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Chapter 4
Refractory Installation in the Cyclone Preheater
4.1 Setting up of scaffolding
- Experienced and skilled workers and equipment with
safety standard are required for the setting up of
scaffolding in Cyclone Preheater.
- The scaffolding is to be set away from the refractory
work with a distance of 10-15cm. The suggested
space will allow easy and convenient functioning,
wherein a crowded space may result in difficulty in
refractory installation and large space gap between the
refractory work and scaffolding may cause
inconvenience and increases the chance for equipment
to fall down.
- A correct scaffolding construction has a strong
structure that is stable and able to be loaded with the
refractory weights that are temporally placed or
stacked on the scaffolding platforms while waiting to
be installed.
- Ladders must be provided to connect each stage of
scaffolding platforms. An opening hole located in the
middle of each scaffolding platform is provided for
conveying the refractory materials from one stage to
another vertically, using the electric hoist as
conveying equipment. It is necessary to provide safety
bars to close the opening holes to prevent from falling
down.
- The correct construction and appropriate design of
scaffolding based on their size and location in
accordance to the repairing areas will promote
convenience of the refractory installation works
including conveying of refractory materials and other
equipments in and out from the cyclones, and between
each stage of the scaffolding.
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4.2 Steel Works
- The steel work quality (welding) in the installation
areas, for example in Cyclone Wall, Flanges, Bars for
bricks hanging at the roof, and anchors fixing joints,
should be first inspected prior to refractory
installation. They must be properly constructed or
fixed; their designs must follow the drawing designs
and the welding joints must be strong and fully
welded.
4.3 Cleaning of the working surface areas
- The steel surfaces of the repairing areas must be freed
from dust, rusts or scales, and oil. Cleaning can be
done by the use of wire brush to eliminate dust, rusts
and scale or fabric sheets to wipe oily surfaces.
4.4 Refractory materials for Cyclone Preheater
- The selection criteria for choosing appropriate
refractory materials for Cyclone Preheater are
working temperature, chemical composition of raw
meals, thermal conductivity of the refractory
materials, fuels use, abrasion resistance, and etc.
- The refractory materials to be used in Cyclone
Preheater are refractory bricks, refractory castable,
and insulating materials.
- When considering linings design for each installation
area, whether using bricks or castable for installation,
the decision largely depends on the characteristics of
the area. The area with complex shapes or with slopes
is difficult for brickwork, such as Transition Zone,
therefore castable lining is more appropriate for easier
and faster installation.
- Various options can be selected for conveying the
refractory materials and installation equipment, such
as conveyer belt, roller, and manpower into the
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cyclones. Whereas pulleys or winch are used in
conveying the materials in a vertical direction inside
the cyclone, as shown in Fig. 4-1 and Fig. 4-2.
Fig. 4-1: Picture illustrating the use of conveyer belt in
conveying the refractory materials into the
cyclone
Fig 4-2:
Picture illustrating
the use of winch in
conveying the
refractory materials
in vertical direction
inside the cyclone
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4.5 Refractory installation guidelines on each section in
Cyclone Preheater
Cyclone preheater can be divided into the following
sections.
1) Connection to riser duct
2) Roof
3) Roof connection to side wall
4) Transition zone
5) Retaining Ring (or Flange)
6) Cylindrical Wall
7) Conical Part
Fig. 4-3: Picture illustrating areas of each section in
Cyclone Preheater
4.5.1 Refractory installation in the connection to riser
duct section
- This section is to be installed with the refractory
castable lining around the dip tube that is made of
heat resistance steel. Due to the expansion of the dip
tube when heated, the ceramic fiber blanket of 3-4cm.
thickness is required to warp around the tube area that
connects to the castable lining to prevent the problem
of cracking of the castable lining from steel
expansion, as shown in Fig. 4-4.
- The installation begins by fixing of stainless steel
anchors, spacing of 15cm. from each other, to the roof
area around dip tube.
- The Refractory Castable is installed from the top of
steel roof, thus an opening hole with an area of
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10x10cm in every 50-60cm interval on the roof must
be provided.
- Each casting panel section should be made
approximately 1m2 in size and a 5mm. space inserted
by ceramic fiber or plywood should be also provided
as expansion joints.
Riser
Duct
Fig. 4-4: Picture of connection to riser duct section with
complete lining
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Fig. 4-5: Picture illustrating how the anchors are fixed in
the connection to riser duct section
- In installing the Refractory Castable in this section,
the castable is poured into the opening holes provided
above the roof, as shown in Fig. 4-6.
opening
hole for
installation
of castable
Fig. 4-6: Picture illustrating the opening hole provided for
installation of castable
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- Use of vibrator during installation. An appropriate use
of vibrator will allow the flow of castable to the
casting panel that must be filled.
- Close the opening holes with the same steel plate
which has been removed previously.
4.5.2 Refractory installation in the roof section
- In normal roof design, the linings are a combination
of both refractory bricks and castabls.
- The refractory brick lining on the roof is designed for
Hanging Bricks, which are to be hanged with I -
beams or Hanger Steel, and Insulating Boards are to
be installed in the gap between the bricks to serve as
an insulating lining, as shown in Fig. 4-7.
Hanger
Steel
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I-Beam
Insulation
Board
Hanging
Brick
Fig. 4-7: Picture illustrating the installation of hangings at the
roof area of Cyclone
- The gap between the hanging bricks and either I-
beams or Hanger Steel is to be installed with
Insulating Board or Ceramic Fiber Bulk to prevent the
heat from penetrating and damaging the I-beams or
Hanger Steel, as shown in Fig. 4-8.
Ceramic
Board
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Fig. 4-8: Picture illustrating the installation of Insulating
Board or Ceramic Fiber in between Hanging Bricks
and I-Beam
- For areas in which hanging bricks could not be
installed, i.e. curve shape, small proportion, between
the bricks rows, and etc., they should be lined with the
Refractory Castable, thus fixing of anchors must be
done first. The refractory installation in these areas
must be done from the top where the opening holes
with 10x10 cm. dimension are provided in every 50-
60cm interval throughout the castable installation
areas.
- Set the wooden moulds inside the cyclone and pour
the castable through the opening holes, and close
them after completion, as shown in Fig. 4-9.
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Fig. 4-9: Pictures illustrating the moulds setting for the roof
area of Cyclone
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4.5.3 Refractory installation in the roof connection to
side wall section
- The refractory installation in this section is to be done
after the completion of the refractory installation on
the roof and cylindrical wall sections.
- The refractory lining is designed with Refractory
Castable.
- Same as other castable linings installation in the roof
area, opening holes with 10x10cm dimension are
provided on the roof in every 60-100cm interval for
castable installation, close them after the installation
of castable is completed.
- The connection area of roof and cyclone wall shall be
filled with Ceramic Fiber Blanket, which will mitigate
the problem of refractory linings expansion during
operation.
- The installation of this Ceramic Fiber Blanket is to be
done by; first attach the foam, which has been cut
with proper dimension, on the top of the utmost
installed bricks ring at the cylindrical wall. After
completing the installation of the castable lining of
the roof section area, remove the foam and replace the
gap with Ceramic Fiber Blanket as expansion joint, as
shown in Fig. 4-10.
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The removal of the attached
foam to be replaced with
Ceramic Fiber Blanket
Opening holes are prepared
for castable installation
Fig. 4-10: Pictures illustrating refractory castable
installation in the roof connection to side
wall section of cyclone
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4.5.4 Refractory installation in the transition zone
section
- The shape of this section is a cone shape or with
slope, which the refractory lining is often designed for
the refractory castable lining as it is more convenient
to install compared to bricks lining that requires
combinations of brick shapes.
- At the first step, anchors are to be fixed with the
interval of 25x25cm. throughout the area.
- There are two linings, one is insulating lining (install
with insulating board) and second is working lining
(install with Refractory Castable).
- Since the insulating board (including other insulating
materials) will absorb the water naturally, the water
will combine with castable mixes and thus affect the
refractory castable lining and lead to the deterioration
of its properties, including the non-fill moulds.
Therefore it is essential to cover the insulating lining
with plastic sheets, oil paint, or wax first before
installing the castable.
- The casting area is separated by casting panels, each
is approximately 100x100 cm. apart, and a 5mm.
thick Ceramic Fiber Blanket or plywood is used to
serve as expansion joints, as shown in Fig. 4-11.
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Fig. 4-11: Picture illustrating the refractory castable
installation in the transition zone section
4.5.5 Refractory installation in the retaining ring section
- In the cyclone, there are several retaining rings or
flanges located in each interval sections. The
Retaining Ring is made of steel, with width of about
70% that of lining thickness, and welded on the wall.
It is used to carry the load from refractory weight as
well as reinforcement of the steel structure.
- Normally, the refractory bricks to be installed on the
first row or ring above the Retaining Ring are special
in shape and larger in size. The special brick designs
are made with the purpose of protecting the retaining
ring from direct heat exposure, whereas their large
size is necessary to withstand the load from the
weight of refractory bricks installed above them.
- The first row (ring) of bricks above and below (last
row before reaching the retaining ring) the retaining
ring are designed to have a backup (insulating) lining
with ceramic fiber only, and not insulating board like
in other rows. This is because these two rows require
the highest strength and such design will protect them
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from dust penetration and prevent them from
corroding into the backup lining and steel surface, as
shown in Fig. 4-12.
Fig. 4-12: Picture illustrating the refractory lining design
at the Retaining Ring area
- Also, the gap beneath the Retaining Ring and the row
of bricks below it (last row before reaching the
retaining ring) is to be inserted with the ceramic fiber
with 4cm thickness, to serve as expansion joint for the
Retaining Ring that will expand when temperature
rises.
- After the first row of bricks above the Retaining Ring
is completely installed, then the insulating board as
backup lining is to be installed before installing the
refractory bricks, as shown in Fig. 4-13
- In case the Retaining Ring is not levelled and aligned,
the Refractory Mortar can be used to compensate or
adjust the level. Each row of installed bricks must be
checked for its level (height) and alignment using a
Levelling Bar, as shown in Fig. 4-14.
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Retaining
Ring/ Flange
First row of
bricks
above the
retaining
ring
Fig. 4-13: Pictures illustrating the installation of refractory
linings in the Retaining Ring section
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Fig. 4-14: Picture illustrating the use of Refractory Mortar to
compensate or adjust the level before installing the
bricks
4.5.6 Refractory installation in the cylindrical wall
section
- The refractory linings in the cylindrical wall section
are to be installed in upward direction, by completing
a row of bricks one by one.
- In each row or ring of refractory bricks, two standard
shapes of combined bricks are used for installation
fitting to the wall contour. However, a special brick
can be designed to enable the use of 1 shape of brick
combination for installation.
4.5.6.1 Refractory Mortar is applied for installation of
refractory bricks in between the bricks and between
the layers of lining (i.e. insulating lining and brick
lining); however the thickness of mortar should not be
more than 2mm.
4.5.6.2 The refractory bricks lining must be tightened against
the backup insulating lining. Also, in some areas, the
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contour radius of the wall may deviate from the actual
drawing, thus the brick combination can be altered,
and mortar can be applied together with the brick
combination at the back of the insulating lining to
slightly adjust the curve of the wall, in order to make
a better fitting of the linings with the wall contour.
4.5.6.3 For ring or row closure, same as the normal practice,
the closure brick shall not be cut more than 2/3 of its
original thickness. And if more than 2 cut bricks are
to be used, they shall not be placed next to each other
(within the row and between the row), but alternately
with full bricks, shown in Fig. 4-15.
Cut brick ring
Fig. 4-15: Picture illustrating the refractory lining at the
cylindrical wall of cyclone where cut bricks with
more than 2/3 of their original thickness are used for
ring closure and they are placed alternately with full
bricks
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4.5.7 Refractory installation in the conical part section
- In this section, the working lining can be either
installed with refractory bricks or Refractory
Castable.
- However, if it is to be installed with refractory bricks,
various shapes of brick are required and the bricks
combination for each row will also be different
depending on the contour radius of the wall.
-
Fig. 4-16: Pictures illustrating the refractory installation in
the conical part section
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4.5.8 Refractory installation in the other parts of
cyclone
4.5.8.1 Manhole
- The lining around the manhole is often designed to
install with Refractory Castable and the area is set
with approximately 20-30cm. from each side of the
edge of the manhole, where further distance is
installed with refractory bricks, as shown in Fig. 4-17.
Fig. 4-17: Picture illustrating how the refractory lining is
installed around the manhole
- Since the Refractory Castable is installed after the
refractory bricks, to prevent the installed refractory
bricks from moving or displacing, the steel bars or
sheets are welded to the wall to fix and hold the bricks
alignment prior to bricks and castable installation, as
shown in Fig. 4-18.
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The steel sheets
or bars are
welded to the
wall to fix and
hold the bricks
alignment
Fig. 4-18: Picture illustrating how the steel sheets or bars are
welded to the wall to fix and hold the bricks
alignment prior to installing the refractory linings
- The refractory bricks installation around the area must
be completed first before installing the Refractory
Castable, as shown in Fig. 4-19.
Fig. 4-19: Picture illustrating how the surrounding area must
be completely installed with the refractory bricks
before installing of Refractory Castable
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4.5.8.2 Poke Hole
- Poke hole is used for the removal of coating (built-up)
that are built on the wall and conical areas of the
cyclone.
- Similar to the manhole, the Poke hole and its
surrounding is to be installed with refractory castable
lining, as shown in Fig. 4-20.
Poke Hole
Poke Hole
Fig. 4-20: Pictures illustrating how the lining of the poke hole
area is installed with Refractory Castable
4.5.9 Refractory installation in the down pipe
- Down pipe is the connecting part among the
connecting stages of cylones. The down pipe consists
of few shorter cylindrical pipe sections; each section
has the flange at both ends (top and bottom) that are
used to connect each of them by fixing with bolts.
- Most of the pipe sections have the diameter of less
than 1 meter, therefore they are to be installed with
Refractory Castable.
- The installation procedures are as follows:
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o Fix the V or Y- shapes anchors with 20cm.
space between each other.
o Install the insulating lining, either insulating
board or insulating castable.
o Cover the insulating lining with plastic sheets
or paint with oil, grease, or wax.
- Two installation methods can be done by :
4.5.9.1 Horizontal Installation Method
- Separate the casting area into 4-6 casting panels with
plywood (as expansion joint).
- Install the panel that situates at the bottom (6 O’clock
position) before using vibrator. Level the surface
following the curve by using trowel. Soon after the
castable is set, rotate the uninstalled panel to the
bottom position (reverse position) then install the
castable, and repeat until all casting panels in the pipe
section are completed, as shown in Fig. 4-21.
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Fig. 4-21: Pictures illustrating the horizontal method of
refractory castable installation in the pipe with a
sequential order of installation on each casting
panel
4.5.9.2 Vertical Installation Method
- An alternative to above method, the pipe section is
place vertically for refractory castable installation, a
better option if the diameter is smaller.
- Separate the casting areas into 2 casting panels.
- Set up the mould for 1 casting panel and install the
refractory castable, remove the mould after the
castable is set. Set up the mould for the remaining
casting panel and provide a 3-5mm. of expansion joint
by plywood, then install the refractory castable to
complete all casting area, as shown in Fig. 4-22.
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Steel
Flange
Wooden
Mould
Fig. 4-22: Picture illustrating the vertical method of
refractory castable installation in the pipe with a
sequential order of installation on each casting
panel
