Work performed
- Assessment of kiln alignment
- Recommendations
Scope
A cement factory called in TALOS after the inner brick lining of a kiln collapsed. The collapse showed that the kiln was misaligned, blasting heat onto the kiln surface and causing the steel shell to expand.
Access
The inspection was carried out inside the kiln during a planned shutdown, using the existing staircase and platform. Managing the interface with the other subcontractors working inside the kiln was an important part of the job.
Solution
TALOS engineers checked the alignment with a total station. The readings showed that the rails carrying the burner inside the kiln had sagged slightly, so the burner was no longer parallel with the kiln and was directing heat onto the kiln surface — which eventually caused the brick lining to fail. Readings matched the design at the entrance but changed gradually toward the rotating section.
Results
The misalignment was traced mainly to operating conditions and the design life of the steel sections: repeated start-ups and shutdowns subject the rails to thermal shock, increasing the chance of differential expansion and steel failure. TALOS provided recommendations for the repair.