New structure of refractory lining for large dry process cement kiln system

Abstract: In the late 1970s, with the emergence of new dry cement kilns, cement workers were promoted
The industry is developing in the direction of large-scale and modernization, and refractory materials are the "heart" of cement kiln system，The normal operation of the system plays a vital role, therefore, choose the appropriate refractory materials and construction technology, needle Continuous technical improvement of the existing problems in the use of refractory materials and the promotion of technological innovation are the guarantee
It is important to increase the operation rate of cement kiln system steadily, reduce the unit consumption of refractory materials and reduce the heat consumption of cement production system The way is also an effective way to help the cement industry to save energy and reduce consumption, high-quality and high-yield development. This article to domestic large
Dry process cement rotary kiln kiln mouth refractory system, kiln hood top hanging refractory, grate cooling machine new crane
The use of refractory materials and low wall wear-resistant prefabricated bricks and technology improvement are briefly described:

1. Rotary kiln mouth refractory system
Operating conditions and current status: kiln refractory materials include kiln castable and adjacent refractory bricks, kiln fire
The service life of the material has a crucial influence on the operation cycle of the entire cement production line. Kiln cylinder body and water.The flat line is inclined to 3.5% ~ 4%, and the cement clinker is discharged from the kiln to the grate cooler after passing through the cooling belt.There is no stable kiln skin, refractory materials in addition to withstand high temperatures above 1400℃, but also need to withstand emergency.The impact of hot air flow, the wear of clinker, the thrust of moving material and the axial stress of refractory brick in kiln are the mechanical effects.Force, thermal stress and chemical erosion damage, the use of conditions are very harsh, so the kiln refractory must.It has good mechanical strength, thermal shock resistance and wear resistance..Improvement plan: For some problems exposed in the use of kiln refractory materials, through analysis of damage
By adjusting the process formula and improving the refractory lining structure, CCB Technology has developed a high-performance kiln.Mouth refractory system:

① In order to adapt to the operating conditions of large cement kilns, extend their service life and reach the castable of the kiln
At the same time as the service life of the adjacent lining refractory brick, the castable of the kiln should be laid in the transition zone with the cooling belt during construction，3-5 ring and kiln castable synchronous life of refractory brick.

② Kiln castable block spacing construction: the traditional kiln construction method, due to the anchoring nail structure is not suitable，The castable of kiln can not withstand the thermal stress and burst due to the unreasonable maintenance of the expansion joint. After construction improvement，The template is required to be made in advance, and the inner plate, outer plate and upper cover plate are assembled and formed in a unified manner, between each two protection plates，Place 5mm ceramic fiber cotton to make through expansion joint. When pouring, the protective iron is taken as the unit, that is, the entire circumference，Divide into pieces, pour into the template from 8:30, pour one piece of guard at a time, vibrate at the same time,
And reserve a good vent, to be condensed, turn to the second pouring point between a block, so repeated, straight.To the end. The construction of block interval fully increases the cooling surface of castable condensation and reduces the condensation time of single castable.The volume, reduce the internal and external temperature difference, reduce the burst and fall off caused by thermal expansion.Through improvement, CCB developed high-performance kiln refractory system, without repair,The service life can reach 24 months, which has obvious advantages over similar products at home and abroad, and fully improves the cement production enterprises，The production efficiency and production efficiency.

2. Grate cooling machine a new type of hanging refractory material and low wall high strength wear-resistant prefabricated brick
Operating conditions and current situation: The ambient temperature of a section of the grate cooler can reach 1100℃, and the side wall and top refractory materials，The hot air scour seriously, often spalling, collapse and other phenomena. The low wall has been subjected to high temperature clinker particles for a long time，Brush, erosion, wear, and alternating contact with hot and cold air, the use cycle is short (6-10 months). tradition，The whole is made of amorphous castable, and high temperature resistant steel and wear-resistant materials are often added when used in this part，Materials and so on to improve its performance, in order to extend its service life, but due to site construction conditions, maintenance, baking and so on
Many aspects of the impact, can not fundamentally change this situation. And the grate cooler equipment needs to grate halfway
When the blind parts of the bed are repaired and replaced, even if the castable of the low wall is intact, the maintenance space must be cleared.This directly increases maintenance costs.Improvement plan: According to the thermal process characteristics of the new dry cement kiln cooler, CCB Technology has studied and studied，In practical application, the grate is cooled according to the characteristics that the low wall temperature of the grate cooler changes greatly and the particles are washed for a long time，Machine low wall castable to high-strength wear-resistant prefabricated brick (castable pre-cast into a certain size shape, with，After curing, baking and heat treatment in the production workshop, the prefabricated bricks that meet the requirements of the equipment are made. equalize，With a service life of more than 3 years, there is no need to stir and pour on site, and only need to assemble and combine to simplify installation.It can greatly shorten the construction period.The side wall and the top of the overall castable to be changed to hanging bricks + sealed self-flowing castable + calcium silicate board, hanging bricks to the best，Quality mullite as the main raw material, adding composite binder, after high temperature and high pressure forming, has good alkaline resistance,Anti-spalling and anti-erosion, combined with 310S material pendant, construction is very convenient, masonry speed is fast.The sealing self-flowing castable can greatly reduce the temperature of the shell and achieve the purpose of energy saving. Make the average service life up to 3，Over the years, fully improve the operation rate of the furnace. (High strength wear-resistant prefabricated brick + hanging brick masonry diagram attached)

3. Hanging refractory material at the top of kiln hood
Operating conditions and current situation: the kiln head cover is connected with the rotary kiln, the grate cooler, the tertiary air pipe and the burner，At the inlet of kiln air and secondary air, the wind pressure is unstable, the gas temperature fluctuates greatly and the clinker particles are washed strongly. meanwhile.With the increasing daily output of rotary kiln, the volume of kiln head cover is larger, and the traditional use of amorphous casting.Material construction, opening, mold, casting difficulty is also increasing, after pouring maintenance, baking is not convenient, very.It is difficult to bake in place, resulting in frequent bursts during kiln feeding or premature damage of refractory materials in the production process，Shut down for repair due to top burn-out.Improvement plan: CCB Technology according to years of technical experience and accumulation, optimized the design of a kiln head cover，Partially sintered hanging refractory: composite hanging member + hanging brick + sealing castable + calcium silicate board. mining，After using the hanging brick technology, it is not only convenient for construction and replacement, but also conducive to improving and guaranteeing the quality and application of refractory materials，Service life. The combined pendant is pressed by 310S material integrated machine, and the hanging hole is reserved under the pendant
The square is welded to the inside of the kiln head cover, and the hanging piece passes through the hanging hole and makes the hanging brick block and the groove tight to each other.The high temperature air flow through the hanging brick layer is effectively avoided. The hanging brick is made of high quality mullite as the main raw material and the composite junction is added，The mixture, after high temperature and high pressure forming, has good resistance to spalling and erosion. Poured with sealed artesian flow，Material and calcium silicate board, the overall tightness of the furnace top is strengthened, effectively avoiding the erosion of high temperature air flow, but also large，Greatly reduce the heat loss in the kiln, improve the heat insulation and energy saving effect and service life of the top of the kiln door cover.Conclusion: With the high-quality development of China's industry and the landing of the national 14th Five-Year Plan implementation plan, durable，Fire material industry is bound to meet the needs of industrial development and continuous innovation; At the same time, in the national "dual carbon" background，Higher requirements are put forward for the thermal insulation, energy saving and environmental protection functions of refractory materials. CCB Technology has gone through more than 30 years，We always adhere to the independent research and development route, and continue to explore the high-temperature industrial field through scientific and technological innovation and practice，New technology, new process, new demand, has developed a series of longevity, high efficiency, energy saving and consumption reduction of new refractories
Material lining structure, to meet all kinds of large cement enterprises continue to pursue to improve equipment operation rate, reduce production costs，Needs. In the future, the company will continue to work together with cement production and other high-temperature furnace enterprises to make common progress and promote，Comprehensive innovative high-quality development of refractory materials, to achieve green, low-carbon, environmental protection sustainable development, construction of the world，The world's first-class aluminum silica refractory comprehensive service system