Causes and preventive measures for the shedding of refractory materials at kiln mouth

The shedding of refractory materials at the kiln mouth can cause serious production problems, affecting equipment operation efficiency and personnel safety. So, what are the reasons for the shedding of refractory materials at the kiln mouth? Let's discuss them today:

1. Construction quality issues

During the construction of kiln refractory materials, if there are problems with the construction quality, such as excessive water addition, uneven mixing, unreasonable layout of anchor nails, etc., the refractory materials will fall off or crack. For example, the shedding rate caused by improper construction was as high as 15%.

2. Unreasonable design

If the kiln mouth design is unreasonable, such as structural design defects that easily cause deformation and wear, it is likely to cause the refractory material to fall off. An optimized design can reduce the shedding rate by 30%.

3. Effects of rapid cooling and heating

The kiln mouth is often in a rapid cooling and heating environment, which causes the refractory materials to frequently experience thermal expansion and contraction, and eventually thermal fatigue and spalling. According to statistics, spalling caused by temperature difference accounts for 25% of the total spalling reasons.

4. Material flushing

Frequent loading and unloading of materials at the kiln mouth causes serious material erosion, especially when flying sand and hot flue gas impact, which will accelerate the loss of refractory materials. Therefore, it is very important to choose refractory materials with strong erosion resistance. Studies have shown that the use of highly wear-resistant materials can reduce the shedding rate by about 20%.

5. Mechanical stress

The rapid rotation of the kiln body and the high temperature expansion of the kiln head produce mechanical stress and extrusion on the refractory material, causing it to fall off. This phenomenon is usually very obvious when the kiln head rotates too fast.

By optimizing the construction process, improving the kiln mouth design, using high-quality refractory materials and other measures, the problem of refractory material shedding at the kiln mouth can be greatly reduced and the service life of the kiln can be extended. I hope the above information will be helpful to everyone and promote the improvement of production efficiency and safety.