Bricking Solutions

Lubricator Filter System

2012-02-24T11:15:00.000-08:00

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.

Without a Bridge your Kiln is an Island

2012-02-17T12:44:00.000-08:00

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.

Improving Kiln Uptime

2012-02-07T10:02:00.000-08:00

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.

Bedding Cart

2012-01-24T15:11:00.000-08:00

Bricking Solutions knows that efficient handling of refractory can make or break a relining project. The Bedding Cart not only allows for the movement of bedding refractory as the bedding process progresses, but provides stair steps to facilitate the placement of refractory to or just above the spring line on larger kilns.

In addition, the deck is on wheels and holds one to two pallets of brick allowing the brick to move in conjunction with the work. A pre built bedding cart is a one time cost for a fixture that can be used over and over again whereas the standard method of erecting wood staging involves reoccurring cost of labor and material to build. In addition, bedding carts help increase the speed of refractory installation thus reducing outage time and increasing production.

Polyurethane wheels to protect new brick.
Ergonomically correct stair step design.
Lightweight aluminum construction.
Forklift pockets for ease of transport in and out of kiln.
Capacity for one to two pallets of brick.
Custom designed and engineered for adjust-ability and kiln diameters.

Pass Thru Trolley

2012-01-11T10:31:00.000-08:00

The Pass Thru Trolley allows a full pallet of refractory / brick to be placed onto the bricking rig from the down kiln end by a forklift, and then the pallet can be moved under the arch to the up kiln end where it can be easily accessed

Bricking Solution’s EZ Flexx machines have a 5.2M (17ft) platform with a 6,810 kg (15,000 lb) capacity. This allows for 3 full pallets of brick, plus men and equipment on the machine. The EZ Flexx double arch trolley moves on rails on the platform. The RTS has a brick pallet cart that rolls on a different set of rails. From the down kiln end, a full pallet will be placed on the brick pallet cart with a fork lift. The masons will then remove the arch trolley steps and push the full brick pallet under the arch to the up kiln end of the machine. Once the brick pallet cart is locked in place, the masons will reinstall the arch trolley steps. This will provide the masons with a full pallet of refractory which is then easily accessible and will limit the amount of brick handling. Once the brick is used and unloaded from the pallet, the empty pallet cart can then roll under the arch trolley for the next pallet of brick to be loaded on the machine.

You can see the full video here: Pass Thru Trolley Video

For more information please visit our website: www.brickingsolutions.com

Bolt together Bricking Rig for a furnace with limited access

2012-01-04T15:22:00.000-08:00

It is always gratifying to receive a message like the one below. Bricking Solutions lived up to its name by solving a limited access issue (48” man access port) along with the challenge of furnishing a large adjustable machine for multiple diameter (16” and 19” Brick I D), multi brick layer cylindrical furnace in a Sulfuric Acid Generation Process.

The result was a unique bolt together machine that just fit the bill resulting in the nice testimonial below.

Bill,

Good to hear from you. The machine worked very well and exceeded our production figures we had for the project. The conveyor worked out great and moved materials in and out very efficiently. The project finished up early and the client was very happy!

Thanks to “The Bricking Solutions Team” for providing the rig and conveyor that made this project successful!

You can always use us for a reference. Also, if you get in a bind and need a rig to rent – call me, we may be able to work together on it.

Sincerely,

Rodney Rudell

Engineering

Southwest Refractory of Texas