A quarterly by Cement Refractory BU of Dalmia-OCL November 2019, 5th Issue For private circulation only

The Science
of Brick
Installation

2
page

Find out how critical

refractory installation is to
refractory performance

Inspection

4
page
Report
When refractory makers
become diagnosticians

Our Technology (TG) team regularly encounters several customer queries regarding Basic bricks and its appropriate usage in cement
kilns. We’ve shortlisted some of the most fundamental and common questions, and TG has happily volunteered to answer them.
Here goes…
1. High Alumina bricks are a time tested op- 3W/mK in comparison to an Alumina In general, Basic bricks offer better re- 2. Where does Dalmia-OCL manufacture
tion for cement kilns. What great advan- lining which has thermal conductivity of fractory life under higher thermal load these bricks in India? Where does the raw
tage do Basic bricks offer over Alumina? around 2W/mK. and continuous operation of the kiln material come from?
compared to Alumina bricks.
There are a few very significant advan- Burner flame temperatures at the tip Dalmia-OCL manufactures Basic bricks
tages Basic bricks offer over High Alumi- vary from 2000 °C to 2200 °C depend- In bigger kilns with more than 6000 at its Rajgangpur plant.
na. Foremost of which is criticality. For ing on the type of fuel being used. If for TPD, Basic bricks have proved they offer
instance, if thermal load is greater than some reason the burner flame hits the a more economical lining option since Magnesia used in Basic bricks comes
5.5 GCal/m2 and the kiln is being fired refractory lining, an Alumina lining is un- they eliminate unforeseen shutdowns. from both natural and synthetic sourc-
with high quantities of pet coke or some able to dissipate heat and will melt un- es. Natural Magnesis is extracted from
alternative fuel, it is so much safer to use der high temperature. On the other hand, It is important to note however though mines in the form of Magnesia Carbon-
a Basic brick lining to avoid unforeseen a Basic brick lining will not only with- that Basic bricks promise good refracto- ate containing ~90% MgO, ~8% Fe2O3,
stoppages. This is because while good stand the higher temperatures when ry performance only under continuous ~2% CaO and ~1% SiO2. Due to presence
quality Alumina bricks can withstand up exposed to flame, it will also pass on operation. In operations intermittent of Magnesia Ferrite, bricks made from
to 1600 °C, good quality Basic bricks can the excess heat at a faster rate towards in nature, Basic bricks will deteriorate natural Magnesia exhibit comparatively
withstand up to 1750 °C. A lining made the kiln shell. Consequently, chances of a faster than Alumina bricks due to their lower refractoriness and higher vulnera-
up of Basic bricks will also offer high- flame related failure are much less with higher expansion and contraction at ev- bility towards redox reactions.
er thermal conductivity: in the range of Basic linings. ery startup and shutdown. Continued on last page...
 Part 3: Ring Closure Part 4: Special Scenarios
Care is to be taken to close every ring correctly. Here are a few things to watch out for: Specific Lining Situations
Always a challenge for bricklayers, level out deformed shells with mortar or
1. Tighten bricks with a hydraulic jack. 4. Staggered position of key bricks and
castable. If necessary, cut bricks to fit best onto the kiln shell.
Maximum jack pressure shouldn’t ex- key shims: do not use more than 2-3
ceed 35-40 N/mm2 (~1/2 brick cold shims per ring. Recommended thick-
crushing strength). During jacking, ness is 2 mm. Use a pneumatic shim
a rubber hammer should be used to driver if available. Without a shim
knock bricks into place. driver, 3 mm thick shims are accept-
able. Phased (bevelled) shims greatly
facilitate driving-in. Drive-in no more
than one shim per joint.
Max. 8mm
Motar joint Filled with Max. 8mm Motar joint Filled with
CORRECT max. 1-1, 5 mm mortar max. 1-1, 5 mm mortar

All of us who understand refractories a delta-shaped gap tends to form be- Key bricks
are well aware of the fact that there are tween the shell and brick’s cold face. Part 2: Bricking Procedure
just three factors that determine refrac-
tory performance: Or take the case of expansion gaps:
bricks do expand in hot condition and Marking the axial line and radial lines 2. Combine standard shapes and key
1. Refractory selection, as such, some gap is usually provided. bricks to obtain a straight joint of 4-6 Filled
• Fixing the axial and radial lines mm thickness. Never cut standard or INCORRECT Max. 8mm with mortar Max. 8mm Filled
2. Refractory operating conditions, and If this “gap” is less than ideal, it leads to with mortar
by (a) level & plumb bob or (b) by key shapes parallel to radial joint to fit
3. Refractory application (or installa- one set of problems. If more, it leads to laser goniometer (level) Not recommended: To fill V-shaped joints with mortar or castable. Crushing
tion) another set of problems. the gap!
• Take care that the centre (axial) strength of thin layers of mortar and castables is much lower than strength
line is perfect (90° angle to brick Key bricks of bricks.
While it is listed at number 3 above, in- Through this centrespread, The Refrac- lining must be guaranteed) Motar
Axial
stallation is perhaps the most import- tory Beat aims to summarise common joints
Brick laying
ant in terms of implications - be it costs, installation errors and mistakes and of-
effort or lost time. It is not uncommon fer practical solutions to address them. • Start rings according to the indi-
to come across cases where an average E.g. how to determine if shell uneven- cated mixing ratio
refractory installed properly has out- ness can be managed during instal- • Knock the bricks in place with a 5. After releasing the bricking rig (or
performed a good refractory, installed lation, or the only option available is rubber hammer screw jacks), rings must remain in con-
Do not
improperly. grinding. • Check regularly if rings are paral- complete tact with kiln shell.
lel to radial lines or not sections longer 3. Inserting the last brick: In case the Welding seam
than 6-8 This may happen with a bad installation
A lot is going on inside the kiln when Before moving ahead, it’s pertinent to • Always check that cold face of the meters brick combination is perfect without
Leather Handling of welding seams
it is in operation. Kiln brick lining for note that the biggest difference be- brick is in full contact with kiln or rubber an open joint, never use the hammer
hammer Never prepare bricks by chipping with hammer – if necessary use a brick saw.
instance rotates continuously and each tween installation-related refractory shell to knock the brick into place.
ring of bricks rotates independent of failures and others (quality-related or • A staggered lining pattern is rec-
its adjacent rings, therefore any brick operating/mechanical condition relat- ommended since overlapping of
which has been installed even with a ed failures) is that installation-related adjacent bricks allows for relative Working
direction is
slight tilt is likely to come off during failures take place almost immediately movement of individual rings always uphill
without edging Bad shimming Filled with Kiln shell Filled with Max. 8mm
rotation. after starting the kiln. There are a few motar motar
exceptions such as the collapse of Alu- RECOMMENDED NOT NOT
There are many welding joints inside mina rings applied adjacent to Basic RECOMMENDED RECOMMENDED
the kiln which can cause the shell sur- bricks (check out the failure investiga-
face to become uneven in some plac- tion report on page 4 for details). Such
es. Application in such areas is usually failures are not immediate and occur Avoid V- or V-shaped joints: Brickwork To be cut on Kiln shell To be cut on Max. 8mm
imperfect. With the bricks not cleanly over a period of time, especially com- will always be loose, even after shimming installation installation

seated or rested on the shell surface, mon when the kiln is run intermittently. Bad installation Connecting new line to old
Radial
joints
Straight Compound lining After breaking out the bricks, the
lining pattern pattern Key brick
old lining remaining in the kiln
Part 1: Lining Methods CORRECT INCORRECT INCORRECT
open joints has to be fixed by angle irons
welded onto the kiln shell. Re-
move concretions on axial joint
Key brick
of old lining (see arrow) by grind-
Steps Steps ing tools, not by a hammer.

Shell Shell

Brickwork turning Brickwork turning Part 5: Installation Report

too fast too slow

A professional application or installation assignment must be concluded with documenting a variety of information ranging from basic data (such as start and finish of works,
rings and brick grades installed, position of brick grades, lining method employed etc.) to deviations between theoretical vs. actual mixing ratios per ring and number of key
shims per ring. A final inspection must follow to observe and record any deformed kiln sections or cut sections, complete with photos. Recording information from pallet labels
Screw jack such as brick quantities, brick qualities, date of production, ASO etc. in the installation report can be of special help in cases where product quality is the potential cause of
refractory failure.

To conclude, we hope as a reader of The Refractory Beat, you found this article informative, educative and personally fulfilling. If you have any questions related to the process
of installation, feel free to email us at [email protected]. Happy refractoring in the meantime!

ISO vs. VDZ The Shape of Brick

4mtr 22
Suitable for kiln having
diameter of 4mtr
Lining thickness 220mm
We’ve already stated that refractory selec- about the height of the brick or its lining What’s 422 in ISO, is B422 in VDZ. The The thumb rule for lining thickness is as
tion is a major determinant of refractory thickness. 22 in 422 and 20 in 320 there- similarities end there, as the two shapes, follows:
performance. We must therefore know fore imply a lining thickness of 220 mm despite meant for the same kiln, with the • Kilns of up to 3 m dia – 160 mm
which shape of brick is to be chosen. There and 200 mm respectively. same lining thickness, are actually differ- • Kilns between 3 m and 3.6 m in dia –
are just two types actually: ISO or VDZ. ent in size. ISO bricks are bigger than VDZ 180 mm
Generally, Basic bricks always come in VDZ VDZ bricks have a similar nomenclature bricks. And it’s all because of how the two • Kilns between 3.6 m and 4.2 m in dia –
shape and Alumina bricks in ISO. For lar- with just one difference. The letter “B” is standards differ from each other. Here’s a 200 mm
DAT Bricking Rig ger kilns however, 5.2 m or more in diam- written before the numeric description. quick comparison between the two: • Kilns between 4.2 m and 5.2 m in dia –
This is one of the safest brick lin- eter, Basic bricks may also be available in A - Outside Chord 220 mm
ing methods, which is so flexible it ISO shape. So what determines the shape B - Inside Chord Application • Kilns above 5.2 m in dia – 250 mm
can be used in kilns of different di- of these bricks? And why are Basic bricks H - Brick Height (Lining Thickness) Kiln bricks are generally laid as pairs i.e.
ameters with the added advantage mostly VDZ. Let’s find out. L - Brick Length two different sizes with different tapers but Why are Basic bricks mainly VDZ and Alum-
that it requires no turning of the HOT FACE - Flame Side same height like 322 & 622 or 425 & 825. ina bricks mainly ISO?
kiln. ISO stands for International Standard COLD FACE - Kiln Shell Side COLD FACE This is done to get stability in the ring and VDZ bricks, being smaller in size result in
Organisation. VDZ on the other hand is a also to meet a wide range of kiln diameters. a larger number of joints in the ring. Since
A
Screw Jack standard followed by German Association One brick is of a diameter higher than that Basic bricks expand by about 1% in hot
Ideal for patchwork, lining up of Cement Producers (Verein Deutsche of kiln, while the other is lower. E.g. condition, a smaller size helps in ensuring a
small kilns (< 4 m diameter) and Zementwerke). Under ISO, bricks are de- larger number of joints in order to provide
short sections (< 4 m running), the scribed as 422, 320 etc. The first digit indi- HOT FACE Theoretically, a 4 m kiln with 220 mm more flexibility to the ring. Alumina bricks
Screw Jack method allows for rap- cates that the brick has been made for a H lining thickness can be lined up with 422 do not expand or contract much with
id setup which employs low-cost kiln with a diameter of 4 m. What it means L bricks. In reality however, it will be lined change in temperatures however. For kilns
equipment and has low mainte- is that the ring formed using these bricks up with 622:322 bricks as the difference over 5.2 m in diameter, since the number of
nance costs to boot. will have an outer diameter of 4 m. The in wedges will provide better fitment and joints will in any case be high, even Basic
DAT bricking rig second and third digits together tell you B consequently greater ring stability. bricks in ISO shape can be used.
...continued from first page

To ensure high quality that offers bet- is “specific consumption”, which means Total length of these four areas is about Stresses in upper transition zone come
ter performance, life and consistency, how much refractory is consumed for eight times the kiln diameter from out- from thermal shocks due to rapidly
Dalmia-OCL improves refractoriness of production of One MT of cement clinker. let. In a kiln with a diameter of 5 m for changing coating conditions, thermo-
Basic bricks it produces by loweing im- Generally it ranges between 200 g to example, Basic bricks would be ideal for chemical attack from alkali, sulphur and
purity levels in Magnesia. The technol- 400 g. only up to 40 m from the outlet and dif- clinker melt infiltration. This is also the
ogy combines synthetic Magnesia with ferent qualities can be chosen depend- area where the second tyre is located
higher primary crystal size along with Life of refractory must never be mea- ing on types of attacks in different areas. causing mechanical loads due to ovality.
fused Spinel or modifier with Zirconia sured only in terms of number of days Excellent thermo-mechanical and ther-
additives in its proven Magnel 85 bricks. from installation. Refractory is a con- In outlet and lower transition zone, the mo-chemical properties of Magnel 85
sumable and its consumption is directly main stresses can be attributed to lining bricks make them ideal for this area.
To ensure flexibility and thermal shock related to clinker production. It is also thrust on retainer, abrasion from cement
resistance, Basic bricks manufactured by related to number of starts and stops clinker, thermal load due to burner flame Dalmia-OCL spoils cement makers for
Dalmia-OCL contain 12%-15% of Alumi- in the kiln. Refractory is damaged every and thermal shock. Dalmia-OCL’s Magnel choice with multiple and unique combi-
na Magnesia Spinel. Magnesia content time kiln is started or stopped. Maxi- 85 has been developed with high abra- nations of synthetic or natural Magnesia,
in its Magnesia Spinel bricks varies from mum life is obtained only under contin- sion resistance and high thermal shock fused Spinel, Zirconia additives to match
80% to 92% and Al2O3 is in the range of uous operation. resistance, making it therefore suitable different types of loads in different parts
8%-15%. Fe2O3 is always kept under 1%. for these areas. of the kiln for the most optimal solution.
CaO and SiO2 are in the ratio of 2:1 in 4. Can an entire kiln be lined up with Basic
the end-product to ensure that these are bricks? Or are these bricks suitable for In the central burning zone, bricks are 5. Has Dalmia-OCL commissioned its Basic
in the form of Di-Calcium Silicate which specific areas only? If so, what are the spe- mostly covered under a stable coating. bricks in Indian cement kilns? What kind of
has high refractoriness. Dalmia-OCL cific uses? Here the bricks need to have adequate performance have these bricks achieved?
avoids keeping any element in the brick capability to retain coating or in other
which may result in formation of low Basic bricks are recommended only for words be sufficiently coating-friendly. Magnel 85, star of Dalmia-OCL’s Basic
melting secondary compounds which the most critical areas of the kiln such as Magnel 80 NC bricks with their high iron brick portfolio is doing duty in multiple
reduce the strength of bricks at clinkeri- the outlet, lower transition zone, central content for higher coating-friendliness kilns across India, details of a few are
sation temperatures. burning zone and upper transition zone. are therefore ideal for this zone. given below:

For production of Magnesia Spinel

bricks, a mixture of pre-synthesized PLANT NAME DIA OF KILN PRODUCTION (TPD) LINING LENGTH QUALITY USED RUNNING LIFE
Spinel and Magnesia is put together in
high pressure hydraulic presses, which
JAYPEE ANDHRA 4.35 4500 1.4-8.2 MAGNEL 85 1 year
is then fired in high temperature tun-
nel kilns. Due to difference in thermal
expansion coefficient between Spinel JK GOTAN 3.6 3000 0.0-6.0 MAGNEL 85 1 year
and surrounding Magnesia resistor, a
micro-crack system gets created, which CALCOM CEMENT
increases brick elasticity without any LTD, UMRANGSU 3.8 3400 2.0-16.0 MAGNEL 85 1 year
negative impact on strength. (RUNNING)
OCL RGP LINE1 0.8-2.6 MAGNEL 85 9 months
3. What is the biggest advantage of Basic 3.8 3000
bricks? How can it be measured? (RUNNING) 24.0-26.0 MAGNEL 85 9 months
DCBL ARIYALUR
The best measure of performance of Ba- 4.35 6000 3.0-6.0 MAGNEL 85 >1 year
(RUNNING)
sic bricks, for that matter any refractory,

Inspection Failure Type

Dalmia-OCL was asked to investigate failure of LF 60-15 bricks after operations

Report
were suspended within 3 months of kiln startup due to high radiation.

Observations
1. Kiln brick lining (0 to 96 m) was done between 27th October, 2018 to 25th Novem-
ber, 2018. Kiln startup was recorded on 27th November, 2018.
2. During inspection inside the kiln, it was observed that bricks had fallen starting
80.2 m to 85 m between the girth gear & 3rd tyre (2/3rd of circumference).
3. Cracks and cavities were seen on cold surface of bricks and approximately 30% of
bricks were found crushed (see photos).
4. A few rings were also observed to be tilting towards the side opposite to kiln incli-
nation (i.e. towards kiln inlet).
5. On further inspection of the fallen bricks, it was found that bricks were cracked
from the bottom portion in one of the rings while all remaining bricks were in good
condition.
6. The original lining pattern of the kiln was 0.4-55.0 - Basic Brick
55.0-65.0 - LF 60-15
65.0-76.2 - HG 40-20
76.2-94.8 - LF 60-15

Kiln location Karnataka

Kiln dimension 6 m dia X 96 m length Cavity formed at cold face Cracks formed at cold face
Bricks in the preheating zone were found to move in upward direction (instead of downward direction)
Brick lining thickness & Quality 220mm(HM-62,HM-61)( LF 60-15)
Kiln operation temperature 400°C with Pet coke and Alternative fuel
Kiln main burner 40%
Pre calciner burner 60%
Year of commisioning 2001

Reasons for failure

Cracks and cavities in the cold face of bricks can usually be attributed to irregularities in kiln shell, which obstruct rotation of bricks/rings. This leads to
mechanical stresses on the cold face side which induces cracks. Since the hot face exposed to the kiln atmosphere was confirmed to be in good condition,
quality of bricks was ruled out as a cause for failure. What’s more, considering the fact that the affected area was near the 3rd tyre, the issue may have
definitely gotten aggravated due to ovality related stresses.

Suggested Remedy
There cannot be a refractory-led solution to a mechanical problem. It was therefore recommended that:
1. Shell thickness in the affected area be checked, including the causes thereof such as corrosion, deformity etc.
2. Migration at the 3rd tyre to be checked and if found over the ideal migration of within 20 mm, shimming of the tyre to be carried out

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