Refractory Engineering and Kiln Maintenance in Cement Plants

Contents: 1. Development of refractories with changing technological scenario. 2. Appropriate refractories for various applications. 3. Improving Kiln up-time. 4. Fundamentals of refractory brick work. 5. Brick lining schemes. 6. Methods of installation of refractory linings. 7. Unshaped refractory products (monolithic). 8. Refractory anchoring. 9. Retaining ring system. 10. Kiln heating up schedule. 11. Inspection, storage and packing of refractories. 12. Refractory management. 13. Kiln alignment. 14. Kiln shell ovality. 15. Maintenance and repair of kiln. 16. Technical terms commonly used in refractory engineering and kiln maintenance. "Refractory Engineering and Kiln Maintenance in Cement Plants deals with two important areas that directly effect kiln availability for production. These two aspects decide if the cement plant would make profit or loss during the year. At the moment there is no book that deals with these aspects. The literature in these subjects is scattered and the totality of the subject is missing. The book Refractory Engineering and Kiln Maintenance in Cement Plants is an utmost requirement for the cement industry and would fulfill the needs of the Cement industry all over the world. It has brought out various developments refractory with the changing technological scenario. Production engineers and managers look for information on the correct refractory materials for different zones of kiln, the schemes of brick-lining, the needs for each individual operating situation and various methods of installation of refractory, so as to maximize the operating life of the klin. The book covers these aspects in detail. Further, the heating-up process of the kiln greatly influences the life of refractory, that is related to 'heating-up schedule'. Maintenance engineers and managers are concerned with various engineering aspects to make the kiln system stable and reliable. The book deals with aspects such as retaining ring systems and anchoring. Chapters on 'Kiln Alignment' and 'Shell Ovality' provide useful information about these most critical aspects of great concern to many. Chapter on 'Maintenance and Repair of Klin' provides information for handling such specialized, critical and costly works. Purchase engineers, inventory engineers, warehouse officers and storekeepers need information on correct methods of inspection, storage and packing of refractory. A separate chapter on these aspects fulfills these requirements and would help in avoiding damage or loss or refractory materials and would ensure timely availability of refractory for replacement, repair and maintenance works. The information in the chapter is also useful in settling the insurance claims regarding refractory supplies amicably. All the requirements of the refractory in a kiln are not met with the refractory bricks alone. There are areas in the kiln system that can be lined with unshaped refractory materials only. This publication deals with various types of unshaped refractory materials, their suitability to different applications and the method of their installation. The book also discusses various issues to improve the up-time of kiln and suggests remedial measures for each problem area. In addition, the chapter on 'Refractory Management' is useful to all levels of management in controlling and monitoring the consumption of refractory per ton of clinker production. The book is expected to bring support to production managers, production engineers, kiln operators, refractory engineers, maintenance managers, maintenance engineers, purchase engineers, inventory engineers, warehouse officers and storekeepers. In addition, the top management will find the book a dependable source for vital information.".…