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Installation manual for Dengda castable refractory used in the rotary kiln

Jun 09,2014
Installation manual for castable refractory used in the rotary kiln
Preparation
1,The tools such as mixers must be cleaned, without any dust, welding slag, waste or mud.
2,The installation site should have security, cooling, anti-freeze, rainproof and other necessary measures. The workers must have been trained.
3,Moisture-proof and rainproof measures must be taken during transport and storage. The storage life of castable refractory is about three months. As a result, the installation period of time in rainy or humid environment should be shortened.
4,Enough castable refractories should be prepared. Cashable refractory should be marked after transported to the installation site, and placed separately according to name and brand.
5,Open the power to check the installation equipments. Spare installation equipments are necessary to keep constructing continuously.
6,Water used for installation must be clean enough, achieving standards for drinking. And the temperature of water should range from 5-35°C. Sewage, muddy water and industrial sewage are forbidden to use for installation.
7,Castable anchor should be painted with varnish or wrapped with plastic membrane after welding and before using. Castable anchor is prepared with $ 8-12 mm round steel or rebar, and heat-resistant stainless steel which is used in above 500°C parts. The sharp of castable anchor could be "Y" or "V", and the total height is 2/3 of the thickness of castable refractories. The anchor should be dislocation welding. The distance between anchors is not restricted, range from 200-300mm, but should not affect the running of the vibrating spear.
Mixing
1, Forced mixer should be used during mixing. Coarse particles and fine powders (in big bag) should be added firstly, and then additives (in small bag). After dry mixing, water is added according to measurement until the castable is mixed homogeneously.
2 The amount of water added could be adjusted according to the local climate conditions and actual installation requirements. References are given as 8-10%.
3,The mixed castable refractoris should be used in 30 minutes. Concretionary castable refractories are forbidden to use.
4,According to the timeliness of castable refractory, a whole bag or barrel castable refractory should be used once.
5,Using of different brands and models of castables is strictly prohibited.
Installation
1,Models are used during installation process. Wooden models should be wetted by water or pasted with a layer of linoleum, while the iron models should be painted with a layer of lube.
2,The models before using must be fixed well to prevent from deformation and shift during installation process.
3,Plastic thin film or linoleum should be paved between the heat-insulation layer (permanent layer) and working layer to reduce the influence of penetration of water.
4,Castable refractories should be vibrated immediately after poured into the model. Missed vibration and overmuch vibration are forbidden. After being vibrated densely, the internal vibrator should be removed slowly.
5,The required thickness should be achieved once during constructing process. The castable should be vibrated densely to eject air.
6,If the castable is satisfy the installation requirement, installation time and water amount are necessary to be reduced to improve the performance of castable refractory.
7,The section of castable refractory after installation must be perpendicular to kiln where the anchor is located. Separate castable layers are forbidden.
Demoulding and curing
Castable refractories are demoulded after 24h curing in moulds, and cured at range of 10-30°C for 48h or dried naturally.
Preheating
1,Curing and preheating of castable refractory are two key steps during installation process. As the result, the preheating schedule must be carried out strictly.
2,Following table is the preheating schedule.

The lime rotary kiln with castable heating curves