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Necessary steps to solve Cement Rotary Kiln problem due to loss of Refractory Lining

Rotary Kiln Refractory Lining Installation


  • Loose bricks in clinker bed of burning zone
  • Delineated (linear instead of round) Red spot on the kiln shell
  • Rapid rise in shell temperature

Possible Effects & Dangers

  • Thermal damage and distortion of kiln shell and tire
  • Further collapse of large sections of linings 

Suggested Actions to Take

  1. Immediately shut down the kiln


Preventive Actions

  • Employ proper refractory installation methods and procedures for rotary kiln
  • Make annual checks of kiln alignment and shell ovality.
  • Use refractory bricks of uniform shapes and proper expansion allowance for each type of refractory brick
  • Avoid excessive turning when kiln is cold during shutdowns 

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Rotary Kiln Problem due to loss of Refractory Lining Installation

Because of the high temperature existing inside a rotary kiln during the clinker manufacturing process, it is necessary to protect the steel shell of the kiln with a refractory lining.

It is not uncommon for the cement rotary kilns all of them operating within a narrow temperature range in the burning zone and having other parameters also similar, yet with large discrepancies as far as their refractory life is concerned. The reason for this can be found in the fact that each kiln has its own specific characteristics and idiosyncrasies which greatly influence its refractory life.
Also refer: How to minimize Refractory Failure and wear of Refractories inside a Rotary Kiln