opening
Pcapillary
Pmeniscus
T [C]
OutletInletAir stream
350350350350CCCC
/165 bar/165 bar/165 bar/165 bar
100100100100CCCC
/1 bar/1 bar/1 bar/1 bar
< Ppore openingPMeniskusPhase 2:
P 164 bar
High temperature, low ventilation and airstreamHigh temperature, low ventilation and airstreamHigh temperature, low ventilation and airstreamHigh temperature, low ventilation and airstream
Pressure- and temperatur gradient in a to be dried refractory body
(Dissertation: Modell zur Beschreibung der Trocknung von Feuerbetonen, Ingo Growendt, 2007, p.25)
0
50
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0 50 100 150 200 250 300 350 400
T empe r a t ur e (C )T empe r a t ur e (C )T empe r a t ur e (C )T empe r a t ur e (C )
S
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S
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(
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S
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a
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p
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s
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(
b
a
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Aufheizdiagramm feuerfester Massen (LCC, MCC, SC, JC)
Heating diagramm of refractory concretes (LCC, MCC, SC, JC)
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
0 10 20 30 40 50 60 70 80 90 100 110
Zeit nach Einbau / h
Time after installation / hrs
T
e
m
p
e
r
a
t
u
r
/
C
T
e
m
p
e
r
a
t
u
r
e
/
C
10 h / 500 C
min. 24 h Erhrtungsdauer
min. 24 hrs setting time
20 h / 110 - 150 C
15 C/h
25 C/h
30 C/h
bis zur Einsatztemperatur
up to temp. of application
Explosive spalling of castable surface (satellite cooler)
Dry out - surface cracking
Typical view on a badly
predried castable , cooler
sidewalls
Explosive spalling of Castable
Spalling of wet LCC castable on burner
Optimized drying schedule
Exhaust gas sealing of kiln and ducts
Protection against humid exhaust gases (filter, basic bricks)
Evaporation holes in the cycloneroof
lockable socket for controled evaporation
Heating up of kiln
Contraction at tyre
Limiting mechanical components
Temperaturedistribution in brick and kiln shell during heating up
In 8h to 1000C
Too slowly heating up, too early turning of kiln
Loose lining
migration, relativ
movement
Too fast heating up
Axial and radial pressure
Spalling , cobblestone surface
Done: Drying and heating successfully finished
first clinker in cooler
Typical timing:
78 h 120 h
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