INSTRUCTION .

Burner Pipe Refractory Installation

Created by : CREP

Approved by : GRC

Approved date : 22. December 2015

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Table of contents:
Page No:

1. General information .................................................................3

2. Refractory Castables ................................................................3
3. Storage .................................................................................3
4. Site of Working .......................................................................4
5. Mixing ...................................................................................4
6. Placement of templates and formwork ........................................6
7. Installation .............................................................................6
8. Curing ...................................................................................10
9. Preheating .............................................................................11

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NOTE!
The present instruction manual is concerned with the situations, which,
according to the experience of FLSmidth, are the most likely to occur. An
exhaustive enumeration of all conceivable situations, which may occur during
the installation, operation and maintenance of the refractory castables, cannot
be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in
the instruction manual, and which the operator is/or feels unable to handle, it is
recommended that FLSmidth is contacted without undue delay for advice on
appropriate action.

Warning!
If this is shown in the instruction manual specific attention and caution is needed.

1. General information

This manual gives a detailed description and overall guidelines for placement of low
cement refractory castables on the burner pipe. In instances where specific
instructions have been provided by the refractory supplier for the application of burner
castable, it is imperative that such instructions be strictly followed.

2. Refractory Castables

A Refractory castable is a dry, powdery material which solidifies into a hard mass after
mixing with water. When heated, the hardened castable gives off water and at high
temperatures it sinters into a ceramic refractory material.
Refractory castable are often used for lining complex areas in which it is difficult to
use lining bricks.
The castable is fixed to the steel casing by anchors which must be fitted as indicated
on the lining drawing and/or as directed by the supplier.

3. Storage

Castables are packed in moisture resistant bags; however, they must be stored in a
frost proof and dry place free from excess dampness. The bags are to be checked for
the expiry date before the usage and bags without the expiry date should not be used.

Important!
If the castable contains solid lumps, this would indicate that the castable sustained
severe damage, rendering it unfit for use.

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4. Site of Working

Working operation is to be conducted under a roof, in a dry and frost-free place,

preferably at temperatures within the range 10 - 25ºC.
At temperatures near or below the freezing point, the operation must be carried out in
a closed, heated room or the necessary arrangements must be made for localized
heating of the working site to ensure that the castable has a temperature of more
than 10ºC up to the stage where the setting process of castable is completed. Where
the temperatures is above 25ºC, ice cold water should be used to maintain the
castable temperature below 25ºC.

5. Mixing

Prior to use, the mixer and all other implements must be cleaned very carefully. Any
remnants, however small, of castables or mortar may bring a drastic change in the
properties of the castable.
Castables are to be mixed in a horizontal forced-flow paddle-type mixer as this gives
us a rapid mix (avoid excessive mixing times), results in a uniform mix.

Important!
Use tools and equipment which are as clean as possible and free from all old
mortar, Portland cement, lime and dirt. Clean water suitable for drinking must be
used.

Mix only as much castable as can be placed immediately. Under ideal conditions, 20
minutes is the maximum placement time. For the initial batch, first determine the
minimum recommended water level for the product being mixed. The castable must
be mixed in the dry state for a few minutes and then with water addition for 4 to 6
minutes. If a mix appears too dry after the 4 to 6 minutes of mixing, water can be
added in 0.1% increments, making sure to stay within the recommended water range
for the specific product. Allow 1 to 2 minutes of additional mixing time between water
additions. Once an acceptable water level is reached, use that amount as the starting
point for the next batch.

Important!
The correct water addition can be determined by forming a hand sized ball of the
ready mixed castable. The ball should be able to retain its shape, when the ball is
thrown in the air a couple of times and caught in the hand, it should start to flow by
itself.

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Ball in hand consistency test-castable mixed with excess water

Ball in hand consistency test-castable mixed with insufficient water

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Ball in hand consistency test-castable mixed with right amount of water.

6. Placement of templates and formwork

All templates and framework must be plane and free from rust or any other
impurities. The length/height of the frame work should be approx. 1000mm. Apply a
thin coat of oil or wax to the inner sides of templates and forms to avoid adhesion of
the castable. The templates and forms must be trial-assembled before the placement
procedure is started. Ensure uniform gap between form work and burner pipe before
casting.

7. Installation

Figure Showing the Casting Arrangement

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The burner pipe could be placed in horizontal or vertical position and supported
properly for the casting. Anchor irons to be tag/lock welded to anchor iron support on
the burner pipe as shown in the drawing below. Plastic caps to be used on the tips of
the welded anchors and use of wax or bitumen on the anchors are recommended.

Burner pipe with ceramic felt

Ceramic fiber, 6 mm thick, is to be wrapped around the burner pipe to take care of
radial expansion. The ceramic felt must be fixed to the burner pipe shell by means of
glue or binding wire between the anchors. The fibre felt is to be made water-proof to
avoid absorbing water from the castable before starting castable installation. For this
purpose, plastic foil, diffusion-proof paint, paraffin wax or bitumen may be used.

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Burner pipe partly casted

Pour well-mixed castable material into the firmly fixed mould on the burner pipe and
vibrate it all the way from the bottom until all air has been expelled from the mixture,
eliminating voids and ensuring proper consolidation of castable. For vibrating one
could e.g. use a vibrator with a poker diameter of 25mm (1 inch) with frequency of
approx 17500 vibrations/minute or a vibration device erected directly on the mould.
Time for vibrating depends on the refractory material used.

Burner pipe with front and top mould

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The castable around the burner pipe may be casted in two halves radially, at 3 o'clock
and 9 o'clock, with 6 mm fibre felt expansion between each. The height/length of the
mould must not exceed 1000 mm. Ceramic fibre, 6 mm thick, is to be placed between
every cast panels as axial expansion joints.

Important!
Be careful not to over vibrate the castables, as the finer particles tend to float to the
surface. Excess castable should be disposed of and not to be remixed.

Further, do not overwork or excessively trowel the surface. A smooth surface

inhibits moisture removal during curing and drying by bringing fines to the surface.

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Exampel of casting the burner pipe in vertical position.

8. Curing
Cover all air exposed surfaces with a polyethylene film, or spray with a commercial
curing compound. This will prevent water evaporation and the moisture is necessary
in the castables to hydrate the cement and thus, develop proper strength. On
completion of hardening (this could take from 12 to 24 hours, depending of the
ambient temperature, but the suppliers instructions must always be followed), the
templates can be removed and the lining must be dried out at an ambient

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temperature of 16 – 25ºC for 24 hours. Improved strength characteristics can be

obtained by extending the period to 48 hours or more.

9. Preheating

A hardened and air dried castable will still contain a certain amount of water and this
is to be driven off. To drive off this water, the castable lining should be preheated
according to the manufacturer's instruction. If these instructions are not available, the
following instructions are to be followed.

Preheating should be carried out as slowly as possible and with a good control over
the temperature. Refractory castables usually have a dense structure which does not
allow the water to escape easily.

Important!
Small Furnace with auxiliary burners can be used for preheating the casted burner
pipe. Alternatively electrical heating system may also be used.

A too rapidly increased temperature may create steam formation in the structure of
the castable, thus causing spalling of the layers from the surface and/or cracks.

Raise the temperature from ambient to 150oC at the rate of ~15oC per hour and the
temperature is to be maintained at 150oC for a period of 12 hours. The temperature of
lining is then increased to 350oC at the rate of ~25oC per hour and maintained at
350oC for a period of 12 hours. The temperature of lining is then increased to 550oC at
the rate of ~25oC per hour and maintained at 550oC for a period of 6 hours, then cool
down to ambient temperature at the rate of 50OC per hour.

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Heat up Curve
600

500

400
Temperature

300

200

100

0
1 6 11 16 21 26 31 36 41 46 51 56 61 66 71
Time in hours

Important!
During preheating sufficient ventilation should be provided so that the water vapour
can escape. Temperatures should be measured on the surface of the lining.

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