RHI - Cement Kiln Brick Installation

Installation of Rotary Kiln Bricks
RHI Business Unit Cement, J. Nievoll, 04.07
Content
Preparatory work
Lining methods
Bricks and mortar
Bricking procedure
Specific lining situations
Kiln start-up
Storage
Installation report
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1. Preparatory work
General information (lining chart, lining method,

mixing ratio, packing list, working instruction ..)
Technical meeting with bricklayers / contractors
Inspection of kiln shell in repair section
Safety instructions
Even after passing the most rigourous safety

instructions keep always your eyes open when entering
and working inside the kiln!
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Safety gear
Adrian (far left) and
Pablo (far right)
are fully equipped:
hard hat, safety
shoes, gloves,
safety glasses and
dust mask. Ricardo
and Juan (center)
have not yet put on
their gloves.
Local safety regulations have always to be followed strictly!

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2. Lining methods
DAT Bricking Rig
Pogo Sticks
Jacks
Glue
Bolts
Lining speed
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DAT Bricking Rig

Safest lining method, adaptable for different kiln diameters,
no turning of kiln
DAT Bricking Rig assembled
DAT Bricking Rig in operation

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Lining with a DAT Bricking Rig
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Pogo Sticks
Low-cost method where pogo sticks support the lining. No
pressurized air. No turning of kiln, wooden rig is not
adaptable for different kiln diameters.
kiln shell
magnesia bricks
with cardboards
pogos
wooden rig
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Screw Jacks: Lining sequence
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Advantages of screw jack method: Rapid set-up, low-cost equipment with

low maintenance costs. Recommended for patchwork, small diameter kilns
( <4 m) and short sections (<4 running meters)
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Glue method
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Bolt method
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Both the glue and the bolt method require a skilled

workforce to avoid safety risks. For gluing, kiln shell
must be clean and dry; low temperatures (<5C) will
retard hardening of the glue follow manufacturers
instruction!
With gluing and bolting the kiln inner space is not
obstructed by bricking rigs, jacks etc. Kiln needs to be
turned for completing the rings.
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Lining Speed
Safety first. Then quality. Then speed
The often cited rule of thumb:
Kilns with 4m >>> 5 meters per shift (10 meters/day)
Kilns with 5m >>> 4 meters per shift (8 meters/day)
must be seen as a minimum today: with detailed planning,
sufficient personnel and a skilled workforce 16-20 meters/day
will be lined without incurring quality
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3. Bricks and mortar

Basic and alumina bricks
VDZ vs. ISO shapes
Clench vs. mortar lining
Metal sheets attached
Cardboards
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Brick Shapes: VDZ vs. ISO

General recommendation: Use VDZ shapes for basic lining and
ISO shapes for alumina bricks
Note: For very large diameter kilns ( > 5.6m) ISO shapes are recommended also for basic bricks, due to the
greater taper, which increases lining stability during kiln start-up
VDZ linings have approx. 30% more brick joints which provides
increased flexibility and thermal shock resistance to the rings.
Basic bricks have cardboard attached to compensate for higher
thermal expansion.
Alumina bricks are usually layed with mortar to adjust greater
dimensional tolerances of alumina brick.
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VDZ Shapes
17 70
ISO Shapes
h/2=(a+b)/2=71,5 mm
a=103 mm
a and b are variable
b is variable
Standard Rotary Kiln Brick Shapes (selection)

SHAPE
DIMENSIONS
[mm]
DIAMETER
[mm]
VOLUME
MARKING
(Basic Bricks)
D1)
[dm]
Colour
65
200
198
2400
2,83
White
76,5 66,5 200
198
3060
2,83
Violet
a
VDZ-Shapes
B220
B320
78
B420
75
68
200
198
4286
2,83
Yellow
B620
74
69
200
198
5920
2,83
Red
B222
78
65
220
198
2640
3,11
White
76,5 66,5 220
198
3366
3,11
Violet
B322
B422
75
68
220
198
4714
3,11
Yellow
B622
74
69
220
189
6512
3,11
red
ISO-Shapes
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220
103
82
200
198
2000
3,66
White
320
103
98
200
198
3000
3,80
Violet
420
103
92,5 200
198
4000
3,87
Yellow
620
103
96,2 200
198
6176
3,94
Red
222
103
198
2009
3,99
White
80
220
Cardboards (basic bricks)

Attached on axial joint (thickness 1.5 mm). Burn-out of cardboard is
faster than thermal expansion of bricks, so great care must be taken
when turning the kiln during heat-up.
Metal sheets (magnesia chromite bricks)

Attached on radial joint of each brick (thickness 0.7 mm). Starts
to soften at approx. 600C and to oxidise at >1000C thus
forming a ceramic bond between bricks. Must not be confounded
with key shims which are driven in to tighten the rings.
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Mortar lining
Mortar on the radial joints helps to even out surface irregularities
of bricks and to distribute stress evenly over the whole area. It is
therefore recommended for kiln sections with increased
mechanical instability or ovality (e.g. tyres, kiln drive, outlet).
Thickness of mortar joint should not exceed 1 mm.
Clench lining
For simplicity and speed of installation most basic bricks are
clench lined, i.e. without mortar or metal sheets.
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4. Bricking procedure
Marking the axial line and radial lines (e.g., by
Radialign)
Staggered vs straight rings
Ring closure (key bricks, position of key bricks, jacking
pressure )
Key shims (position, thickness, drive-in procedure )
Fit to old brickwork (L-shapes, position of cut / standard
size bricks )
Re-shimming of old brickwork
Open axial joints in old brickwork what is acceptable?
Preparing for warming-up
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Marking the axial line and radial lines

Fixing the axial and radial lines by (a) level & plumb bob or (b)
by laser goniometer
22 70
Recommended: Staggered lining

pattern. Overlapping of adjacent
bricks allows relative movement of
individual rings without edging
Not recommended
Compound lining pattern
axial joints
radial joints
straight lining pattern
23 70
Brick laying
Start rings according to the indicated mixing ratio
Knock the bricks in place with rubber hammer
Frequently check that rings are parallel to radial
lines
Check always that cold face of brick is
in full contact with kiln shell
Do not complete sections

longer than 6-8 meters!
24 70
Working direction is always uphill
Recommended: Staggered lining
25 70
Tolerated: Straight lining
26 70
Two Taper System
Compare theoretical and actual mixing

ratio in every ring, document deviations!
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Checking the mixing ratio
4.5 m. Theoretical ratio B622:B322 100:88;

actual ratio B622:B322 101:86
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Brickwork turning
too fast
Brickwork turning
too slow
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Ring Closure
Take great care to close every ring correctly!
(1) Tighten bricks

with hydraulic jack.
Maximum jack
pressure should not
exceed 35-40 N/mm2
(~1/2 brick cold
crushing strength).
During jacking knock
bricks with rubber
hammer
30 70
(2) Combine standard shapes and key bricks to obtain a straight

joint of 4-6 mm thickness. Never cut standard or key shapes
parallel to radial joint to fit the gap!
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Avoid V- or -shaped joints: Brickwork will always be loose,

even after shimming
Open joints
Key brick
32 70
(3) Inserting the last brick: In case the brick

combination is perfect without open joint, never knock
with hammer onto the brick!
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(4) Staggered position of key bricks and key shims. Do not use more
than 2-3 shims per rings. Recommended thickness 2 mm. Use
pneumatic shim driver if available. Without shim driver, 3 mm thick
shims are acceptable. Phased (bevelled) shims greatly facilitate
driving in. Drive in not more than one shim per joint.
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Whats wrong?
35 70
Whats wrong?
36 70
Whats wrong?
37 70
(5) After releasing the bricking rig (or srew jacks), rings must
remain in contact with kiln shell
Recommended: pneumatic
shim driver ...
... but still widely used: hammering
in the key shims
38 70
New lining meets old lining

After breaking out the bricks, the old lining remaining in the kiln has
to be fixed by angle irons welded onto the kiln shell. Remove
concretions on axial joint of old lining (arrow) by grinding tools, not
by hammer
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Whenever possible do not

cut the first ring, install cut
bricks between full rings.
Use long bricks (L shapes)

to fill gap of 200-300 mm.
With standard shape bricks,
never use bricks <100 mm.
Compound lining enhances
stability. Document position
of cut rings.
40 70
Whats wrong?
41 70
Do not cut magnesia bricks with water! Wet magnesia bricks will
probably hydrate during kiln heat-up
42 70
Re-shim open
radial joints in
old brickwork
to avoid any
risk of brick
slip during kin
heat-up
open radial joints
Open axial joints in old brickwork: fill gaps up to 60 mm wide with

ceramic blanket. If gap is >60 mm, remove adjacent ring and fill in cut
long shapes
43 70
Preparing for kiln heat-up

After closing the last ring and removing the bricking rig, screw
jacks etc., turn the kiln at lowest speed by 180 and check the
lining for open joints, sagged rings. If necessary, tighten rings
with additional key shims.
Compare theoretical and actual number/shapes of installed
bricks. Document deviations from theoretical number.
In case of nose ring castables, follow drying instructions of
supplier.
44 70
5. Specific lining situations

Deformed kiln shell
Correcting rings in radial direction
Partial repairs (patching)
Retaining rings
Veitsch-Magotteaux retaining ring system (VMRRS)
Nose ring
Cone sections
45 70
Deformed kiln shell

Always a challenge for bricklayers. Level out deformed
shell with mortar or castable. If necessary, cut bricks to fit
best onto the kiln shell.
46 70
Not recommended: To fill V-shaped joints with mortar or

castable. Crushing strength of thin layers of mortar and
castables is much lower than strength of bricks
mortar
welding seam
47 70
Bricks over welding seams

Never prepare bricks by chipping with hammer if necessary
use brick saw
48 70
Correcting rings in radial direction
Use mortar or ceramic paper of

max. 2 mm thickness. Steel
shims are NOT recommended.
Removing of expansion
cardboard is NOT
recommended.
49 70
NOT recommended: To remove cardboards
50 70
Partial Repairs
(Patching)
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Retaining Rings
For simplicity, two retaining rings (50 x 50 mm) are recommended
Recommended
Accepted design
Use standard shapes if possible, avoid cutting. A 50 mm step in the

outlet section usually does not obstruct clinker flow
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Retaining Rings
Accepted: Cut bricks at the
outlet side. Always cut basic
bricks dry!
Accepted: To avoid brick

cutting and in case an existing
retaining ring is not removed, it
can be covered by castable.
Insert plastic between brick
and castable!
The combination of retaining ring and castable (with metallic

anchors) provides very high stability. Spiralling in front of the
retaining ring is made more difficult with a compound lining of
standard bricks and 300 mm long bricks
53 70
For severe lining thrust, RHI has developed a special retaining system:
the Veitsch Magotteaux System. It consists of honeycomb cast iron
segments supplied by Magotteaux, Belgium, and special shaped
ANKRAL R2 bricks.
Installation drawing
54 70
View towards the outlet
Cone section
Recommended: special shapes
to fit as tight as possible to the
kiln shell. Use as little mortar
as possible in radial joint
brickwork in cone section
should not be compressed
Not recommended: standard

shapes plus mortar and cut
bricks in the lower and upper
end of cone
Consult drawing for position of axial expansion joints
55 70
6. Kiln start-up
Warming-up curve
Burn-out of cardboards
Re-shimming in case of warm-up interruptions
Shut-down procedure
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Warming-up curve
after ALSOP 2005, The Cement Plant Operations Handbook, 4th ed.
57 70
Burn-out of cardboard between 200-800C is more rapid

than thermal expansion of magnesia bricks, so turn kiln
at lowest speed. Monitor temperature difference
between tyre and kiln shell (<160C) and tyre migration.
In case heating-up has to be interrupted and kiln must
be cooled down, check lining stability before relighting
the kiln. If necessary, re-shim loose sections of the
lining.
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This may happen with a bad installation ....
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This may happen with a bad installation ....
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Would you call this correct re-shimming?
61 70
Shut-down curve should follow heat-up curve in the

reverse sense. Entering the kiln before 24 hours after shutoff will prove difficult because of red hot coating firmly
attached to lining.
Breaking down and emptying the coating during cool-down
by turning the kiln at highest speed is definitely NOT
recommended. It may twist the lining, crush the bricks at
the retaining rings and deform the outlet segments.
62 70
7. Storage
General storage instructions
Shelf life (basic bricks, aluminous bricks, mortar)
Hydration of magnesia bricks
Wet bricks, wet lining sections
63 70
Check materials upon arrival for transport damages.

Store refractory materials under roof in ventilated, dry rooms and
protected against rain, splashing water, snow etc. from all sides.
Under tropical conditions, open plastic shrink wrapping to avoid
condensation of water within the pallet.
Maximum shelf height

Magnesia and alumina bricks
Light weight / insulating bricks
Castables, gunning mixes, mortars ...
64 70
4 pallets
2 pallets
2 pallets
Maximum shelf life

Fireclay and alumina bricks are not susceptible to hydration and
can be stored indefinitely.
Mortar should not be stored at customers warehouse for more
than 12 months.
Magnesia bricks are susceptible to hydrate, especially under
tropical conditions and when made from high purity, synthetic
magnesia.
65 70

Radial cracks (arrows) are an inequivocal sign of hydration;
hydrated bricks cannot be used anymore.
66 70
Bricks with radial cracks have

lost their mechanical strength
and must be discarded
When knocked with a steel

hammer, hydrated bricks sound
dull and break easily
67 70
Wet bricks and wet lining sections

Magnesia bricks which have become wet must be stacked
openly and ventilated at ambient air temperatures until dried
completely. Do not use hot air, do not expose wet bricks to
the heat radiated from the kiln shell. After drying, check
bricks carefully for radial cracks.
New lining sections which have become wet must be
removed and replaced by dry bricks.
68 70
Wet bricks must be removed!
69 70
8. Installation report highly recommended!

Basic data (start and finish of works, rings and
brick grades installed, position of brick grades, lining
method etc.)
Theoretical vs. actual mixing ratio per ring, number of
key shims per ring
Remarks (e.g., deformed kiln sections, cut sections)
Pictures
Final inspection of the installation
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Thank you for your attention !
www.rhi-ag.com
71 70

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Installation of Rotary Kiln Bricks

RHI Business Unit Cement, J. Nievoll, 04.07

Installation of Rotary Kiln Bricks

General information (lining chart, lining method,

Even after passing the most rigourous safety

Installation of Rotary Kiln Bricks

Local safety regulations have always to be followed strictly!

Installation of Rotary Kiln Bricks

Installation of Rotary Kiln Bricks

DAT Bricking Rig

DAT Bricking Rig in operation

Installation of Rotary Kiln Bricks

Lining with a DAT Bricking Rig

Installation of Rotary Kiln Bricks

Installation of Rotary Kiln Bricks

Screw Jacks: Lining sequence

Installation of Rotary Kiln Bricks

Advantages of screw jack method: Rapid set-up, low-cost equipment with

Installation of Rotary Kiln Bricks

Installation of Rotary Kiln Bricks

Installation of Rotary Kiln Bricks

Both the glue and the bolt method require a skilled

Installation of Rotary Kiln Bricks

Installation of Rotary Kiln Bricks

3. Bricks and mortar

Installation of Rotary Kiln Bricks

Brick Shapes: VDZ vs. ISO

Installation of Rotary Kiln Bricks

a and b are variable

Installation of Rotary Kiln Bricks

Standard Rotary Kiln Brick Shapes (selection)

76,5 66,5 200

76,5 66,5 220

Installation of Rotary Kiln Bricks

Cardboards (basic bricks)

Metal sheets (magnesia chromite bricks)

Installation of Rotary Kiln Bricks

Installation of Rotary Kiln Bricks

Installation of Rotary Kiln Bricks

Marking the axial line and radial lines

Installation of Rotary Kiln Bricks

Recommended: Staggered lining

Installation of Rotary Kiln Bricks

Do not complete sections

Installation of Rotary Kiln Bricks

Working direction is always uphill

Recommended: Staggered lining

Installation of Rotary Kiln Bricks

Tolerated: Straight lining

Installation of Rotary Kiln Bricks

Two Taper System

Compare theoretical and actual mixing

Installation of Rotary Kiln Bricks

Checking the mixing ratio

4.5 m. Theoretical ratio B622:B322 100:88;

Installation of Rotary Kiln Bricks

Installation of Rotary Kiln Bricks

(1) Tighten bricks

Installation of Rotary Kiln Bricks