Installation of refractory materials

Rainer Gocht
Installation of refractory materials in rotary kilns and corresponding aggregates
Requirements and loads on the refractory lining in rotary kilns
Refractory failures in rotary cement kilns

67%
Operation
17%
Quality

10%
Installation

3%
Fabrication

2%
Selection

1%
Design
10 20 30 40 50 60
Before the kiln stop

Before the kiln stop make sure, you have all the necessary information on hand:

• Safety regulations
• Kiln stop schedule
• Refractory lining history
• Material lists (warehouse, pending orders)
• Availability and condition of own and rented tools
• Contracts with Subcontractors

Preparatory meetings (production, maintenance, subcontractors…)

In case of any doubt, suppliers should be contacted

When the kiln has stopped

• Before starting any job: safety briefing

• Revision of the preheater

• Removing instable (stable) coating

• Measuring the remaining brick thickness

• Layout for the new lined sections

• Sufficient material on site?

• Removing the old refractory lining

• Good illumination for the working area

Measuring the remaining brick thickness
Removing the coating and the old refractory lining
Good illumination for the working area
The installation method must generally satisfy three requirements:

1. Safety for installation personnel. The installers have to comply with the
installation and safety instructions. This includes, besides a complete safety
gear, also global and local safety requirements.

2. Installation quality. The bricks must be installed in such a way that the lining fits
tightly against the kiln shell. This way a loosening or twisting during operation is
impossible.

3. Acceptable bricking progress. The bricking progress can be improved by using

modern installation devices (like the REFRA-Rig), fork-lifts, roller conveyors and
other equipment .
Safety – The most important issue
Installation in rotary kilns
Installation methods

• Methods, where the kiln has to be turned during installation

• Methods, where the kiln cannot be turned during installation

Methods, where the kiln has to be turned during installation

Advantages:

• Kiln can be rotated during the repair job.

• Bricking is always done in the most favorable position, i.e. in the

position between 7 and 8 o'clock, ensuring a good lining quality.

Disadvantages:

• More frequently rotated kilns do consequently require more frequent

reconstructions of access paths and electrical wiring.
Screw Jack Method
Screw Jack Method
Screw Jack Method
Advantages of this Method:
1. Low acquisition cost for supports and bricking equipment

2. Low safety risk

Disadvantage of this Method:

1. Linings of max. 5 r.m. in length can be installed only

2. Not suitable for rotary kiln diameters bigger than 4.40 m (5,80 m)

3. Bricking progress about 14 to 16 working hours per ton

4. Risk of damaging the kiln shell by applying too much pressure.

Aluminum – light weight screw jack
Technical details:

Max. compressive force: 68.000 N

Pipe diameter: 160 mm
Rough justification range: 600 mm
Fine tuning range: 120 mm
Weight approx.: 55-65 kg

Coarse adjustment with Spring compressive device

bolt setting with debit advice
U - Iron and Bolt Method
U - Iron and Bolt Method
U - Iron and Bolt Method
Advantages of this Method:
1. No constrictions in the kiln from scaffoldings, platforms or supports.
2. Minimum costs incurred for required equipment and materials.
3. High bricking progress, totally about 8 to 10 working hours per ton.
4. Modest safety risk when properly fixing and welding on the bolts.
5. Stretches of up to 20 m can be bricked at the same time

Disadvantages of this Method:

1. The nuts welded onto the kiln shell often remain in the kiln. As a result, the brickwork may
be destroyed in the event of any relative movement between brickwork and kiln shell
2. Keying of the bricks to be inserted into the brickwork from above is often not that properly
done, and thus some bricks may already be damaged during keying
Glueing method
 Glueing method
1. kiln rotation 2. kiln rotation

starting-
point

starting-point

3. kiln rotation 4. kiln rotation

starting-
point

starting-
point
Glueing method

Advantages of this Method:

1. There is always free access to the lining work, since no scaffoldings or platforms are required.
2. Two layers can be glued one upon the other (dam ring), too.
3. Low procurement costs for material.
4. High bricking progress, totally about 7 to 9 working hours per tonne.

Disadvantages of this Method:

1. If the kiln shell is not clean enough, there is a safety risk

2. Storability of the glue in hot countries max. 6 months.
3. No mortar correction possible in the glued section
Installation with Glue
Methods, where the kiln cannot be turned during installation

Advantages:

• Since the kiln is not rotated, it is required to lay access paths and
electrical wiring once only.

Disadvantages:

• The kiln cannot be rotated during the entire time of bricking.

• Complicated installation of bricks overhead.
• More difficult mortar installation
• Different radius at bottom and top as on both sides mean different mixing ratios
• When lining a complete kiln, the closing area is in the same position along the whole kiln.
Installation with „Pogo Sticks“
Installation with „Pogo Sticks“

Advantages of this Method:

1. Method is very reliable.

2. Bricking progress is totally about 8 to 12 working hours per ton of bricks.

3. Different brick heights can be installed at the same time.

Disadvantages of this Method:

1. If the “pogo stick” is getting older, the springs don’t have strength enough, to press
the brick well against the kiln shell.
Installation with „Pogo Sticks“
REFRA-Rig II
REFRA-Rig II

• Newly designed and modified bricking machine exclusively made by

REFRATECHNIK.
• Adjustable diameters from 3.5 – 6.5 m (MINI-RIG 1.8 – 3.4 m)
• Free adjustable twin wheels, additional supports on working platform
• Foldable side railings
• Mortar protection shields for switches
• Excellent price / performance ratio
REFRA-Rig II
REFRA-Rig II

Advantages of this Method:

1. Since it is wheel-mounted, the entire structure can easily be moved
in the kiln so that there is no need to reassemble the platform
again and again.

2. The method is very reliable.

3. High bricking progress, totally about 6 to 8 working hours per ton.

Disadvantage of this Method:

1. Higher investment costs for rig and transport and storage container
REFRA-Rig II
REFRA-Rig II
REFRA-Rig II
REFRA-Rig II (type 18/34)

MINI-Rig
Adjustable diameter 1.8 – 3.4 m
REFRA-Rig II (type 18/34)
REFRA-Rig II
Installation Tools I
Torch

Carpenters Pencil Flexible Straight Edge

Folding Rule

Spirit Level

Tape measure Plumb Line

Installation Tools II

Scutch Hammer

Rubber / Plastic Hammer

Jack-Hammer Shim Driver

Lump Hammer
Installation Tools III

Trowel
Scraper / Spatula

Welding Equipment

Twirling Stick
Mover

Power Drill
Installation Tools IV
Concrete Vibrator

Pneumatic Shim Driver

Installation Tools V

Diamond Disc Saw

Installation Tools VI

Force Cast Mixer

Installation Tools VII

Gunning Machines

high grade
MCG/LCG technology
water pressure
up to 90 bar

fast

improved
nozzle technology
Installation Tools VIII
NOT LIKE THIS!!!!
Different lining patterns for installing bricks in rotary kilns
Aligned lining
Staggered Lining
Interlocking or compound lining
1. Clench Lining method

Points to be observed

The a-side of the bricks must be completely in contact with the kiln shell and the
horizontal joint must point in the direction of the kiln axis.

The brickwork of the next ring often becomes stepped, particularly near welding
seams in the rotary kiln. To compensate for this, thin mortar joints may be applied
initially between the bricks and, in the case of larger welding seams, beneath the
bricks. In no case any steel strips should be used to compensate for this.

The clench lining should not be chosen for mechanically unstable kilns or in tyre
areas respectively with large ovality due to the low compensation for tension.
Different brick shapes

111 211 311 411 511 611 711 811 Key-

113 213 313 413 513 613 713 813 Bricks
115 215 315 415 515 615 715 815
118 216 316 416 516 616 716 816 BP XX
120 218 318 418 518 618 718 818
220 320 420 520 620 720 820 BP + XX
222 322 422 522 622 722 822
225 325 425 525 625 725 825
230 330 430 530 630 730 830
 H

L
Basic brick – VDZ shape

A
Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik
Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechni
Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik
Refratechnik Refratechnik Refratechnik Refratechnik Refratechnihni
Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik
Refratechnok Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik
Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik Refratechnik

Card board
spacer 2mm
Basic
B 622
220 mm

Diameter ~ 6,0 m
Brick height recommendation

Recommended brick thickness Kiln diameter

180 mm less than 3,6 m

200 mm 3,6 to 4,2 m
220 mm 4,2 to 5,2 m
250 mm more than 5,2 m
Mixing calculation

X (1st shape) = ______ pieces per ring

 D 
π ∗  d − Y b ∗  Y (2nd shape ) = ______ pieces per ring
 Y a 
X =
Xa
X b − ∗ Yb
Ya Xa = Dimension of a-side of Shape X
Xb = Dimension of b-side of Shape X
 D 
π ∗  d − X b ∗  Ya = Dimension of a-side of Shape Y
 Xa 
Y =
Yb −
Ya
∗ X
Yb = Dimension of b-side of Shape Y
b
Xa

D = Inside kiln diameter

d = Inside kiln diameter minus 2 x lining thickness
Checking the radial
direction of the brickwork

juntas horizontales

heavy abrasion
crack formation
premature wear
Combination of shapes (Bigger diameter)
Combination of shapes (Smaller diameter)
Wrong combination of shapes
Misalignement of rings
Correction with mortar
Correct lining
2. Installation with Mortar

Advantages compared with other methods

Refractory bricks installed with mortar from a virtually gas-tight monolithic unit.

Any mechanical loads are distributed more uniformly over the entire lining, so
that brick hot face spalling is rarer.

Differences in brick dimensions in the rotary kiln, particularly in respect of taper,

can readily be compensated for by means of mortar, so that it is easier to follow
the theoretical mixed lining ratio.
The following points must always be observed when
laying refractory bricks in rotary kilns with mortar:

The mortar must be mixed in accordance with the

manufacturer´s instructions, there being basically
three types of mortar available for rotary kilns:

A) High-alumina mortar our grade KX-R

B) Magnesia mortar our grade AG-R or PX-R

C) Fireclay mortar our grade CX-R

D) Insulation mortar our grade OX-R

3. Installation with Metal Shims

From our experience, the installation with metal shims has not proven satisfactory. The following
should be noted in case of an installation of bricks with metal shims:

Any irregularities in the kiln shell must be corrected by changing the mixed lining so
that the a-side of the bricks always lies firmly against the kiln shell and the horizontal
joints point in the direction of the kiln axis.

Mortar should be used to compensate for any irregularities at welding seams and
distorted kiln zones. Never place steel strips between the bricks for additional
compensation.
When closing the rings, ensure that the bricks here are inserted without metal shims,
to avoid by all means the insertion of two metal shims into one brick joint.
Expansion joints in Brickwork

High-alumina, alumina-rich and lightweight bricks

do not need any additional joints.

Different thermal expansion behaviour of magnesia bricks

must be compensated by the insertion of cardboard spacers.

Thermal expansion = 1.5 to 2 %.

10 m + 1.5 % thermal expansion = 10.15 m

Relining of a rotary kiln

1) Reference lines are drawn on the kiln shell near the vertical welding seams every
1.2 to 1.6 m.

2) If only some areas of the rotary kiln have to be repaired, the vertical welding
seam nearest the old brickwork is also taken as a reference line.

3) For placing the first layer a horizontal welding seam can be taken as a reference
line. The starting line is determined at the lowest point of the kiln.

The lowest point in the kiln is determined at the start of the section to be lined. The same is done
every 5 m and at the end of the section to be lined. These points are then connected by a line.
Reference lines

horizontal welding joints

of kiln shell

auxiliary line
parallel alignment
e.g. chalk line

parallel alignment

vertical welding joints

of kiln shell
Relining of a rotary kiln
Bottom reference line

Welding seam
Bottom reference line with level

Level with 70 to 80 cm
Bottom reference line with lead
Bottom reference line

Length shouldn’t be more than 5 meters

No reference point close to a welding seam

For each new installed section, a new bottom

reference line should be drawn.

The alignment of all reference lines should be

verified
Alignment verification of reference lines

0,60 m
0,30 m

0,80 m
1.00 m
0,40 m
0,50 m

Sentence of Pythagoras
Starting the Instalation
First rows
First rows
Alignment control – Radial reference lines

From the reference 6 rings

790 mm 1.200 mm
Alignment control – Radial reference lines

Reference
Lines
Torsion control during installation
Lining of the lower half (bed)
Expansion card board
Lining of the lower half (bed)
Keying of brick rings

Only original bricks should be used to close the rings.

If a number of keying bricks are used, they should be used
in alternation in each case with standard VDZ or ISO shapes.
Ensure that the horizontal joints of the bricks point exactly
parallel to the kiln axis in the closure zone.

The metal shims for keying the individual bricks should have a
thickness of not more than 2mm.
Never use more than one metal shim per joint.
Distribute the keying shims over the entire closure area.
Sharpening of metal shims makes insertion much easier.
Keying of a lining at the kiln outlet
 • Make sure that the a-side of the last
bricks are tightly pressed against the
kiln shell and that the horizontal joint
extends in the direction of and parallel
to the kiln axis

• Make the opening for the last brick in

such way that a standard VDZ or ISO
shape brick fits

false • The last brick must be installed duly

parallel to the adjacent bricks

• The ring is secured by knocking in

keying shims which should be
distributed over the entire closure zone
false
Keying (clench)
Keying of brick rings
Keying of brick rings
Keying of brick rings
Hydraulic Jack

?
The air pressure should be:

4 to 7 Bar

or

60 to 100 psi
Keying of brick rings
Keying of brick rings
Keying of brick rings
Keying of brick rings
Keying of brick rings
Keying of brick rings
Keying of brick rings
Keying of brick rings

6 mm ?

0 mm
Keying of brick rings

Metal strip
Keying of brick rings
Keying of brick rings
Keying of brick rings
Concentric stress cracks
Keying of brick rings
Installation of
the last brick
Installation of the last brick
What happened here?
welding seam higher
than 8 mm

to be cut on installation Laying bricks over welding seams

to be filled with mortar
welding seam higher
than 8 mm The following should be noted:

to be cut on installation • In case of welding seams

to be filled with mortar projecting more than 8 mm
welding seam from the shell, the brick there
max. 8 mm above should be cut out.

• In the case of welding seams below

8 mm, the bricks are backed with
mortar so that the rings at the welding
to be filled with mortar
welding seam seams can also be installed parallel to
max. 8 mm the other brick rings.

• Bricks being installed by the glueing

method have to be cut out above the
to be filled with mortar welding seams.
Laying bricks over welding seams

Max. 8mm mortar

Max. 8 mm mortar
Welding seam
Laying bricks over welding seams
Badly deformed kiln shell
Deformed kiln shell
Installation of Refractory Bricks over distorted kiln Shell

The following details should be noted:

1) The a-side must fit tightly against the kiln shell.

2) Horizontal joints exactly in the direction of and
parallel to kiln axis.

3) Over distorted kiln shell with mortar lining.

4) Compensate any irregularities with mortar

5) Leave the deformed part open and put finally the bricks
over the distorted area.
Adjustment for distorted
kiln shell (radial)
 filled with mortar
max. 8 mm

Adjustment for distorted

kiln shell (axial)

filled with mortar

max. 8 mm
Adjustment over distorted
kiln shell (axial)
Installation over deformed kiln shell
Bulged kiln shell
Bad installation of bricks
Collapsing of brick lining
Installation of the last ring between new and old lining
Installation of the last ring between new and old lining

Problems occur when joining the new to the old lining. The distance is often
somewhat larger than a standard VDZ or ISO shape brick. In such cases two bricks
always have to be cut.

To solve this problem, Refratechnik produces B- and ISO- shapes in a length of 300 mm.

e.g. for B shapes B 220 L e.g. for ISO shapes 222 L

B 320 L 322 L
B 420 L 422 L
B 620 L 622 L
B 820 L P 22 L
BP 20 L P +22 L
BP +20 L
Installation of the last ring between new and old lining
Two layer lining
Two layer lining
Kiln outlet with grate or rotary coolers

Lining with refractory bricks

A) The brick quality to be used here must have a very high abrasion
resistance, a good thermal shock resistance and a good hot
strength to be able to withstand the abrasion in the kiln outlet.

B) All the nose ring bricks must be made from standard ISO or VDZ
shapes, since specially manufactured shaped bricks do not have
the required cold crushing strength, because of the complicated
production technique for shaped bricks.
Outlet designs for a rotary kiln with brick lining
Outlet designs for a rotary kiln with brick lining
Lining with refractory castable
A) Quality of castable:
This should be a material with an extremely high cold
crushing strength and a good thermal shock resistance.
B) Anchoring:
To anchor these castable ultra-high refractory steel should be
used, minimum thickness 10 to 12 mm.

C) Drying and heating-up:

To ensure a drying and heating-up of the castable without any
problems, care must be taken during installation to provide
vapour venting holes and working joints.

D) When lining the kiln outlet with castable

it must be ensured that the retaining ring is located at the
beginning of the area being lined with castable.
Castable nose ring
Kiln outlet design with castable lining
Welding of the anchors

It must be ensured that special

welding electrodes,
required for the Cr-Ni steels, are used
Nose-ring of a grate cooler kiln
Kiln outlet with planetary or satellite coolers

The area around the satellite cooler inlets can be lined as follows:

1) Completely with a castable

2) With special shaped bricks and castable

3) With cast steel rings and castable

Kiln outlet with planetary or satellite coolers
Castable

A) High abrasion resistance required.

B) Highly refractory anchors required. Preferably movable anchors.

C) Ideal dimension 20 x 40 cm, maximum dimension 40 x 60 cm.

D) Ensure that drying of the material during the heating-up process

is facilitated by sufficient vapour venting holes (approx. 100/m²).

E) The zone where the castable is to be installed should be

secured by a retaining ring against the pressure of the brickwork
in the direction of the kiln outlet.
Outlet section for a rotary kiln with satellite cooler (castable version)
Outlet section for a rotary kiln with satellite cooler (castable version)

REFRAMULLITE 63 LCC AR
Kiln outlet with planetary or satellite coolers

Special shape bricks and castable

1. The high-alumina bricks around the planetary cooler inlets must

be highly abrasion-resistant (SiC containing bricks).

2. The bricks have a have a teeth on the back to ensure good

connection between the brick and the castable.

3. The castable to be used must be anchored appropriate and

must also have a good abrasion resistance.
Outlet section for rotary kiln with planetary cooler (castable - brick version)
Outlet section for rotary kiln with planetary cooler
Refractory lining for a satellite cooler
Refractory lining for a satellite cooler
Refractory lining for a satellite cooler

Lifter section
Retaining rings

sense of material
Retaining ring construction

Avoid any welding on the thrust face of the retaining ring to ensure that the brick fully fits
against the retaining ring.
Welding has to be done on the inner side of the ring, i.e. opposite the thrust face.
If welding on the thrust face cannot be avoided, the welding seam has to be ground afterwards.
Retaining rings

sense of material

detail

50 mm
weldings
50 mm
Retaining rings
Retaining rings

Castables over the retaining ring are particularly advantageous in areas in which the rotary
kiln has already undergone considerable deformation.

1) The castable to be used here should have a good strength and a good resistance against
infiltration.

2) Anchoring should be carried out with flexible anchors.

3) The individual sections should be 80 cm maximum in length and 40 – 50 cm in width. The

segments should be separated from each other by working joints.
Dam Rings

Dam rings are installed in the outlet zone of rotary kilns with planetary coolers in order to
render the load on the individual tube coolers uniform. Two types are distinguished:

Type 1: A single-layer dam ring with maximum height 300 mm.

Type 2: A double-layer dam ring in rotary cement kilns up to a maximum height of

500 mm or a three-layer lining dam ring for lime kilns up to a height of 900 mm.
Type 1: A single-layer dam ring, maximum height 300 mm.

300 mm Dam Rings

Type 2: A double-layer dam ring, maximum height of 500 mm.

200 mm

300 mm
Type 1: The length of the dam ring varies individually and ranges from 1 to 5 m.

Advantages of this dam ring design:

1) Stock-keeping is simplified since only a few ISO shapes are necessary.

2) The uniform brick thickness of 300 mm results in the radiation temperature on the kiln shell
being rendered uniform.

3) It is not possible for rings to drop out of the second layer.

Type 2: Double-layer dam ring

1) The individual steps should not differ by more than 50 mm.

2) The lower layer should be well interlocked to the upper layer

3) To obtain a good interlocking of the layers a large number of ISO and VDZ
shapes are available.
Cam Lining

A cam lining is build by using different brick thicknesses in one ring. The intention is to mix
the kiln feed or clinker in order to achieve a better heat exchange not only when heating
up the raw material but also when cooling down the clinker.

A cam lining is used

1) In the area of the kiln inlet

2) In the area of the kiln outlet

3) In planetary cooler tubes

2 step cam lining for a rotary kiln

625 / 325
620 / 320
3 step cam lining for a rotary kiln

630 325

622 / 322
1) Kiln inlet:
A cam lining in the kiln inlet zone mainly consists of lightweight firebricks. A tumbling
effect is produced by the cam lining and does not result in increased dust evolution as
it is the case for example, when lifters are used.

2) Kiln outlet:
A cam lining in the kiln outlet zone requires highly abrasion-resistant bricks. An
intermediate stage between the lowest and highest stage provide a longer lifetime of
the bricks.

3) Planetary cooler tubes:

To achieve uniform wear of the entire brickwork in a tube cooler the cams are made
from highly abrasion-resistant high-alumina grades.
3 step cam lining for planetary cooler tubes

Kronal 50 AR
3K211
Kronal 63 AR
218

Kronal 63 AR
3K215
3 step cam lining for planetary cooler tubes
Lining of a cone section

Installation is carried out as follows:

1. The last ring in the cylindrical part of the rotary kiln - zone with smaller diameter - is cut to size.

2. The 1st brick in the cylindrical part of the rotary kiln - zone with larger diameter - is also cut to
size according to the cone angle.

3. The cone section itself is lined with mortar as mixed lining.

4. Closing of the individual rings in the cone is to be made starting from the smaller to the larger
diameter.
Installation of cone with standard bricks (VDZ or ISO)

corretion of Detail X Detail A Detail B

mortar joints
Example for a
joint calculation
Inlet chute and inlet cone

The inlet chute and the cone are lined with castable.

Note the following:

1) Adequate anchoring

2) Appropriate working joints

3) Vapour venting holes for drying of castable without any difficulty

Distance between inlet chute and kiln inlet cone
Kiln inlet cone
Burner lance
Burner lance
Burner lance
REFRACORUND 95 ED lining of the burner lance tip
Burner lance (Drying out)
Drawings – how to read and understand them
Drawings
 4
Drawings
5. Thickness of individual layers 2
6. Important additional information
6
1
3

5
1. Item numbers for different shapes and qualities
2. Mixing ratio in the cylindrical part
3. Distance between support flanges
4. Informations about „dificult sections“
Drawings – part list
General instructions for refractory installations in thermally loaded static units

The static units in a cement clinker production line can be lined either with bricks, castables or with
precast blocks.

All lining methods have advantages and disadvantages.

As a standard, bricks in the static parts of the plant are laid with mortar.

All known application types, such as ramming, casting, gunning, jet-casting or pumping, can be
chosen for a castable linings.
Refractory lining of a straight wall
with prefabricated blocks,
bricks and monolithics
Brick lining

Correct mixing of mortar

Brick lining

Mortar over the complete

surface of the joint !!!
Brick lining

All straight walls lined with standard bricks are anchored by 6 anchors per m²

FE4, FE5, FE6 and FE7

FE9, FE10, FE11 and FE12

Brick lining

Correct placement of
anchor and anchor bricks
in straight walls.
Brick lining

For all cylindrical parts where rings or arches can be formed no

metallic anchoring is required.
 Design of
expansion joints

Appropriate expansion joints: Up to a wall length of about 2 m the expansion joints are
only placed at the corners.
Expansion joint
and supporting
flange
Brick lining

Correct mixing ratio of

bricks in conical /
cylindrical parts.
Inlet chamber
Inlet chamber
Inlet chamber
Castable lining

Helpful: Reference lines with the layout before welding the anchors
Castable lining

Quality, distance, correct welding plastic caps for the expansion

Castable lining
Correct size of the panels and expansion joint distribution
Castable lining
Installation of insulation, f.e. calcium silicate boards with impregnated surface
Castable lining
NOT LIKE THIS!!!!
Castable lining
NOT LIKE THIS!!!!
Castable lining

Correct type and fixing of the framework

Castable lining

Correct consistency of castable

too dry consistency optimal consistency too wet consistency

Castable lining

Too much water

Too much vibrating

Bad type of framework

 A general lining
recommendation!!!

Is this possible???
 Kiln zone distribution
Inlet

Safety zone
(Central) Burning zone
or
(Sintering zone)

Outlet
Preheating zone
or
(Calcining zone)
Upper
transition
Lower zone
transition
zone
Outlet zone

Kiln type Length

All kilns with planetary cooler 1 - 1,5 x Ø

All kilns with grate or rotary cooler up to two rings on uphill side of retaining ring

Normal conditions: Severe conditions:

KRONEX® 85 KRONAL® 63/60 AR

KRONEX® 87 ALMAG® 85/AF/ES/CF
Lower transition zone

Kiln type Length

All kilns 1-2xØ

Normal conditions: Severe conditions:

TOPMAG® AF/CF ALMAG® 85/AF/ES/CF

REFRAMAG® AF/CF MAGNUM® E
ALMAG® A1
Central burning zone (sintering zone)

Kiln type Length

Precalciner Kiln with grate cooler 6-8xØ

Preheater kilns with planetary cooler 4xØ

All other kilns 3xØ

Normal conditions: Severe conditions:

PERILEX® 80/83/CF ALMAG® 85/AF/ES/CF

REFRAMAG® AF/CF TOPMAG® AF/A1/CF
Upper transition zone

Kiln type Length

Precalciner Kiln with grate cooler 3-4xØ

Dry process kilns

3xØ
Preheater kilns > 4,0 m Ø

All other kilns 2-3xØ

Normal conditions: Severe conditions:

PERILEX® 80/83/CF TOPMAG® A1/CF

REFRAMAG® AF/CF ALMAG® AF/A1/ES/CF
TOPMAG® AF/CF
Safety zone

Kiln type Length

All kilns 2xØ

Normal conditions: Severe conditions:

KRONEX® 50 KRONAL® 50/60 AR

KRONEX® 60 PERILEX® CF
Preheating zone (calzining zone)

Kiln type Length

Lepol kilns 2-3xØ

Wet process kilns (long dry) Between safety and chain zone

All other kilns Between safety and 1 m from kiln inlet

Normal conditions: Severe conditions:

REFRATHERM® 150 KRONAL® 50/60 AR

KRONEX® 20/30/40 KRONEX® 30

Ringformation: KRONAL® 63 AR
Chain zone

Kiln type Length

Wet process kilns 4-8xØ

Dry process kilns (4 - 8 x Ø)

All other kilns -

Normal conditions: Severe conditions:

KRONEX® 30/40 KRONEX® 30/40

(REFRACLAY® 40) (REFRACLAY® 40 LCC (AR))
Inlet zone

Kiln type Length

All kilns Approx. 1 m

Normal conditions: Severe conditions:

KRONEX® 30/40 KRONEX® 30

(REFRACLAY® 40 LCC) KRONAL® 60 AR
(REFRACLAY® 40 LCC/ZAR)
(REFRA-SiC® 50 AR)
Excellent customer ?!?!?!