The service life of cement kiln refractory castables is short due to high temperature, rapid cooling and heating, material scouring, mechanical stress, construction and other factors, which restricts the operation rate of the kiln and even causes castables to fall off and burn through the kiln barrel. During operation, a cement plant had a large amount of flying sand and large particles of clinker leaking out of the cold air sleeve of the kiln head cover. After stopping the kiln for inspection, it was found that the kiln barrel was burned through and leaked outward under the cold air sleeve of the kiln barrel.
Factors affecting the service life of kiln refractory castables
1. Selection of refractory materials
In production, kiln refractory castables are subjected to high temperature erosion, long-term abrasion of clinker, scouring of secondary air and rapid cooling and heating caused by starting and stopping the kiln. Therefore, kiln refractory castables should have high temperature erosion resistance, wear resistance and good thermal shock resistance.
2. Selection and construction of anchors
The material, shape, thermal expansion treatment, welding, etc. of anchors directly affect the service life of refractory materials. The material should generally not be lower than 0Gr25Ni20, and must be welded firmly. The anchors should be expanded, and the anchors should be painted with asphalt paint or wrapped with tape.
3. Construction and water injection control of refractory materials
The performance of refractory castables is closely related to the construction of castables. In the actual production and maintenance on-site construction process, the construction team often chooses only convenient construction methods. If the technical personnel do not follow up in place, it is easy to cause the performance of refractory materials to decline and the service life to shorten. During the construction process, the construction personnel sometimes increase the water injection volume in order to make the castables easier to pour and speed up the flow of the castables, resulting in a significant reduction in the strength of the castables.
4. Baking of refractory materials
It plays a great role in the performance of the castables. If the baking is not good, it is easy to cause the refractory materials to burst during the rapid heating process, causing the castables to fall off.
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