Brick Lining Installation

8/18/2019 Brick Lining Installation

1/34

B r i c k

l i n i n g i

n s t a l l a t i o n

JULY 2007 / Version 2

Brick lining installationgolden rules


2/34

B r i c k

l i n i n g i


Foreword

These Golden Rules for Brick Lining should be guidelines for thepersonnel in charge of kiln rebricking in the plants.

• This booklet contains the most important rules and should therefore be

handed out to all involved persons before starting the lining.• It deals only with the most common dry lining method, but other

methods (mainly mortar) are important in special cases.

• It is a good idea to discuss the content with the persons involved to

ensure it is fully understood.• As it only contains the most important rules and does not cover specific

situations, it cannot replace necessary training, especially for safety!

• Information given is not sufficient for the person responsible for

Refractory in the plant. He will need to study the related procedures ofthe Cement Portal’s Refractory Domain carefully.(connect to: http://webcementportal.lafarge.com)

We hope that this booklet will make your work more successful.


3/34

B r i c k

l i n i n g i


Content

1 –

Safety gear2 – Safety equipment

3 – Reference lines are drawn axially & radially

4 –

General rule: Lining patterns are staggered5 – Mixed ratio is adjusted

6 – Mortar is used to correct deformed shell / welding

7 –

Key bricks are not in one line8 – Shims are not installed close to key bricks

9 – Rings are closed using hydraulic jack

10 – Bricks are cut with a brick cutting machine

11 –

Cut bricks are always in between full bricks

12 – Closing of the last ring is done properly

13 – Cardboard spacers are placed adequately

14 –

Additional guidelines


4/34

B r i c k

l i n i n g i


Safety gear

Longsleeved

For all personnel

Overalls

Hard hatSafety shoesGlovesSafety glasses

Dust maskEar protections

Polyester

Non-skidAbrasion resistant

Remark: Follow the detailed safety procedures published on the Cement Portal’sRefractory domain:

How to ensure safety for brick demolition & brick lining worksHow to ensure safety for brick cutting

How to ensure safety for castable mixing


5/34

B r i c k

l i n i n g i


PolycarbonateScratch resistant

Heavy duty

rubber apron

For cutting bricksFace shield

Apron

1


6/34

B r i c k

l i n i n g i


Safety equipment

Equipped with compressedair reservoir (5l) + non-return valveAlarm if pressure < 4.5 bars

Using a brick rig is the only safe kilnbricking method

If you have to pass through the coating, asafe way is to use Tunnel cages


7/34

B r i c k

l i n i n g i


Inside the kiln, all electrical

equipment used must be class II(double insulation) supplied bysafety transformers situated outsidethe kiln

Compressed airhosepipes andcouplings

are in goodcondition

2


8/34

B r i c k

l i n i n g i


Axial

Reference lines are drawn axially &radially

2nd point

1st point


9/34

B r i c k

l i n i n g i


Radial

3

Base lines

Parallel

Welding

Parallel


10/34

B r i c k

l i n i n g i


General rule: Lining patterns are staggered


11/34

B r i c k

l i n i n g i


Use a rubberhammer for brickinstallation

Ensure the kiln shell surfaceis clean and smooth

4


12/34

B r i c k

l i n i n g i


Mixing ratio is adjusted

Right

Wrong


13/34

B r i c k

l i n i n g i


No brick upside downCheck hot face marking

5

Wrong Right


14/34

B r i c k

l i n i n g i


Mortar is used to correct deformed shell /welding

Right


15/34

B r i c k

l i n i n g

i n s t a l l a t i o n

Wrong

6


16/34

B r i c k

l i n i n g


Key bricks are not in one line

Right

Key bricks


17/34

B r i c k

l i n i n g


Key bricksface to face

Key bricks side to side

Wrong

7


18/34

B r i c k

l i n i n g


Shims are not installed close to key bricks

Shims

Maximum of 2 to 3 shims per ring

Shim thickness = 2 mm max.

2 shims


19/34

B r i c k

l i n i n g


Use shim driver

8


20/34

B r i c k

l i n i n g


Rings are closed using hydraulic jack

Pressure to be applied = ½ brick cold

crushing strengthTypical CCS ranges are 50 to 70 N/mm2


21/34

B r i c k

l i n i n g


Example: ANKRAL-ZECold crushing strength = 70 N/mm2

Pressure to be applied = 350 bars or 5000 PSI

9

Conversion factor:1 N/mm2 = 10 bars = 145 PSI


22/34

B r i c k

l i n i n g


Bricks are cut with brick cutting machine

Do not cutin this

direction

Mandatorydirection

of cut

Minimum brickcutting length is

respected.

Dry cut for basicbricks


23/34

B r i c k

l i n i n g

i n s t a l l a t i o

nMinimum cut

2/3 of original length

200 mm300 mm

140 mm200 mm

Minimum cutBrick originallength

10


24/34

B r i c k

l i n i n g


Cut bricks are always in between fullbricks

Cutbricks

Oldbricks

Full bricks

It is recommendedto have 300 mmlong bricks


25/34

B r i

c k

l i n i n g


nCut

bricks

Full bricks

Retaining ring

11


26/34

B r i

c k

l i n i n g


n

Closing of the last ring is done properly

Tight lining must be ensured for the last ring, too.

Hammer

Mortar, liquidenoughClosure brick

Piece of

wood


27/34

B r i

c k

l i n i n g


n

12

Instead of mortar, additional

metal shims can be used

Shims


28/34

B r i

c k

l i n i n g


n

Cardboard spacers are placed adequately

To allow expansion

No cardboardAlumina

1 cardboard of 1 mmbetween each ring

Dolomite

1 cardboard of 2 mmbetween each ring

Magnesia

Cardboard spacersBricks type Remark:

These are general rules.

Follow exactly theinstructions given by therefractory suppliers.

Never remove thecardboards from theoriginal bricks!


29/34

B r i

c k

l i n i n g


n

Nosering

No cardboard

spacers Retaining ring

13

Remark:For installation of the retaining ring, see details in the “How to install & line

a retaining ring” procedure in the Cement Portal’s Refractory domain.


30/34

B r i

c k

l i n i n g


n

Additional guidelines

Don’t change thequality under the tiresor the girth-gear

On deformed areasbricks should be laidwith mortar

Don’t hesitate to discuss with yourTC Refractory Expert if you have any doubt!

Mortar


31/34

B r i

c k

l i n i n g i n s t a l l a t i o

n

Notes

14


32/34

B r i

c k


n

Notes


33/34

B r i

c k


n

Notes

15


34/34

B r i

c k


n

Direction des Performances Cimentières (DPC)

95, rue du Montmurier - BP 7038291 St-Quentin-Fallavier Cedex - France

Tel. + 33 4 74 82 16 16

Brick Lining Installation

Documents

Transcript of Brick Lining Installation