What’s the reason for the refractory brick falling during the new build cement kiln drying?

What’s the reason for the refractory brick falling during the new build cement kiln drying?

Many cement companies have encountered the problem of newly-built refractory bricks falling during kiln drying: using professional maintenance teams, special tools, and high-quality refractory materials, but the newly-built refractory bricks are heating up near the end In the process, there was a brick falling accident. In severe cases, many refractory bricks were found to be severely twisted and tilted after entering the kiln. I had no choice but to recool the kiln and refill the bricks. This problem was the use of bulky and backward spirals in the past. Never appeared when screwing. Analysis of the reason: the bricks are not locked tightly, which is the main reason why the refractory bricks fall off. Judging from the situation on the spot, most of the reason for the falling bricks is this.

(1)Improper use of cement.

(2)The tightness of each ring of refractory bricks is not enough during masonry.

(3) The bricklaying machine has insufficient pressure.

(1) Improper use of cement. In the masonry process, it is necessary to use cement to bond the kiln bricks, and also to use the cement to level the kiln bricks. When the cement is not evenly applied, it will easily cause the type of refractory bricks to be out of balance, resulting in tilting of the brick surface and inconsistent tightness of the size of the bricks. . The impact of using cement is particularly prominent during construction in winter. Due to the lowering of the ambient temperature, the fluidity of the refractory cement becomes poor and there is a freezing phenomenon. When the entire ring is locked with a locking iron plate, the cement has already frozen, and the cement begins to rise during the heating process. Melt, the mortar in the brick joints is lost under the gravity extrusion of the refractory bricks, causing the annular brick joints to increase, and when the bricks are enlarged to a certain extent, the refractory bricks become loose and fall off, causing a brick dropping accident.

(2) The tightness of each ring of refractory bricks is not enough during masonry. When using a bricklaying machine to build, the method often adopted in order to catch up with the construction period is to not rush to lock the bricks in place at one time when the bricks of each ring are locked. On the bricklaying machine, use a sledgehammer to hit the top of the refractory bricks in the kiln from the end of the kiln to the head of the kiln. This method of masonry has a drawback: Because it is not locked initially, the refractory bricks will inevitably slide downward under the action of its own gravity, causing the bottom surface of the refractory bricks to not close to the inner wall of the kiln, and there is a void phenomenon. After the cavitation is formed, hitting the locking iron plate will only increase the tightness between the circular refractory bricks and the bricks, and will not change the voiding problem. When the kiln temperature rises to a certain level, the rotary kiln needs to be turned over intermittently. The voiding phenomenon has increased.

(3) The bricklaying machine has insufficient pressure. The working pressure of the bricklaying machine was insufficient to withstand the refractory bricks, and it was unable to make it close to the kiln shell, resulting in slight voids. During the construction process, it is necessary to ensure that the air supply pressure of the air compressor is between 0.55MPa and 0.65MPa, which is our weakness. During winter construction, due to the long compressed air pipeline connected to the bricklaying machine, the thickness of the connecting pipeline, the problem of the oil-water separator of the air compressor, the lack of frequent water discharge from the air storage tank, and the air leakage of the connecting pipeline will cause the bricklaying machine. If the air supply pressure is insufficient, the insufficient air supply pressure will lead to insufficient pressure on the top brick of the bricklaying machine, resulting in a void at the bottom of the refractory brick.

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