Exporter of refractory dryout services refractory dry out of incinerator services, refractory dry out of pre heater of cement plant, thermal stabilization of turbine rotor and refractory dryout of convection and breaching section. Issues such as burner size and placement, exhaust location, air volume, air velocity, thermocouple placement, etc. You should apply our company for the different refractory labels, amounts and widths. Dryout design considerations and practices for cryogenic. While heating, there must be free air flow over the system to ensure removal of moisture. The use of conventional refractory created hot spot problems during operation as the refractory was not able to be properly dried out. This necessitates another sru outage to affect repairs and another dry out procedure, costing another 4 to 6 days of downtime. Inspection of refractory after air drying and firing testing of refractory as installed. The apparent porosity is the volume of the open pores, into which a liquid can penetrate, as a percentage of the total volume of the refractory. Api certified 936 refractory personnel must have knowledge of installation, inspection, testing and repair of refractory linings. Boiler refractory dryout courtesy of rentech boiler systems. Thermbond eliminates the risks and costs of conventional. By utilizing stateoftheart equipment, including digital process controllers, fully proportional fuel actuators, and solidstate features, our engineers are able to provide flexible service that meets the most demanding of specifications. General description of the procedure of the dry out of a refractory lining.
Curing or dry out time has been greatly reduced from 7580 hours on average to 4045 hours on average. Following improper dry out procedures can have the following adverse effects upon the refractory. Rcf is a refractory ceramic fibre material, also know as asw alumino silicate wool. National heat has over ten years of experience undertaking refractory dry outs for many clients around australia. Guide says i have to go up 150 c in 68 hours and keep at that temp about 12 hours, then in 12 hours i have to go up to 550c and hold there about 1 hour for every 1 thickness.
Outstanding abrasion resistance from dust erosion, rubbing, and heavy impact. Table 1 compares installation times over a 24month life cycle for sifca nose blocks and a conventional refractory castable nose ring. Customer specified thermbond for the new installation. In some cases, the problem of explosive fractures occurs due to the high steam pressure generated at. Longer period of low temperature drying causes more even heat distribution. The curing and firing of refractory castables darley firebrick. In addition, at no time during the curing process should be casting be moved or shaken. As the refractory castable is heated, a volume expansion takes place within the lining as water turns to steam, causing pressure to build and the permeability of the material then dictates the rate at which the dryout can proceed if explosive spalling is to be avoided. Speeding up the process can and has resulted in refractory failures leading to hot spots on the metal coverings after firing of the mainburner. Mass, temperature and pressure measurements during the dry out of. It is not intended as, and should not be taken as, a warranty of any kind, including but not limited to a warranty of. It does not contain recommendations for any particular refractory for any particular use. Longer period of low temperature drying causes more even heat distribution resulting better. The refractory dryout contractor, being the party with the match in hand when the.
The values and the information given are subject to. Greencast 94 plus ii i refractory distribution and. Various capacity of oil and gas burners, including high velocity burners up to 5,000,000 kcalhr. Spar recommends consulting an experienced dry out company. Separate the individual slices with a trowel or spade. Benteng api technic provide the proper dry out and heating up services refer to the manufacture instruction and typical dry out and heating up diagram. Whilst the values and application information in this product data book are typical, they are given for guidance only. At this point, kiltas recommends you to contact people who has experience and is professional about dry out. Unfortunately, standard refractory dryout schedules, provided by all refractory.
Jun 10, 2002 preparation for a dry out should take into account the following items, which have nothing to do with the actual dry out, but can improve the outcome of the dry out process. Lining areas subjected to rubbing, grinding, or highvelocity, dustladen gases. The dry out of refractory entails more than just following a heating schedule. Pdf drying stages during the heating of highalumina, ultralow. Ive got a usage manual from the refractory company, the correct procedure is after drying the cement about 48 hours, the first drying and firing waaaay too long.
Dryout design considerations and practices for cryogenic gas. Plibrico company llc technical bulletin 1010 north hooker. After water pressure test, clean it and put into precommissioning and then supply oil to the boiler formally. Everything you need to know on rotary kiln refractory. The information presented in this book is for general educational use only. Materials, equipment, and personnel are qualified by the methods described, and applied. To dry the monolithic refractory, a hot air burner, which has long been used to dry and preheat conventional brick ladles, is employed. There are two main types of refractory mortars available. The curing and firing of refractory castables densecretes and litecretes.
Proper refractory dry out is key to optimum service life. Heating procedure for castable refractories kiltas refrakter. Refractory dry out the key to a long refractory life is a dryout using gccs high velocity gas combustion systems. Meunier and others published mass, temperature and pressure measurements during the dry out of refractory. Many clients or end users shorten the required time for proper boiler refractory dry in due to the time and costs involved, but this comes with risks. As a result, refractory dry out methods using our procedures can ensure even heat by eliminating hotcold spots to extend the life of your refractory. Drying refractory in steamgenerating boilers insulation. Secondary reformer refractory dry out operation ijert. The steam always found its way out and the dryouts were completed without any detrimental effect to the refractory lining.
Refractory, or the lining utilized on the interior of rotary kilns, is a critical component in ensuring process efficiency and prolonging the life of a rotary kiln. The correct application of heat curing and controlled release of water in the castable is very important for the life time. Here, well discuss everything you need to know about refractory, including how it works, the different types, and best practices for preventative care. These standard dry out schedules are generic and require temperature monitoring rarely found at power plants, where monitoring. After installation, repair or replacement of boiler refractory materials, its important to follow the manufacturers recommended curing and dry in schedule and procedures. Unfortunately, standard refractory dry out schedules, provided by all refractory manufacturers with their products, are difficult to apply to refractory used on a steamgenerating boiler. Pdf drying stages during the heating of highalumina, ultra. For the dry out of a refractory lining external high velocity burners are used. Refractory baking and dry out cycle requires very slow and controlled heating of refractory as recommended by the refractory manufacturers. These are guidelines for the installation quality control of monolithic refractory linings and may be used to. Our refractory dry out services is consist for the following.
Combustion air blower with capacity up to 5000 nm3hr. The dry out of refractory involves more than following a heating schedule. Thermbond has provided excellent performance for over 15 years in multiple plant locations. Any deviation from this program may result in the refractory cracking or even failure falling down. Refractory experience in circulating fluidized bed.
The refractory mortar is utilized only to build fire places and shall not be applied on hot faces. Pdf secondary reformer refractory dry out operation. Boiler refractory dry out is to ensure proper drying, curing of. I have not participated in the dry out, neither have i accomplished the procedure. Check with the refractory manufacturer or refractory expert for a compromise between safe heating rates and operating costs. Boiler refractory dry out is to ensure proper drying, curing of refractory applied on furnace and other components. Explosive spalling of low cement castable refractories a. It is used to lay firebrick in places that are exposed to extremely high temperature. Boiler dry out if new refractory has been installed in the furnace it will have to be slowly dried out before raising the furnace to normal operating conditions. Scribd is the worlds largest social reading and publishing site. For this comparison, both options begin with the removal of a conventional castable nose ring. Dryout procedure for refractory lining at site refractory.
Highalumina, lowsilica castable for severe abrasion features. Using normal boiler startup procedures, monitor and raise the exit gas. Ramming procedure open the carton and the moisture proof packaging at all 4 corners of the cube with the precut slices in a vertical position. Resco recommends that an experienced dry out company be consulted. Refractory dryout our expertise in these areas ensures maximum flexibility and minimum downtime. When mixed together these products exhibit a fast exothermic set and can be he heated at a much faster rate than conventional refractory products. Secondary reformer refractory baking and dry out cycle requires very slow and controlled heating of refractory. Heatingup for drying to the operational temperature of the installed monolithic refractory lining shall be carefully carried out because rapid heating causes cracks. Controlled heating, through these reactions ensures maximum strength. After completion of refractory erection which is around 1400 tons per units it has to be dried out to remove the moisture and to attain the physical and chemical properties. Pdf magnesia refractory dryoutmanaging the risk of. Installed refractory linings and castings containing calcium aluminate cement binders should be cured prior to drying.
Dry out procedures for refractory must be completed as per the vendors instruction, which will include a temperature ramping and holding program. An effective dry out procedure, and one carried out in compliance with the manufacturers specification, is the key to ensuring that a furnace operates to both the manufacturers specification and the operators expectations. Boiler commissioning procedure linkedin slideshare. Sulphur plant and tail gas treating unit startup and. The survey concentrated on operating units in the united states. The secondary reformer having monolithic refractory material contain water or water based liquid which are needed to place the material and help the setting.
Formula series dry formulations are mixed only with formula series liquid activator. Pdf the purpose of this work was to investigate the drying kinetics of highalumina, ultralowcement. The castable composition chosen for this study consisted of a. The dry out procedures and curing methods the dry out procedure requirements for the test samples. Exporter of refractory dryout services refractory dry out of incinerator services, refractory dry out of pre heater of cement plant, thermal stabilization of turbine rotor and refractory dry out of convection and breaching section. The calderys range includes selfflowing castables, dry gunning and shotcreting materials, bricks, ramming and plastic mixes, dry vibrating mixes, taphole clays, injection and grouting products, prefabricated shapes, and more. Discover our comprehensive product range, going beyond monolithics to cover all your refractory needs. Curing is necessary to prevent moisture loss during the setting of the material. Harbisonwalker handbook of refractory practice disclaimer. Refractory dryouts national heat treatment division. The worst case scenario is having to bring the sru down shortly after acid gas has already been. Drying stages during the heating of highalumina, ultralowcement refractory castables article pdf available in journal of the american ceramic society 867.
New refractory contains water which will flash into steam and damage the material if it does not have a chance to evaporate before reaching normal furnace operating temperature. Claus plant equipment sulfur recovery engineering inc. The refractory material was not normally thermally cured at the factory. The refractory usually undergoes considerable chemical changes, during initial heating.
Drying refractory in steamgenerating boilers insulation outlook. Dec 05, 2016 api 936 refractory personnel certification examination effective april 2017 december 2017 replaces october 2009 api certified 936 refractory personnel must have knowledge of installation, inspection, testing and repair of refractory linings. Drying refractory is critical for strong, longlasting refractory applications. At no time during the casting, curing, or drying process should the castable reach freezing temperatures. Thermocouples during the refractory installation is the best time to install. Pdf secondary reformer refractory dry out operation prem. Observe the refractory suppliers recommended procedure. This dry out program is given for the average amount of material as an information guide. Brimstone sts limited september 16, 2011 page 3 of 15 than ideal temperatures will require a longer than normal dryout schedule with reduced ramp rates and additional or longer hold points. These refractory standards help materials science laboratories, material processing companies, product manufacturers, and other producers and users of such materials and products in their proper fabrication and treatment procedures to ensure good quality and workmanship towards safe utilization. The heat curing procedure for refractory materials entails more than a schedule. Important considerations for refractory dryouts, startups. It will never reach its maximum strength, and it will contribute to a spall at the refractory surface.
Refractory dry out is carried out as per the curve given by refractory manufacturer. Previous water tube boiler commissioning procedure and. Thermal stresses will be produced if heating rate is too rapid. Gcc specializes in all forms of refractory dry out. A dry out procedure should be prepared prior to dry out. The temperature at which the material is placed installed is of utmost importance.
Refractory experience in circulating fluidized bed combustors. This property is important when the refractory is in contact with molten charge and slag. It is of critical importance to execute a uniform and graduated drying out procedure with professional standards and practice. In addition, stringent quality control procedures and checks during every stage of the refractory drying out, from conception to maintenance, should be implemented to ensure a maximumlife refractory lining installation. Issues such as burner sizing, exhaust location, air volume and velocity need to be determined. Harbisonwalker handbook of refractory practice 2005. Pdf drying stages during the heating of highalumina. The firm or person executing the drying out procedure is solely responsible for any damages.
Preparation for a dry out should take into account the following items, which have nothing to do with the actual dry out, but can improve the outcome of the dry out process. It is not uncommon for moisture to be absorbed by the refractory. Magnesia refractory dryoutmanaging the risk of hydration article pdf available in journal south african institute of mining and metallurgy 1116. In some applications, manufacturers have created refractory material that requires little to no dry out time and effort. Refractory mortar is a specially engineered mixture of sand, calcium aluminate, cement, and fireclay. With gulf coast combustions refractory dry out knowledge and expertise, you and your clients will get a longlasting life on your refractory. Materials, equipment, and personnel are qualified by the methods described, and applied refractory quality is closely monitored based on. It is not uncommon for moisture to be absorbed by the refractory during final stages of inshop fabrication, transit to the job site, and before the upstream combustion products are first passed through the unit. Refractory dry out procedures boiler furnace scribd. Dry out is the initial heating of castable lining in order to remove retained water from within the refractory castable without adversely affecting its structure or physical properties. Pdf magnesia refractory dryoutmanaging the risk of hydration. Dry out time for refractory material has also improved.
1061 38 633 292 525 215 1211 1168 223 905 823 1451 389 50 1099 837 1332 884 1163 260 254 943 197 1150 1069 726 773 41 997 307 441 979 760 407 1297 575 1119 332