PRADEEP KUMAR
The coating is thin and washed away from the brick Surface. Around 9 meter area. High variation in chemistry when OPC clinker is switched over to Oil well cement or sulfate resistant Cement. The second reason is Formation of distorted flame which Eroded the coating and brick. With Petcoke firing the liquid becomes more Viscous and destruct the bricks.
SDCCL
The mag chrome got eroded due to high thermo-chemical load. Some how alumina bricks retain the coating and prolonged condition of this condition would have damaged the alumina bricks too.
Perilex-83
SDCCL
SDCCL
Perilex bricks at 11.5 m. Bricks undergone severe thermal and Thermo chemical srtesses due to variation in clinker Chemistry.Petcoke under reduced conditions further aggravate the situation.
groove formation due to shell deformation Or wrong installation of key bricks. Key bricks must be just fit in .Too much hammering can cause damage. Not more than two Shims must be inserted in a ring with a gap of 3 to 4 bricks.
SDCCL
Crack on the cold face shows that the brick was under severe mechanical stress too Shell distortion at 9 M causes mechanical stresses on the brick.
SDCCL
About 30 mm it has bulged inwards which is well beyond the toleralance limits. 9.0 m area. Maximum tolrence Limit is +/- 10 mm.
SDCCL
Melting pit
This happended during start-up , high percentage of liquid forms. The hot aggressive liquid (Lava) attacked the bricks , and washed the brick surface.
GCW
Bricks got soften and eroded due to high liquid formation during kiln start-up ( lava)
GCW
Bricks got softened and eroded. Very high Percentage of melt Formation( lava)
GCW
APCW
APCW
Even the spinel brick is Penetrated by liquid ,in burning Zone, 8 15 M. Calculated liquid % is 33 .
Refractory failure at 12 m After 4 months of operation. The spinel bricks underwent severe aggressive liquid attack.( 33 % liquid)
APCW
Hercynite based bricks are senstive to redox conditions. The white coloration is due to redox conditions prevailing In the kiln. Flame needs attention. Picture taken at 7 M area
APCW
Avoid reduced conditions. Shape the flame to get convergent and hot flame Optimize the momentum . Momentum with low % primary and high velocity is always better than Momentum with % primary air and low velocity.
Excessive liquid , > 33% causes liquid penetration deep into the bricks and destroy the texture of the brick , even the conventional spinel bricks. Reduced conditions make the coating very unstable. During coating dislodgement it took away part of the brick.
Remedies Optimise the liquid at around 30 -31 %. Use fused spinel bricks Like Almag AF and Ankral R2 Shape the flame to avoid reduced condition Dislodge the rhino horn by installing proper shock blasters.
Installation Errors
APCW
Installation error
The brick rings are not straight. Though We use pnemato-o-ring this error can occur. Human skill is also needed. This spinel bricks can undergo mechanical stresses and reduce the refractory life. The lining was opened and was corrected.
APCW
HCW At 11 M
After starting the kiln within two days hot spot appeared. This V-gap formed due errors in installation. The brick ring must be perpendicular to the axis.
HCW