Current Volume 8
Abstract
Rotary kilns are industrial furnaces used for the continuous processing of raw materials at high temperature, the kilns are long steel cylinders lined with refractory bricks, slightly tilted. They are subjected to complex stresses and deformations due to high temperatures and heavy loads, so monitoring and planned maintenance are essential to avoid very expensive unexpected shutdowns and other damages to the shell. This paper presents a review on monitoring the shell temperature and deciding based on the values obtained from the monitoring device the appropriate action to protect the refractory linings and the shell. Shell scanners and process sensors are the major monitoring devices while the shell cooling fans, water cool system and other process adjustment are the major shell temperature controls. The shell's temperature is carefully monitored and maintained below 400°C to prevent stress and damage. Between 380oC and 400 oC process adjustment must be done to drop the temperature below 400oC. Fatigue cracks might occur with continued operation above 400 oC, when the maximum allowed limit of 450°C has been reached the kiln shell burns and total deformation will occur that can only be corrected by replacing the entire portion. Controlling the temperature and taking appropriate measures at temperature below 400oC also protects the refractory bricks and will increase kiln efficiency, reduced downtime, and improved clinker quality. This directly translates to lower production costs and increased profitability for cement manufacturers.
Keywords
Cement kiln, High temperature, Kiln shell, Refractory, Shell cooling.
Citations
IRE Journals:
Samuel Audu Seth , Mohammed Ahmed Bawa , Aje Tokan , Jacob Shekwonudu Jatau
"Protecting the Cement Kiln Refractory and Shell from High Temperature" Iconic Research And Engineering Journals Volume 8 Issue 12 2025 Page 769-777
IEEE:
Samuel Audu Seth , Mohammed Ahmed Bawa , Aje Tokan , Jacob Shekwonudu Jatau
"Protecting the Cement Kiln Refractory and Shell from High Temperature" Iconic Research And Engineering Journals, 8(12)
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