World Cement - North America 2018

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A part of every process
While there are three different methods for installing
monolithic refractories, they all require the same setup:
placing the equipment on the ground and running a
steel or rubber delivery line from a pump or gunite
machine for material transfer. In many cases, the
delivery line can exceed 100 m in length, and much of
that delivery line runs vertically, meaning it is especially
important to choose a powerful and reliable machine.
The choice of any method to place monolithic
refractories is dependent on the use of high-quality and
dependable mixing, pumping, and spraying equipment.
Monolithic refractory materials used in cement kilns are
dense and abrasive, so contractors must ensure their
equipment can handle the conditions with minimal
downtime for maintenance or repairs.
In addition, features, such as swing-out hoppers and
20 min. quick-change-out 4 in. flat packs, enable fast
and easy maintenance. To minimise transportation costs
and setup time, the ideal set up is a mixer and pump
mounted on the same chassis.
What is new?
One of the newest advancements in the refractory
industry is the addition of equipment used to eliminate
dust generated during the mixing phase of refractory
installations. For example, Blastcrete Equipment, a
refractory and shotcrete equipment manufacturer, recently
launched its DustAway system. This dust mitigation process
includes the combination of a dust cover placed over the
refractory mixer, combined with a specially-made bulk
bag that has a dust ruffle attached to the bottom. The
dust ruffle encapsulates a flange on the mixer cover and
contains the dust in the mixer as the bulk bag is unloaded
into the mixer or the hopper over a gunite machine. The
dust ruffle stays in place until water can be mixed with the
dry material, which only takes a few seconds.
When using the dust ruffle with a gunite machine
for the dry process, a small cartridge dust collector is
used to collect the dust from the hopper over the gunite
machine, as well as any dust that might be generated
from the rotor section of the rotary gun.
Conclusion
For contractors accustomed to installing brick refractory,
now is a great time to embrace monolithic refractory
installation methods. While the processes calls for specific
mixing and material placement, advances in materials,
such as colloidal silica, and equipment designs lessen the
barrier to entry. Training is also readily available. Overall,
monolithic installations will allow contractors to save
considerably in terms of time and labour costs.
About the author
Jim Farrell is the CEO of Blastcrete Equipment LLC. With more
than 40 years of industry experience, he oversees production,
as well as research and development, for the refractory and
shotcrete manufacturing company.
Services Include:
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