WO2018167586A1

WO2018167586A1 - Fabrication of immersion tube with shackle for cement rotary kiln

Info

Publication number: WO2018167586A1
Application number: PCT/IB2018/051171
Authority: WO
Inventors: Abbas MOFAZALI
Original assignee: Mofazali Abbas
Priority date: 2017-03-11
Filing date: 2018-02-24
Publication date: 2018-09-20

Abstract

The Immersion tube with a shackle for cement kiln comprises refractory upper segment along with hanger parts; refractory hanger; refractory intermediate segment; refractory lower segment; refractory holder connections. The refractory holder connection is composed of a refractory shackle, refractory countersunk bolt, and refractory fish plate strap.

Description

Fabrication of Immersion tube with Shackle for Cement Rotary Kiln

The technical field of this invention is related to the equipments of cement factory.

Application Number: 08144772 Application Date: 29.10.1993

Publication Number: 5441081 Publication Date: 15.08.1995

Grant Number: 5441081 Grant Date: 15.08.1995

An immersion tube for a cyclone has a plurality of rings stacked atop one another and connected to one another. Each ring is comprised of a plurality of plate-shaped segments. The plate-shaped segments of one ring are suspended under the force of gravity from the plate-shaped segments of another ring positioned above said one ring for connecting the segments of each ring to one another. Each segment has contact surfaces for connecting each segment of the one ring to the segments of the other ring positioned above said one ring, wherein the contact surfaces comprise first inclined planes facing outwardly with respect to the immersion tube. Preferably, the contact surfaces comprise also second inclined planes facing inwardly with respect to the immersion tube.

As it is obvious in the prior art, the plate-shaped segments of one ring are suspended under the force of gravity from the plate-shaped segments of another ring positioned above and each upper ring holds the plates below.

This is exactly the major fault with this system in which each ring is connected to the ring below under the gravity and all of the segments will collapse by the pyramid fall and result in multi-billion cessations of kiln in the cement factories. In fact, despite this method, the invention claimed here completely denies the suspension under gravity. The present invention creates a resistant metal texture to stop the collapse and it never falls or collapses.

In the present invention, the collapse of the kilns is prevented by creating a resistant texture in the immersion tubes and the durability of the immersion tubes increases for years. In fact, the new invention has set a record for the durability and life span of over 3 years and even up to 5 years.

Among the special potentials of this invention, we can refer to the structural resistance and the thickness of the plates and installation of locking shackles which overcome the problem of deformation and collapse because of heat.

This idea originates from Catch ideas from the metal texture of a hand watch strap with the resistant metal structure. In fact, it can be used in the mineral and cement industries for a long time by creating a resistant metal texture for a metal transfer for material handling.

The collapse can be prevented by creating a suitable and resistant texture in the immersion tube and design an immersion tube which lasts for many years like a resistant metal texture which works efficiently.

This invention is concerned with the probable cessation of the Rotary Kiln in industrial complexes for cement production. Since the structure is weak and the materials used for Immersion tube segments are old-designed, when the temperature and heat rises, the holder tenon are deformed, burnt, and collapsed into the loading path of Rotary Kiln in a pyramid shape which blocks the loading passage and cessation is repeatedly imposed on the kiln.

This invention intends to reduce and control the cessation of rotator kiln and decrease the costs for preserving the equipments and personnel life working in cement factory. The old designs of Immersion Tube with holder Edge & Tenon in most of the cement factories has always faced with such problems as deformation, burnt, and collapse in a pyramid shape due to the following major weaknesses:

A - Weakness in Transformation & Deformation of Holders:

Since the design and form of Holders Edge & Tenon in the Segments of old-designed immersion tube is weak, when exposed to heat and high temperature in Pre-heater Cyclones, the lower Segments plates exert the highest weight on the upper plates and it will be the origin for the formation of the pyramid collapse.

B - Weakness in Transformation & Deformation of Segments:

In Thermal shock and very high temperature ranging from 900 to 1100, it is extremely deformed and loses the circular shape and turns into an oval shape. Under such circumstances, the holders of old immersion tube plates exit from each other and the whole segments of immersion tube are collapsed at once.

C - Weakness in Transformation, Corrosion & burn of Segments:

Using weak material results in weakness in the structure as well as physical and chemical segments of immersion tube. On one hand, the segments are easily burned and deformed inside the Pre-heater Cyclones by the Thermal shock, high temperature, and uncontrollable condition for exploitation.

On the other hand, they suffer from extreme chemical corrosion because of proximity between immersion tube segments, Alkalies annoying cycles, Volatile Combined cycle in baking system, and the combination of sulfur and chlorine with the nickel existing in the weak material which forms Malicious carbides and leads to metal corrosion. The factors for corrosion include:

A : Alkalies the origin of which is raw material and include Clay minerals and feldspars.

B : Sulfates the origin of which is fuel and include Sulfates Sulfides and thiosulfides

C : Chlorides the origin of which is fuel and raw material and are mostly in the form of KCL and Nacl

D - Weakness in Pyramid Collapse of Segments:

Old immersion tube segment is locked into each other in the form of a brick wall in a ring of steps by holder edges & tenons. Therefore, when one of them at the head of the pyramid falls, all of them collapse along with the lower rings in the pyramid shape and finally lead to the blockage of entering load into the Rotary Kiln of cement factories and repetitive cessations are continuously produced.

After obtaining ideas from the resistant metal texture, designing a resistant and durable immersion tube with distinctive capabilities by omitting all of the weaknesses of the old designs were included in the main targets of designing as follows:

A- More resistant holders:

Capabilities: with the application (Refractory steel shackles) and elimination of weak holder related to the old immersion tube design

B- More resistant material :

Capabilities: with the application (best of Resistant refractory casting steels for example: 1.4848 or 1.4852 and etc. according Steel Key Handbook) and elimination of weak material related to the old immersion tube design

C- Resistant metal texture

Capabilities: with the application of a resistant metal texture by connecting vertical and horizontal refractory shackles and screws between the segments of vertical and horizontal rings and elimination of suspended weak texture related to the old immersion tube.

1- Preventing constant cessation of the cement kiln due to the collapse of immersion tube segments

2- Increasing the efficiency of factory production

3- Saving money for factory

4- Increasing the life span of immersion tube segments

5- Decreasing the repair cost and constant replacement of immersion tube segments

6- Reducing the burnt and death toll for the workers due to the blockage of kiln loading path

7- Long-term and easy use of the new development

Fig.1

View of an assembled segment

Fig.2

Exploded view of a segment

Fig.3

View of the installed segments beside each other

Segment No. (1) is a sample of upper segments which is installed in the highest rings of immersion tube segments. This ring of segments is connected to the ceiling of pre-heater cyclones and in fact the whole weight of immersion tube is transferred to the cyclone ceiling in this way. Their number in the upper ring ranges from 36 to 48 in different factories.

Segment No. (2) is a hanger which is used as the holding leg and connects the upper segments to the ceiling of the cyclone.

Segment No. (6) of lower segments is related to the middle and lower rings of immersion tube and includes five rings and in each ring, the number varies from 36 to 48 depending on the diameter of cyclone in different factories and the pre-heater of each factory is developed according to the diameter of cyclone.

Segment No. (3) (9) (7) (8) are related to the series of holding connections (Connectors) which include refractory shackle, refractory Cuntersunk bolt (9) and (3) and refractory fish plate strap which are used for creating a resistant texture in the immersion tube and connection to the pre-heater cyclones.

The Immersion Tube with shackle is composed of four main segments. The first and second segments are upper segment and hanger. The hangers are put inside each other on the bumps which are installed above the upper segment and the hangers are installed on the rim of riser duct in the middle of cyclone.

In fact, the whole weight of immersion tube is transferred to the ceiling of the cyclone from this area in a hanging way and the remaining segments of immersion tube are in the 5 lower rings including 4 rings of intermediate segment and one ring of lower segment and all of the mentioned parts are connected and woven to each other by the refractory connectors including shackles, Cuntersunk bolt, and Fishplate like a resistant steel texture.

Implementation method for applying the invention

In case cement factories are interested to use the above explained innovative development, the following steps are required to be taken:

1- Visiting the site and collecting data about the place

2- Studying and examining the available drawing

3- Evaluating the feasibility on the pre-heater department and existing pre-heaters

4- Doing the designing and engineering evaluations

5- Providing the primary draft

6- Producing the segments of new design

7- Disassembling the segments of the old design

8- Assembling the new segments

This invention is applicable in the factories producing grey and white cement and probably in the plaster factories. In the pre-heater department and rotating kilns of these factories, the old immersion tubes are used. This invention is a new type of this segment with a permanent connection and texture.

Claims

The Immersion Tube with shackle for Cement Kiln is composed of the following parts: A- Refractory Upper Segment along with hanger parts; B- Refractory Hanger; C- Refractory Intermediate Segment; D- Refractory Lower Segment; E- Refractory holder Connections.
According to claim 1, Refractory holder Connections is composed of the following parts: A- Refractory Shackle; B- Refractory Cuntersunk bolt C- Refractory Fish plate strap
Upper segments (1) which is installed in the highest ring of immersion tube segments by the hanger to the ceiling of pre-heater Cyclone.
Hanger (2) which is the holding leg and connector of upper segments to the ceiling of cyclone.
Lower segments (6) related to middle and lower rings of immersion tube.
According to claim 1, hangers are installed on the bump above the upper segment which are interconnected.
According to claim 6, these two segments are installed on the edge of riser duct in the middle of cyclone.
According to claim 1, except of hanger and upper segment, the remaining parts of immersion tube are in the five lower rings including 4 rings of intermediate segments and one ring of lower segment.
According to claim 1, all of the mentioned parts are connected and woven to each other by the refractory connectors including shackles, Cuntersunk bolt, and Fishplate like a resistant steel texture.