AGCC Confidential
Installation Guidance for
Cement Rotary Kiln
Oct 2016
Development Center
Basic Concept
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Tight Installation
Tight installation fix the bricks, and reduce mechanical
damage, and maximize brick's performance.
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Basic Concept
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Joints
Straight joint pattern Staggered joint pattern
Hooking
* Straight joint pattern hooks with adjacent
rings, and causing mechanical damage.
Staggered joint pattern is suitable for cement rotary kiln.
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Pre-Installation
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Shell Cleaning
Polishing with grinder Burning with acetylene burner
The kiln shell needs to be cleaned before installation.
4
Pre-Installation
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Base Lines
Radial lines Axial lines
Level gauge
Center * Radial lines : every 1m
Baselines need to be marked before installation.
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Pre-Installation
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Base Lines
Check whether the bricks are parallel to radial lines.
6
Installation
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Span End
Old bricks
Base brick
Cut brick
Base brick Removing card board
No gap Cut bricks
Old bricks
150mm 150mm
Proper span end work leads to tight ring formation
in the axial direction.
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Installation
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Span End
Compound Joint Pattern
If cut brick length becomes less than 150mm, change
into compound joint pattern.
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Installation
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Closing
Key Bricks
Base Bricks
Hydraulic pump
Steel Shim
MPa kg/cm2 PSI Bar * Don't use more than 3 pieces of steel
shims per ring.
40-50 400-500 5700-7100 400-500
+ Cylinder diameter : 3.5 - 4.0 cm
Proper closing work leads to tight ring formation
in the radial direction.
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Installation
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Tight Joints
Tight joints work is essential point of tight installation.
10
Installation
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Mortar
Axial Joint
Twisting
Tight joint (< 5~10 mm)
Open joint
Open joint Hard Mortar
Mortar work is effective for adjusting open joints.
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Installation
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Mortar
Radial Joint
Sliding
Spaces
Incorrect angle Correct angle
Mortar
Spaces
under bricks
Mortar work is effective for adjusting incorrect angles.
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Application
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Radial Mortar
Tire Section
Mortar at radial joints 3m ~ 5m
Mortar
Excessive Ovality
Mortar work at radial joints is recommended for
tire section.
13
Application
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Block Formation
Severe Shell Deformation
Section
Block formation is recommended for severe shell
deformation section.
14
Application
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Leveling with Castable Refractory
Big Level Difference Section
Mortar
Castable refractory Level difference
(> 8 mm)
Clearance space
(15 ~ 25 mm)
Leveling with castable refractory is recommended for
big level difference section.
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Application
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Card Board
Removing
Condition
Pattern
Every
Normal
10th Ring
Every
Twisting
3rd Ring
Clearance space After Shell All Rings
after burnt Replacement (2~4m)
Card board adjustment is recommended for tight ring
formation in the axial direction.
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Application
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Installation in Very Cool Conditions
Warm up mortar materials and kiln shell
by heater to prevent freezing.
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Convenient Tools
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For marking correct radial lines
Right angle scale
Bendable scale
Compass
Alignment device
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Convenient Tools
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* Mini pump for adjusting narrow space
* Grease for inserting steel shim and key brick
* Wedge for supporting brick
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for extending the life
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