Improving the service life of castables for cement rotary kiln burners is a comprehensive technical issue, involving material selection, construction technology, maintenance and other aspects. The following are some specific measures and suggestions:
1. Material selection
High-performance castables: Select castables with high strength, high wear resistance, high thermal shock stability and alkali corrosion resistance. For example, high-strength mullite castables, corundum high-strength low-cement refractory castables or G-17K new kiln mouth castables. These materials can maintain good performance and extend service life in harsh working environments.
High-quality aggregates and binders: Select aggregates and binders with stable quality and reasonable particle size distribution to ensure the overall performance of the castables.
2. Construction technology
Standardized construction: Strictly follow the construction specifications to ensure the construction quality of the castables. Before laying the castables, the surface of the kiln mouth should be thoroughly cleaned to remove impurities such as oil and rust.
Reasonable design of anchoring system: adopt reasonable anchoring system design, such as using double-angle cold-bent wavy anchoring nails to increase welding area and strength. At the same time, rationally arrange the nails to ensure a firm connection between the castable and the kiln body.
Optimize casting thickness: According to the working conditions of the kiln mouth and the performance of the castable, reasonably determine the thickness of the castable. Generally speaking, appropriately increasing the thickness of the castable can improve its wear resistance and thermal shock resistance.
Strictly control the proportion of mixed water: When stirring the castable, the proportion of mixed water should be strictly controlled to avoid excessive water addition, which will reduce the strength of the castable.
3. Maintenance
Regular inspection: Regularly inspect the kiln mouth castable to promptly detect and deal with cracks, shedding and other problems. For problems found, they should be repaired or replaced in time.
Reasonable maintenance: After the construction of the castable is completed, reasonable maintenance should be carried out. The general maintenance time should be no less than 24 hours to ensure that the castable is fully hardened and reaches the design strength.
Reduce rapid cooling and heating shock: During the use of the kiln mouth, rapid cooling and heating shock should be avoided as much as possible to reduce the thermal stress damage of the castable.
4. Other measures
Optimize the kiln head pressure control: By adjusting the exhaust volume of the high-temperature fan at the kiln tail and the air volume of the residual air fan at the kiln head, the pressure at the kiln head is kept stable and balanced. Avoid the harsh working environment and equipment damage caused by the positive pressure at the kiln head.
Improve the kiln mouth structure: Redesign the kiln mouth structure, such as using a box-type combined guard plate, adding a cooling hood, etc., to improve the protection effect and service life of the kiln mouth castable.
Increasing the service life of the castable for the cement rotary kiln burner requires starting from multiple aspects such as material selection, construction technology, and maintenance. By taking comprehensive measures and continuous optimization and improvement, the service life and performance stability of the castable can be significantly improved.
HOME