Analysis of refractory degradation

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Analysis of refractory degradationProcedures for its identification and documentation.

 

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Wear or Damage?

  • Ideal Wear

  (As consequence of  OEE > 0.85, service life of 12, 24, 36 months)

  • Normal Wear (to date)

  Slow, continuous loss of lining thickness, with service life < 12, 24, 36 months

  • Damage

  Sudden, rapid loss of lining thickness (at any time)

Factors influencing Service Life

Factors influencing kiln refractories Service Life

Factors influencing kiln refractories Service Life

 

Extended factors influencing service life

User’s Responsibility

  • installation
  • drying/heating-up
  • service conditions
  • thermal-mechanical- chemical

Producers Responsibility

  • raw material quality
  • quality of manufacture
  • product design

Combined Responsibility

  • selection
  • packing / storage

 

User’s Responsibility

  • installation (10%)
  • drying/heating-up (?)
  • service conditions (67%)

thermal (18%)-mechanical (24%)-chemical (25%)

Producers Responsibility

  • raw material quality (17%)
  • quality of manufacture (3%)
  • product design (1%)

Combined Responsibility

  • selection (2%)
  • packing / storage (?)

Indicators come from various sources

Information available to plant

  • Refractory specification sheets
  • Previous refractory history of kiln
  • Shell scanner print-outs
  • Location of hotspots on kiln shell (welds, tyres, drive)
  • Shell ovality / alignment and permanent deformation data
  • Number / duration of kiln stops
  • Variations of kiln feed rate / chemical composition
  • Colour of clinker (reducing conditions)
  • Intensity of clinker burning (free lime)
  • Photos showing in-situ appearance of worn refractory
  • Appearance of vertical cross-section of refractory

Factors requiring laboratory tests

  • Chemical and mineralogical composition of worn refractory
  • Macro- and micro-texture of worn refractory
  • Micro-chemical analysis of worn refractory
  • Thermal conductivity

Data-sheet as indicator

Magkor-B-L-P

Magkor-B-L-P

Lining history as indicator

Lining history as indicator

Lining history as indicator

Location as indicator

Location as indicator

Location as indicator

Location as indicator1

 

Shell ovality / alignment as indicator

Shell ovality . alignment as indicator

Shell ovality . alignment as indicator

Shell ovality . alignment as indicator22

In-situ appearance as indicator

In-situ appearance as indicator

In-situ appearance as indicator

Vertical cross-section as indicator

Vertical cross-section as indicator

Vertical cross-section as indicator

Vertical cross-section as indicator22

Vertical cross-section as indicator22

 

Brick colour as indicator

Brick colour as indicator

Brick colour as indicator

 

best Regards

if you have any question Regarding Refractories

please contact us at : project20062015@gmail.com

 

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Posted in Cement Kiln Refractories, kiln refractories and lining, Maintenance Engineering.

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