View
222
Download
0
Category
Preview:
Citation preview
8/16/2019 SRIC InstallTechnique
1/84
Refractory InstallationRefractory Installation
For cement Rotary KilnFor cement Rotary Kiln
11THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
2/84
What did affect to refractory life?What did affect to refractory life?
Quality of Refractor Quality of Refractoryy The Correct InstallationThe Correct Installation
22THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
OperationOperation ProcessProcess
8/16/2019 SRIC InstallTechnique
3/84
Refractory installation’s RequirementsRefractory installation’s Requirements
1)1) Installed with qualificable acceptance.Installed with qualificable acceptance.
2)2) Optimum time or suitable scheduleOptimum time or suitable schedule
33
. .
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
4/84
Refractory Installation forRefractory Installation forRotary KilnRotary Kiln
11)Preparation before shutdown.)Preparation before shutdown.
44
Gap, migration ,Kiln Ovality Check.Gap, migration ,Kiln Ovality Check. Interpret & AnalysisInterpret & Analysis
Mechanical AdjustmentMechanical Adjustment
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
5/84
Kiln Ovality CheckKiln Ovality Check
55THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
6/84
Kiln Shell ReplacementKiln Shell Replacement
in case shell too thinin case shell too thin
66THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
7/84
22) Refractory Materials Checking() Refractory Materials Checking(33 months Earlier)months Earlier)-- 33 monthsmonths before shutdown shall check.before shutdown shall check.
Quality of materials, appearance, Package.Quality of materials, appearance, Package.
Quantity of Material, classification, sparedQuantity of Material, classification, spared
refractory.refractory.
77
-- 22--44 weeksweeks before shut down or final check is verybefore shut down or final check is very
important.important.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
8/84
Brick Combination.
DiameterDiameter 44..66 mmISO Shaped brickISO Shaped brick 620620 :: 420420
78 : 62 4:3
VDZ Shaped Brick BVDZ Shaped Brick B 620620 : B: B420420
88THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
4848 :: 145 1145 1::33
ISO Shaped brick less shortage problem, linedISO Shaped brick less shortage problem, lined
faster & stronger than VDZ Shaped brick.faster & stronger than VDZ Shaped brick.
8/16/2019 SRIC InstallTechnique
9/84
Warehouse & Material handling
99THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
10/84
33) Machines, tools Equipment checking) Machines, tools Equipment checking-- DeDe--bricking Machine.bricking Machine.
-- materials Transferred Machine.materials Transferred Machine.
-- Bricking Machine.Bricking Machine.-- Pneumatic jack hammer.Pneumatic jack hammer.
-- Concrete mixing machine.Concrete mixing machine.
1010
-- Brick Cutting Machine.Brick Cutting Machine.-- Forklift, lifting hoist, belt conveyer.Forklift, lifting hoist, belt conveyer.
-- Bridge.Bridge.
-- Lighting, welding & Carpenter tools etc.Lighting, welding & Carpenter tools etc.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
11/84
44)Man power preparation.)Man power preparation.11 month before shutdown.month before shutdown.
-Training the precaution & safety course.
- Refractory knowledge.
- Refractory installation knowledge.
1111
- Skilful & trained man-powers needs.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
12/84
Preliminary work before dePreliminary work before de--bricking.bricking.
Refractory Inspection after kiln cooled down.Refractory Inspection after kiln cooled down.--2424 hours afterward, prepare to inspect physicalhours afterward, prepare to inspect physicalcoating forming, coating thickness, smoothly,coating forming, coating thickness, smoothly,length, Refractory appearancelength, Refractory appearance
--Record, pictureRecord, picture
1212
--Abnormality, damage, worn, samplingAbnormality, damage, worn, sampling11) line of used brick might displaced from before.) line of used brick might displaced from before.
22) Cracking, spalling, Damaged feature.) Cracking, spalling, Damaged feature.
33) Remaining thickness Drilling, UT.) Remaining thickness Drilling, UT.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
13/84
Remaining ThicknessRemaining Thickness
UT Tester UT Tester.
1313THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Drilling methodDrilling method..
8/16/2019 SRIC InstallTechnique
14/84
-Correct all necessary data, analysis and evaluate to
improve refractory life time such as
1) Applied Ceramic Fiber to release stress fromthermal expansion & uneven brick retainer.
2) 2) Mortar Applied at tyre or high mechanical
1414
3) Select suitable refractory for necessaryapplication
-Resume all data and linkage to operating condition.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
15/84
*Plan to locate refractory to be replaced.*Plan to locate refractory to be replaced.
Coating and Brick Dismantling.Coating and Brick Dismantling.
CoatingCoating
--Chipping from kiln outlet to kiln inletChipping from kiln outlet to kiln inletdirection.direction.
SRIC
1515
* De* De--bricking machine.bricking machine.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Coating removing
8/16/2019 SRIC InstallTechnique
16/84
BrickBrick
--Chipping from kiln inlet to kiln outlet direction.Chipping from kiln inlet to kiln outlet direction.
* De* De--bricking bricking machine, Temporary brickbricking bricking machine, Temporary brick
stopper in case partial replacement and preventstopper in case partial replacement and preventsliding of existing bricks.sliding of existing bricks.
1616THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
17/84
BrickBrick
--Removing damage brick and waste from rotary kiln.Removing damage brick and waste from rotary kiln.
•• By Man hole, Rotate and drop to cooler, ManuallyBy Man hole, Rotate and drop to cooler, Manually
removingremoving
1717THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
18/84
Kiln Shell inspectionKiln Shell inspection
--Deformed Area & Marking with color spray.Deformed Area & Marking with color spray.
--Scaling, rust & acidic coated on shell, sand blasting.Scaling, rust & acidic coated on shell, sand blasting.
--Shell welding joint, another welding spot, kiln mark.Shell welding joint, another welding spot, kiln mark.
1818
Horizontal welding jointHorizontal welding joint
Vertical welding jointVertical welding joint
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
19/84
Transportation of refractory to kiln.Transportation of refractory to kiln.
1919THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
20/84
How to correctly carry out theHow to correctly carry out thebricking of cement rotary kiln?bricking of cement rotary kiln?
--Installation methodInstallation method--Kiln rotation Screw jack, gluing, channel method.Kiln rotation Screw jack, gluing, channel method.
2020
--wooden mouldwooden mould
PneumaticPneumatic – –OO--Ring.Ring.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
21/84
Bricking with kiln rotationBricking with kiln rotation
Screw jack.Screw jack.
-- Lining achieved by laying a half section longLining achieved by laying a half section long 55--1010 meter and tighten with screw jack.meter and tighten with screw jack.
2121THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
22/84
Bricking with kiln rotationBricking with kiln rotationchannel methodchannel method
--The method was applied from screw jack method.The method was applied from screw jack method.
Bricks have been laid and tighten with channel andBricks have been laid and tighten with channel andfasten with bolt and nut.fasten with bolt and nut.
2222
Wood wedge Welded nut
Channel steel
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
23/84
Bricking with kiln rotationBricking with kiln rotation
Gluing method.Gluing method.
-- Lining achieved by applied epoxy resin &Lining achieved by applied epoxy resin &
hardener withhardener with 55 pieces of brick longpieces of brick long 55--1010 meter.meter.
install nextinstall next 55--1010 pieces same length without glue.pieces same length without glue.
2323
onsequence to t e prev ous w en g ue sonsequence to t e prev ous w en g ue salready hard.already hard.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
24/84
Bricking without kiln rotation.Bricking without kiln rotation.Formwork method.Formwork method.
11)Formwork or contour )Formwork or contour -- use wooden made arch support, hydraulicuse wooden made arch support, hydraulic
ack and wood wed e for insist brick linin .ack and wood wed e for insist brick linin .
2424
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
25/84
Bricking without kiln rotation.Bricking without kiln rotation.22) Pneumatic or Mult) Pneumatic or Mult--OO--Ring.Ring.
-- Applied from pneumatic cylinderApplied from pneumatic cylinderindependently with arch support to install aindependently with arch support to install a
2525
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
26/84
Methodize and it’s comparisons.Methodize and it’s comparisons.
Kiln rotation method.Kiln rotation method.
11) advantage) advantage
-- Simple method regarding to necessary equipment.Simple method regarding to necessary equipment.-- Low investment cost.Low investment cost.
22) Disadvantage) Disadvantage
2626
-- n as o e ro a e ur ng n ng process.n as o e ro a e ur ng n ng process.-- Take risk if bricks are not adequately fastened and slip.Take risk if bricks are not adequately fastened and slip.
-- Ring cannot be tightened prior closing.Ring cannot be tightened prior closing.
-- Kiln diameter larger thanKiln diameter larger than 44 meter might cause screwmeter might cause screw jack slipped & shell distorted. jack slipped & shell distorted.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
27/84
Methodize and it’s comparisons.Methodize and it’s comparisons.
Without kiln rotation method.Without kiln rotation method.
11)) advantageadvantage
-- Safe in operation.Safe in operation.
-- Gain accurate brick installed for brick ratio and conform to shell.Gain accurate brick installed for brick ratio and conform to shell.-- Kiln does not to be rotated.Kiln does not to be rotated.
-- Suitable for small and large kiln diameter.Suitable for small and large kiln diameter.
2727
-- Highest speed up bricking rate.Highest speed up bricking rate.-- Manage and relate in parallel activities.Manage and relate in parallel activities.
22) Disadvantage) Disadvantage
-- Very high cost on an equipment .Very high cost on an equipment .
-- High affordability to assemble an equipments.High affordability to assemble an equipments.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
28/84
Installed rate in each methodInstalled rate in each method
Rotation method m2/hour m2/manpower
Screw jack method 1-3.5 0.17-0.25
Gluing method 3-7 0.4-1.2
Channel method less than gluing 0.2-0.5
2828
Formwork method
Formwork or Contour 1.8-3 0.1-0.2
M-O-R (Clench or dry
mortar) 9.5 0.75
M-O-R (With mortar) 6.5 0.5
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
29/84
Kiln Rotation and place Man hole atKiln Rotation and place Man hole at 66 OO
oo
ClockClockThe Center line will be checked with accurate tools.The Center line will be checked with accurate tools.
--Aluminum bar dimensionAluminum bar dimension 2525xx5050xx30003000 mm.mm.
--Leveling bar Leveling bar --Plumb bobPlumb bob
2929
-- ompass.ompass.--Nylon wireNylon wire
--Measuring tape.Measuring tape.
--Chisel ,Steel Hammer ,Color spray.Chisel ,Steel Hammer ,Color spray.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
30/84
Center line and Cross section line byCenter line and Cross section line by Kiln RotationKiln Rotation
fixed.fixed.
11) Place an aluminum bar on kiln outlet crossways.) Place an aluminum bar on kiln outlet crossways.
3030THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
31/84
22) Check aluminum bar and adjust level with leveling) Check aluminum bar and adjust level with levelingbar bar
3131THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
32/84
33)Place & made Plump bob on level to center of)Place & made Plump bob on level to center of
aluminum bar. (calibrated form QSD)aluminum bar. (calibrated form QSD)44) Gently spot the end of plum to kiln shell.) Gently spot the end of plum to kiln shell.
55) Marking with Chisel and spray the point round) Marking with Chisel and spray the point roundshaped color.shaped color.
3232
½ L½ L½ L½ L
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
33/84
66) Every) Every 55 meter check the center points.meter check the center points.
77) Draw string wire from beginning point to last point.) Draw string wire from beginning point to last point.
88) Spray color cover string and remove string off.) Spray color cover string and remove string off.
3333THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
34/84
33..44 Circumferential lines or radial controlled lines byCircumferential lines or radial controlled lines by
Kiln rotation fixed..Kiln rotation fixed..
--Separated the center line with compass and crossSeparated the center line with compass and cross
exactlyexactly 11 meter along.meter along.
3434
0 1 2 3 4 5 6 7 80 1 2 3 4 5 6 7 8 99 10 11 12 1310 11 12 13 1414
THE SIAM REFRACTORY INDUSTRY CO.,LTD.WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
35/84
-- Use pointUse point 11,,33,,55….and point….and point 00,,22,,44,,66…..set for…..set for
crossing With compass radiuscrossing With compass radius 11..88 meter.meter.
3535
0 1 2 3 40 1 2 3 4 5 65 6
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
36/84
3636
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
37/84
-- Draw more the lateral lines which achieved fromDraw more the lateral lines which achieved from
crossing pattern.crossing pattern.
0 1 2 3 40 1 2 3 4 5 65 6
3737
0 1 2 3 40 1 2 3 4 5 65 6
0 1 2 3 40 1 2 3 4 5 65 6
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
38/84
--Extended scaffolding and draw higher lateralExtended scaffolding and draw higher lateral lineslines
and cross section line together.and cross section line together.
-- The half upper section will do during bricking.The half upper section will do during bricking.
3838
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
39/84
Center line and Cross section line byCenter line and Cross section line by Kiln Rotation.Kiln Rotation.
--Check and draw center line then rotate kilnCheck and draw center line then rotate kiln 2020oo
alternately’alternately’
-- Separated the center line in every meter.Separated the center line in every meter.
3939
0 1 2 3 4 5 6 7 80 1 2 3 4 5 6 7 8 99 10 11 12 1310 11 12 13 1414
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
40/84
--Rotate kilnRotate kiln 2020oo and check the second center line.and check the second center line.
0 1 2 3 4 5 6 7 80 1 2 3 4 5 6 7 8 99 10 11 12 1310 11 12 13 1414
4040
0 1 2 3 4 5 6 7 80 1 2 3 4 5 6 7 8 99 10 11 12 1310 11 12 13 1414
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
41/84
--Turning approximatelyTurning approximately 1616 times and draw thetimes and draw the
center lines with cross section lines until completed.center lines with cross section lines until completed.
-- Actually it is very necessary to check center lineActually it is very necessary to check center line
on the last line according to Manon the last line according to Man--hole athole at 66 O’clock.O’clock.--During turning kiln,During turning kiln, cleaning, repairing ,kilncleaning, repairing ,kiln
4141
done at the same time.done at the same time.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
42/84
4242
Checking & marking shellChecking & marking shelldeformationdeformation
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
43/84
Bricking.Bricking.
--Use Channel bar or HUse Channel bar or H--beambeam 100100xx100100xx30003000 mm.mm.placeplace align to the center line.align to the center line.
-- Support the other side of HSupport the other side of H--beam with heavilybeam with heavily
substances such as bricks.substances such as bricks.
4343
4 5 6 7 8 94 5 6 7 8 9 10 11 12 1310 11 12 13 1414
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Brick patternBrick pattern
8/16/2019 SRIC InstallTechnique
44/84
11)Straight joint pattern.)Straight joint pattern.
Brick patternBrick pattern
4444
. .
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
45/84
11) Always clean dirt away from kiln shell.) Always clean dirt away from kiln shell.22) Place Channel bar along and aligned to the center) Place Channel bar along and aligned to the center
line.line.
33) Gently install first course of brick from brick) Gently install first course of brick from brick
retainer or existing brick as figure.retainer or existing brick as figure.
4545
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Straight joint pattern.Straight joint pattern.
8/16/2019 SRIC InstallTechnique
46/84
4646
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Stagger joint or Bonded patternStagger joint or Bonded pattern..
8/16/2019 SRIC InstallTechnique
47/84
4747
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
48/84
4848
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Kil d f tiKil d f ti
8/16/2019 SRIC InstallTechnique
49/84
Kiln deformationKiln deformation
-- Nominated brick ratio by installedNominated brick ratio by installedfrequently larger or smaller size more onfrequently larger or smaller size more on
deformed area.deformed area.
-- 22 oror 33 mm. different in level can adjustmm. different in level can adjustwith mortar.with mortar.
4949
-- DuringDuring 44--88 can threat the deformed shellcan threat the deformed shellwith plastic refractory or fine grain sizewith plastic refractory or fine grain sizecastable.castable.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Convex deformed kiln shellConvex deformed kiln shell
8/16/2019 SRIC InstallTechnique
50/84
Convex deformed kiln shellConvex deformed kiln shell
XX
5050
XXTHE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Convex deformed kiln shellConvex deformed kiln shell
8/16/2019 SRIC InstallTechnique
51/84
5151
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
52/84
Welding Joint
5252
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Wrong combinationWrong combination
8/16/2019 SRIC InstallTechnique
53/84
Wrong combinationWrong combination
XX XX
5353
Larger brick lined more than ordinaryLarger brick lined more than ordinary
Smaller brick lined more than ordinarySmaller brick lined more than ordinary
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Ri h C bi iRi h C bi i
8/16/2019 SRIC InstallTechnique
54/84
Right CombinationRight Combination
5454
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Convex deformed kiln shellConvex deformed kiln shell
8/16/2019 SRIC InstallTechnique
55/84
Convex deformed kiln shellConvex deformed kiln shell
Mortar applied here
5555
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Concave deformed kiln shellConcave deformed kiln shell
Mortar applied here
Mortar applied at lower and upper section
8/16/2019 SRIC InstallTechnique
56/84
Mortar applied at lower and upper section
5656
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Prohibit for using
8/16/2019 SRIC InstallTechnique
57/84
Prohibit for using
adjustable plates.
XX
5757
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
XX
Reasons
-Loose lining.
-Interfaced cracking
-- Remove channel bar and wooden spacer off clean allRemove channel bar and wooden spacer off clean all
8/16/2019 SRIC InstallTechnique
58/84
Remove channel bar and wooden spacer off, clean allRemove channel bar and wooden spacer off, clean all
dirt, install the adjacent section alongdirt, install the adjacent section along 88--1010 meter thenmeter thenassemble MOR.assemble MOR.
5858
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Bricking at brick retainerBricking at brick retainer
8/16/2019 SRIC InstallTechnique
59/84
Bricking at brick retainer.Bricking at brick retainer.
1)cutting brick as shape and cover brick retainer
Material flow
5959
.
Low cement castable C-60-A
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Bricking at brick retainer.Bricking at brick retainer.
8/16/2019 SRIC InstallTechnique
60/84
33) install with brick and castable.) install with brick and castable.
6060
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Install brick at tyre area or high mechanical stress areas.Install brick at tyre area or high mechanical stress areas.
8/16/2019 SRIC InstallTechnique
61/84
- Motar is being trowelled 1-2 mm. thick at axial& radialbrick sides at tyre area 3-5 meter long.
- Or use the pre mortared brick.
6161
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
3-5 meters 3-5 meters 3-5 meters
Install brick at tyre area or high mechanical stress areas.Install brick at tyre area or high mechanical stress areas.
8/16/2019 SRIC InstallTechnique
62/84
Mortar applied at radial& axial sides.
6262
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Pre mortared brick
Brick cutting principle.Brick cutting principle.
8/16/2019 SRIC InstallTechnique
63/84
1) The cutting ring shall be remain 2/3 off original length.2) From brick retainer nor existing ring brick at the adjacentmust be original length.
3) Whenever cut more than 1 ring,The cutting ring must beseparated.4) Cutting many rings take long time and high cost, Special
6363
.
L
X
BRICK STOPPER
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Brick cutting principle.Brick cutting principle.
8/16/2019 SRIC InstallTechnique
64/84
1)1) 22//33 L< X < LL< X < L 11 Ring CutRing Cut
2)2) 11//33 L< X
8/16/2019 SRIC InstallTechnique
65/84
Cut Cut
6565
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
How to install a half upper section.How to install a half upper section.
8/16/2019 SRIC InstallTechnique
66/84
pppp
Set up MultSet up Mult--OO--Ring.Ring.
--Assemble platform, support rack.Assemble platform, support rack.
--Connect and adjust arch support.Connect and adjust arch support.--Pneumatic hose, connecting coupling, control valve.Pneumatic hose, connecting coupling, control valve.
6666
--Check all joint, spacer rod, clearance interval kilnCheck all joint, spacer rod, clearance interval kilnshell and rubber plate simultaneously.shell and rubber plate simultaneously.
--Space between brick surface to rubber plates mustSpace between brick surface to rubber plates must
be adjusted tobe adjusted to 100100 mm.mm.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
--In case the distance between rubber and brickIn case the distance between rubber and brick
8/16/2019 SRIC InstallTechnique
67/84
In case the distance between rubber and brickIn case the distance between rubber and brick
surface is misaligned, adjust the height of platformsurface is misaligned, adjust the height of platformor radial of arch support needed.or radial of arch support needed.
--UnUn--uniform of intervening distance of brickuniform of intervening distance of bricksurface and rubber can cause some brick loosensurface and rubber can cause some brick loosenduring installation proceeding.during installation proceeding.
6767
--Check air pressure, main air requiredCheck air pressure, main air required 55 barbarminimally.minimally.
--Lubrication oil for trapping water condensed inLubrication oil for trapping water condensed in
hose need to be replaced from filter.hose need to be replaced from filter.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Set Up Mult-O-Ring
8/16/2019 SRIC InstallTechnique
68/84
6868
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
--lay up brick in both sides and open cylindrical valve onelay up brick in both sides and open cylindrical valve one
8/16/2019 SRIC InstallTechnique
69/84
brick per cylinder.brick per cylinder.--Applied hard surface plastic hammer in each brick duringApplied hard surface plastic hammer in each brick during
install frequently.install frequently.
-- brick ring can be closed by pressing at axial side withbrick ring can be closed by pressing at axial side withpneumatic jackpneumatic jack approximatelyapproximately 28002800--30003000 kg/cmkg/cm22..
6969
-- e ease pressure a pneumat c va ves an removee ease pressure a pneumat c va ves an remove
Arch support to next ring.Arch support to next ring.
-- On the prior ring, utilized the first set of pneumatic set toOn the prior ring, utilized the first set of pneumatic set tosupport prior brick ring and remove pneumatic jack.support prior brick ring and remove pneumatic jack.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
--Check the distance from left & right of closing andCheck the distance from left & right of closing and
8/16/2019 SRIC InstallTechnique
70/84
calculated or simulate by use installed brick.calculated or simulate by use installed brick.--Follow the precaution, avoiding and try best ratio, minimallyFollow the precaution, avoiding and try best ratio, minimally
key brick, separated when it were being keys. By mean ofkey brick, separated when it were being keys. By mean of
maximum tighten ring without any damage or displacementmaximum tighten ring without any damage or displacementlater.later.
7070
-- --
maximum allowed until ring tighten enough is accepted.maximum allowed until ring tighten enough is accepted.--While ring closing period, the next ring shall be installedWhile ring closing period, the next ring shall be installedbrick up.brick up.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Closing the ringClosing the ring
8/16/2019 SRIC InstallTechnique
71/84
--Applied pressureApplied pressure 28002800 kg/cmkg/cm22 safesafeenough for tightening the ring.enough for tightening the ring.
7171
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Closing the ringClosing the ring
8/16/2019 SRIC InstallTechnique
72/84
Key Bricks
Steel shim 4 pcs, maximum, 2-3mm., thk.
Key Bricks
Steel shim 4 pcs, maximum, 2-3mm. Thk.
7272
X
X
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Closing the ringClosing the ring MS-80-AF
620 420 P20 P+20 D d
8/16/2019 SRIC InstallTechnique
73/84
620 420 P20 P+20 D d
5 2 1 0 804 741
4 2 0 2 804 741
4 3 1 0 804 738
3 3 0 2 804 738
3 4 1 0 804 734
2 4 0 2 804 7342 5 1 0 804 731
4 2 1 1 794 731
3 2 0 3 794 732
7373
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
2 3 0 3 794 728
2 4 1 1 794 724
4 2 2 0 784 721
3 2 1 2 784 722
2 2 0 4 784 722
3 3 2 0 784 718
2 3 1 2 784 718
2 4 2 0 784 714
3 2 2 1 774 712
8/16/2019 SRIC InstallTechnique
74/84
7474
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
8/16/2019 SRIC InstallTechnique
75/84
7575
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Final check and ring tightening
8/16/2019 SRIC InstallTechnique
76/84
7676
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Steel Anchors With Plastic Cap.Steel Anchors With Plastic Cap.
8/16/2019 SRIC InstallTechnique
77/84
Flat bar ShapeFlat bar ShapeFlat barFlat bar – –footing with holder.footing with holder.
7777
Round, rod TypeRound, rod Type Corrugated TypeCorrugated Type Corrugated shape with holder Corrugated shape with holder
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Stainless anchor property.Stainless anchor property.
8/16/2019 SRIC InstallTechnique
78/84
Stainlesssteelgrade Composition
Scalingtemperature
AISI 253 MA %C
8/16/2019 SRIC InstallTechnique
79/84
-Bricking first and casting at kiln outlet & inlet together.
-Casting during center line made.
-Ceramic paper applied for resist brick on the adjacent of nose ring
broken.
7979
- Followed castable user guide whenever castable must be installed.
Ceramic fiber board 10 mm.Thk.
High Alumina Brick
KB-70-PB,BX-80
Low cement castable 60%
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Kiln outlet castingKiln outlet casting..
8/16/2019 SRIC InstallTechnique
80/84
AnchoringAnchoring
--Welding suitable anchor SUSWelding suitable anchor SUS 310310, SUS, SUS 253253 MA with weldingMA with welding
electrodeelectrode
--AWSAWS 309309,, 310310..
8080
-- Visually checking, Impact test.Visually checking, Impact test.
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Kiln outlet castingKiln outlet casting..
8/16/2019 SRIC InstallTechnique
81/84
Expansion joint
- ply wood 3 ,4 ,5, and 10 mm.
-Ceramic fiber blanket 1260 o C 5 mm and 12.5 mm.thk.
Casting Mould
8181
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
-Wooden form-Steel mould.
Kiln outlet castingKiln outlet casting..
8/16/2019 SRIC InstallTechnique
82/84
8282
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
Ceramic fiber board 10 mm.thk
Some problems might be found while castingSome problems might be found while casting
8/16/2019 SRIC InstallTechnique
83/84
Impurity in panImpurity in pan--mixer & Surroundingmixer & Surrounding
Flash Setting or Rapid setting of castableFlash Setting or Rapid setting of castable
8383
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
1)1) Clean all equipmentClean all equipment
2)2) Use only drinkable water while mixing.Use only drinkable water while mixing.
3)3) Cooled down castable & surroundingCooled down castable & surrounding
mme ate y act onmme ate y act on
Some problems might be found while castingSome problems might be found while casting
8/16/2019 SRIC InstallTechnique
84/84
Castable not setting or very long time settingCastable not setting or very long time setting
Immediately actionImmediately action
1) Reduce mixing water.
8484
THE SIAM REFRACTORY INDUSTRY CO.,LTD.
WORLD CLASS REFRACTORY PRODUCTS AND SERVICES
2) Installed some heater fan & spot light.
3) Add some accelerator.
Recommended