Friday, February 24, 2012

Lubricator Filter System

Bricking Solutions now have a protective cover for our lubricator filter system, this new cover will come standard on all new premium bricking machines. It will also be available as a retrofit for all machines in the field.

The cover will mount with the two top bolts that currently are used to secure the lubricator filter to the arch as pictured below. The cover will protect the lub-filter system from falling brick or damage when in storage or assembly.

Friday, February 17, 2012

Without a Bridge your Kiln is an Island

Recently our International Sales Manager, Daniel Chavis went and visited the Lehigh Hanson Cement Plant. Daniel and the production manager discussed a possible new kiln access ramp. She explained in their current situation their only access to their 9' kiln was through a side door entrance on the hood. 
This scene and others are very familiar.  Your crew steps onto the burn floor in preparation for kiln maintenance.  The door is opened.  The kiln is cooling down.  The outage clock begins to tick.  Will your crew safely, easily, and quickly cross the gap between the burn floor and the kiln?  Or has your kiln become an island?  Cement plants worldwide come up with many unusual ways to bridge that gap.  Unfortunately, most solutions are heavy, cumbersome, and often unsafe.

With safety as the priority, kiln access should be engineered taking in account the burn floor configuration to create a custom designed access which safely, easily, and quickly provides a ramp into the kiln.   With safety in mind, the design must meet International standards (and American where applicable) reducing safe access concerns for your workers and put a smile on your safety officer’s face when checking your kiln access ramp.

Not all burn floors are created equal.   It’s easy to design a ramp when there are no obstructions or elevation issues.  Straight access to the kiln is ideal, however not realistic.  Unfortunately each burn floor and kiln presents many different engineering design problems.

Tuesday, February 7, 2012

Improving Kiln Uptime

The kiln is considered the heart of a cement plant and its performance happens to be the deciding factor for the total profitability of the plant.

Healthy operation of the kiln with uninterrupted availability for production is directly linked with the quality and quantity of the kiln output.

A trouble free up keep of the kiln is vital to ensure high productivity of the plant.

A study of kiln down time in various cement plants indicates that the down time of the kiln due to mechanical failures rates from 8 to 35% where as the down time due to refractory work alone ranges form 20 to 35%

Close attention is called for the proper maintenance of all the components of the kiln system and to follow healthy refractory engineering practices.

A look into the failure of refractory bricks reveals that there are a great many factors including thermal stresses, infiltration and corrosion, mechanical stress, and improper installation.

Our contribution to improving kiln up time will be by reducing down time through faster methods of refractory maintenance and longer up time due to tools that help speed up installation and improve the quality of installation.

We call this contribution – The Circle of Refractory Maintenance. This contribution is important to not only the managers responsible for the maintenance of the kiln, but to the plant and corporate managers responsible for the overall profits of the company.

The following presentation describes the components of the “Circle” and how they work together to reduce downtime and increase runtime. Through out the presentation actual case studies will illustrate the results and benefits of employing all or parts of the tools in the “The Circle of Refractory Maintenance”.

In the year 2000 Brokk AB purchased Bricking Solutions formerly known as Pneumat O Ring International.

Out of this marriage the Brokk / Bricking Solutions Kiln Maintenance System was born.

Our “Solutions” for kiln maintenance needs involves the following tools:

·         Kiln ramps for quicker, safer and faster kiln access

·         Remote controlled Tear Out robots for fast precise removal of coating and brick

·         Radialign laser marking of kiln shell to insure proper alignment of installed brick to the kiln axis.

·         Material handling products to insure delivery of undamaged brick to the kiln shell.

·         Bricking machines that increase the speed of installation to reduce down time while at the same time insuring the highest quality of installation to increase brick life and uptime.

We call the coordinated and proper use of these tools “The Circle of Refractory Maintenance”.

The 3 main objectives of this system are Safety, Quality and Speed.

  • Safety is a moral responsibility with the side benefit of being cost effective. It increases employee morale and thus productivity resulting in shorter outages. It also reduces cost related to time lost due to injury and personnel turn over.

  • Quality installation is an intangible the can be measured by fewer bricks lost to damage and increase life of refractory measurable by increase in kiln run time and grams of refractory used per ton of clinker produced.

  • Speed is measured by shorter outages and increased run time.