What Is a Cement Rotary Kiln Refractory Lining?
The cement rotary kiln lining refers to the refractory material protective layer installed on the inner wall of the cement rotary kiln shell. The performance and service life of the lining directly affect production continuity and economic efficiency, making it one of the key focuses in rotary kiln operation and management.
Causes of Premature Failure of Cement Rotary Kiln Refractory Lining
Problems with refractory materials inside a cement rotary kiln mainly occur in the burning zone. This area operates at extremely high temperatures and therefore has the shortest service life. The reasons for the shortened service life of refractory bricks in this zone may include the following:
1.Kiln coating issues
In modern cement production, a kiln coating is formed to protect the refractory bricks. If the kiln coating is unstable or poorly formed, the service life of the refractory bricks will be significantly reduced.
2.Coal injection pipe issues
Improper control of the coal injection pipe—such as incorrect angle, airflow rate, or air pressure—can cause the flame to directly contact the refractory bricks, greatly shortening their service life.
3.Installation (brickwork) issues
Alkaline bricks are generally used in the high-temperature zone of cement rotary kilns, and these bricks have a relatively high thermal expansion coefficient. If expansion joints are not properly allowed for, or if installation is not carried out according to specifications, the refractory bricks may crack during operation due to compressive and shear stresses.
4.Frequent kiln shutdowns
Since the refractory bricks used in the high-temperature zone are typically alkaline bricks with relatively poor thermal shock resistance, frequent kiln shutdowns can lead to spalling and peeling of the refractory lining.
Preventive Maintenance Measures
1.Select suitable refractory bricks for the high-temperature zone and optimize the cement calcination process to ensure a stable kiln coating.
2.Control coal injection pipes scientifically, avoiding frequent adjustments of angle, air pressure, and airflow.
3.Strictly follow refractory brick installation standards to ensure proper laying and expansion gaps.
4.Avoid frequent kiln shutdowns to reduce thermal shock and prevent spalling of the refractory lining.
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