Brick Lining Installation-Golden Rules

Brick lining installation

Brick lining installation golden rules

JULY 2007 / Version 2

• These Golden Rules for Brick Lining should be guidelines for the personnel 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 of the Cement Portal’s Refractory Domain carefully. (connect to: http://webcementportal.lafarge.com)

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

Brick lining installation

Foreword

1 – Safety gear 2 – Safety equipment 3 – Reference lines are drawn axially & radially 4 – General rule: Lining patterns are staggered 5 – Mixed ratio is adjusted 6 – Mortar is used to correct deformed shell / welding 7 – Key bricks are not in one line 8 – 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

Brick lining installation

Content

Brick lining installation

Safety gear For all personnel Overalls Hard hat Safety shoes Gloves Safety glasses Dust mask Ear protections

Long sleeved

Polyester Non-skid Abrasion resistant

Remark: Follow the detailed safety procedures published on the Cement Portal’s Refractory domain: How to ensure safety for brick demolition & brick lining works How to ensure safety for brick cutting How to ensure safety for castable mixing

Face shield Apron

Heavy duty rubber apron

Brick lining installation

For cutting bricks

Polycarbonate Scratch resistant 1

Brick lining installation

Safety equipment Using a brick rig is the only safe kiln bricking method Equipped with compressed air reservoir (5l) + nonreturn valve Alarm if pressure < 4.5 bars

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

Compressed air hosepipes and couplings are in good condition

Brick lining installation

Inside the kiln, all electrical equipment used must be class II (double insulation) supplied by safety transformers situated outside the kiln

2

Brick lining installation

Reference lines are drawn axially & radially

Axial

2nd point 1st point

Base lines Parallel

Brick lining installation

Radial

Parallel

Welding

3

Brick lining installation

General rule: Lining patterns are staggered

Brick lining installation

Use a rubber hammer for brick installation

Ensure the kiln shell surface is clean and smooth 4

Brick lining installation

Mixing ratio is adjusted

Wrong Right

Wrong

Right

Brick lining installation

No brick upside down Check hot face marking

5

Brick lining installation

Mortar is used to correct deformed shell / welding Right

Brick lining installation

Wrong

6

Brick lining installation

Key bricks are not in one line

Right

Key bricks

Key bricks side to side

Brick lining installation

Wrong

Key bricks face to face 7

Brick lining installation

Shims are not installed close to key bricks Shim thickness = 2 mm max.

Maximum of 2 to 3 shims per ring

Shims

2 shims

Brick lining installation

Use shim driver

8

Brick lining installation

Rings are closed using hydraulic jack

Pressure to be applied = ½ brick cold crushing strength Typical CCS ranges are 50 to 70 N/mm2

Brick lining installation Example: ANKRAL-ZE Cold crushing strength = 70 N/mm2 Æ Pressure to be applied = 350 bars or 5000 PSI Conversion factor: 1 N/mm2 = 10 bars = 145 PSI 9

Brick lining installation

Bricks are cut with brick cutting machine

Minimum brick cutting length is respected. Dry cut for basic bricks

Do not cut in this direction

Mandatory direction of cut

Brick original length

Minimum cut

200 mm

140 mm

300 mm

200 mm

Brick lining installation

Minimum cut 2/3 of original length

10

Brick lining installation

Cut bricks are always in between full bricks Cut bricks Old bricks

It is recommended to have 300 mm long bricks

Full bricks

Brick lining installation

Cut bricks

Full bricks Retaining ring 11

Brick lining installation

Closing of the last ring is done properly Tight lining must be ensured for the last ring, too.

n Closure brick

Mortar, liquid enough

Y Piece of wood Hammer

Shims Instead of mortar, additional metal shims can be used

q

Brick lining installation

p

12

Brick lining installation

Cardboard spacers are placed adequately

To allow expansion Bricks type

Cardboard spacers

Magnesia

1 cardboard of 2 mm between each ring

Dolomite

1 cardboard of 1 mm between each ring

Alumina

No cardboard

Remark: These are general rules. Follow exactly the instructions given by the refractory suppliers. Never remove the cardboards from the original bricks!

Brick lining installation

Nosering

No cardboard spacers

Retaining ring

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. 13

Brick lining installation

Additional guidelines On deformed areas bricks should be laid with mortar Mortar

Don’t change the quality under the tires or the girth-gear

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

Brick lining installation

Notes

14

Brick lining installation

Notes

Brick lining installation

Notes

15

Brick lining installation

Direction des Performances Cimentières (DPC) 95, rue du Montmurier - BP 70 38291 St-Quentin-Fallavier Cedex - France Tel. + 33 4 74 82 16 16