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
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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
Trocknung Trocknung Trocknung Trocknung Aufheizen Aufheizen Aufheizen Aufheizen
Anmerkungen: Generell sollt e vor dem Beginn der Trocknung und des Aufheizens ein mindest ens 24 st ndiges Aushrt en der Masse st at t gefunden haben!
1* > Ofendrehung 180 alle 45 minut es - Referenzmant elt emperat ur in der Brennzone ca. 100 - 150C
2* > Ofendrehung 90 alle 30 minut es - Referenzmant elt emperat ur burning zone ca.. 200 - 235C
3* > Ofendrehung kont inuierlich - Referenzmant elt emperat ur burning zone ca. 260 - 310C
* t heoret ical calculat ed shell t emperat ure - 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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Zeit nach Einbau / h
Time after installation / hrs


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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 / h Time after installation / h Time after installation / h Time after installation / h
Heating diagram of refractory concretes Heating diagram of refractory concretes Heating diagram of refractory concretes Heating 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 50 MCG, LCG) Stationary areas wall thickness 50 MCG, LCG) Stationary areas wall thickness 50 MCG, LCG) Stationary areas wall thickness 50- -- - 300 mm 300 mm 300 mm 300 mm
Behaviour of drying rate
as a function of drying time
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Dryiing time
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Drying time [h] Drying time [h] Drying time [h] Drying time [h]
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Drying rate as a function of time Drying rate as a function of time Drying rate as a function of time Drying rate as a function of time
t
kn
Phase 1 Phase 1 Phase 1 Phase 1
continous drying
rate
Phase 2 Phase 2 Phase 2 Phase 2
Decreasing drying rate
Low vapour pressurelow drying rate
P
pore opening
P
meniskus
>
Phase 1:
outlet Inlet
air
100 100 100 100 C CC C
/1 bar /1 bar /1 bar /1 bar
20 20 20 20 C CC C
/0.02 bar /0.02 bar /0.02 bar /0.02 bar
T [C]
Ppore opening
P
capillary
P
meniskus
P 1 bar
Low temperatur, continous airstream with high ventilation
Ppore opening
P
capillary
P
meniscus
T [C]
Outlet
Inlet
Air stream
350 350 350 350 C CC C
/165 bar /165 bar /165 bar /165 bar
100 100 100 100 C CC C
/1 bar /1 bar /1 bar /1 bar
< Ppore opening P
Meniskus
Phase 2:
P 164 bar
High temperature, low ventilation and airstream High temperature, low ventilation and airstream High temperature, low ventilation and airstream High 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)
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T e mpe r a t ur e ( C) T e mpe r a t ur e ( C) T e mpe r a t ur e ( C) T e mpe r a t ur e ( C)
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Aufheizdiagrammfeuerfester Massen (LCC, MCC, SC, JC)
Heating diagrammof refractory concretes (LCC, MCC, SC, JC)
0
100
200
300
400
500
600
700
800
900
1000
1100
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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
e
r
a
t
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r

/

C
T
e
m
p
e
r
a
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u
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/

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
upto 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