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Refractory Rescue

Published by , Deputy Editor
World Cement,

Wouter Garot, SILICON, describes how moveable anchoring systems could benefit the refractory industry by reducing installation and repair work and offer improved corrosion resistance for refractory materials.

Over a billion tons of cement are made per year, and cement kilns are at the heart of this production process. Continual demands made in the cement industry for greater productivity and lower maintenance costs have pushed the industry to the limits of the conventional technologies existing on the market today. SILICON has recognised many of these limits and it has become the company’s mission to transform the refractory industry through the use of superior anchoring systems.

Moveable anchors

One of the company’s most popular types of anchors used in the cement industry are the ‘moveable anchors’ mainly used in rotary kilns where stress occurs due to refractory movement. These conventional anchors are commonly fastened to an omega shaped bracket by manual electrode welding and are tack welded so that they break ‘free’ during operation and ‘float’ within the omega bracket. This allows the anchor to move with the refractory material as it undergoes variable loads, thereby greatly reducing stresses on the refractory material.

The SpeedBolt® was developed to facilitate the installation of moveable anchors for dynamic refractory linings in the cement industry and other applications where rigid anchoring systems are to be avoided. It also offers a solution to lessen the vast number of hours that usually go into the installation and repair work of anchoring systems in cyclones, rotary kilns, klinker coolers, calciners, ducting and more, whilst also offering corrosion resistance.

The design of the new SpeedBolt Heavy Bullhorn anchor is based on a standard SILICON Heavy Bullhorn anchor. It is adapted to easily place the anchor through the eye of the SpeedBolt and lock it in place using the SpeedClip. This adaptation enables a faster installation time. A solid holding power for heavy refractory is achieved with the anchor’s corrugated legs. The strongly corrugated wave will hold the refractory through any movement it may make, allowing the refractory lining to be flexible and tough. The moveable anchors are available in many different metal alloys in ø8, ø10 and ø12 mm.

How it works

The SpeedBolt anchor is welded onto a casing; the shank is ø16 mm which ensures a solid weld base for the heavy refractory load – the Bullhorn anchor is placed through the SpeedBolt eye. Finally, the plastic SpeedClip is put in place by hand or with a hammer to securely position the anchor. The clip melts at temperatures above 220°C (428° F) giving the Bullhorn anchor freedom to move. The SpeedBolt can be installed on flat and curved surfaces, side-hand, overhead and downwards.

The SpeedBolt anchor does not need replacement when the Bullhorn anchor needs to be replaced in the next turnaround. It is made of stainless steel and will resist corrosion at the shell side for several turnarounds. This eliminates the need to weld a new SpeedBolt each time, thereby saving extra time in the installation of the new anchors, which then only need to be clipped in the SpeedBolt eye again as before.

Dual lining

A dual lining version has also been developed where improved insulation is required. In the case of a dual lining system, a threaded stud or shoulder stud is first welded onto the casing. The SpeedBolt is screwed on top after the back-up layer is installed.

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