Contents
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](https://www.cementequipment.org/wp-content/uploads/2016/08/Factors-influencing-kiln-refractories-Service-Life.jpg)
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](https://www.cementequipment.org/wp-content/uploads/2016/08/Magkor-B-L-P.png)
Lining history as indicator
![Lining history as indicator](https://www.cementequipment.org/wp-content/uploads/2016/08/Lining-history-as-indicator.png)
Location as indicator
![Location as indicator](https://www.cementequipment.org/wp-content/uploads/2016/08/Location-as-indicator.jpg)
Shell ovality / alignment as indicator
![Shell ovality . alignment as indicator](https://www.cementequipment.org/wp-content/uploads/2016/08/Shell-ovality-.-alignment-as-indicator.jpg)
In-situ appearance as indicator
![In-situ appearance as indicator](https://www.cementequipment.org/wp-content/uploads/2016/08/In-situ-appearance-as-indicator.jpg)
Vertical cross-section as indicator
![Vertical cross-section as indicator](https://www.cementequipment.org/wp-content/uploads/2016/08/Vertical-cross-section-as-indicator.jpg)
![Vertical cross-section as indicator22](https://www.cementequipment.org/wp-content/uploads/2016/08/Vertical-cross-section-as-indicator22.jpg)
Brick colour as indicator
![Brick colour as indicator](https://www.cementequipment.org/wp-content/uploads/2016/08/Brick-colour-as-indicator.jpg)
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