Solution For Newly Laid Refractory Bricks Falling Off During Kiln Drying

Solution for newly laid refractory bricks falling off during kiln drying
Having been involved in the refractory brick industry for such a long time, I believe many cement companies have encountered the problem of newly laid refractory bricks falling off during the kiln drying process. Let's not talk about the negative impact of extreme cold and heat on the service life of refractory materials. From the perspective of problem-solving, it is extremely troublesome and the construction risk is very high. Therefore, we need to seek corresponding solutions.
Solution measures
1. Strengthen the maintenance and upkeep of equipment in daily life
In response to the insufficient working pressure of bricklaying machines, it is necessary to strengthen the maintenance and upkeep of the equipment on a regular basis. To ensure the effectiveness of the oil-water separator, it is necessary to frequently release water from the storage tank. During the construction process, it is important to ensure the normal operation of the air compressor and maintain the compressed air pressure within the range of 0.55MPa to 0.65MPa.
2. Notice on Locking Bricks
When locking bricks, it is necessary to make the bottom of the kiln bricks as close as possible to the inner wall of the kiln body. After locking one ring, the next ring can be built. After all the masonry is completed, the kiln should be rotated in stages and the locking iron plate should be added. When adding the locking iron plate, it should be tightened as much as possible below the centerline of the rotary kiln to ensure that there are locking iron plates at the four points of 90 °, 180 °, 270 °, and 360 ° around the kiln circumference. Two locking iron plates are not allowed in the same brick joint.
3. Solve the problem of twisted circumferential seams
Before masonry, a circumferential line should be placed every 2 meters inside the kiln barrel, and the circumferential line should be parallel to the circumferential weld seam of each section of the barrel. When laying refractory bricks at the bottom, construction must be carried out based on the axial and circular lines. Every 5 rings of the bottom must be inspected, and the distances between the circular joints and the circumferential lines must be measured to ensure consistency. The next few rings of bricks should be adjusted according to the distance deviation. It is not allowed to adjust them in one step, but should be adjusted gradually. At the same time, the circular joints must be controlled within 2mm, and the coincidence of the axis must be ensured during adjustment.
4. Avoid processing bricks
Try to avoid processing bricks as much as possible. If the length of the processed brick is less than 60% of the original brick length, the adjacent ring of standard bricks should be removed, and the standard bricks and small bricks of the processed brick should be staggered to eliminate the ring joints. When staggered, wet masonry must be used, and high-temperature mortar is more effective. If the length of the processed brick is less than 50% of the original brick length, an extended brick (brick length of 298mm) can be used for processing and masonry, which has a better effect. High temperature mortar wet masonry must also be used during masonry.
5. Taking into account the deformation of the kiln barrel and other factors
In the process of masonry, it is necessary to comprehensively consider the deformation of the kiln body and the irregular size of the bricks. It is neither strictly based on the proportion of bricks nor blindly built. In short, two principles must be mastered: the surface of refractory bricks should not have steps; The bottom surface of refractory bricks must be in full contact with the inner wall of the kiln barrel.