Guy Nielson Co. | Kilns | Refractory Contractors
Guy Nielson Company works with many different kiln applications. These applications include cement, lime, pulp & paper, incineration, coke calcining and sugar. All of these applications have something in common, the need to combine the necessary experience with a quality minded company to provide solutions a diverse industrial base.
Regardless of the kiln is rotary, vertical, or highly specialized such as a coke calcining rotary hearth; Guy Nielson Company has the experience to assist your plant.
The process of constructing and operating an industrial kiln involves several steps, including the design, selection of materials, construction of the kiln structure, and the firing process. Here's a Guy Nielson general overview of the process involved in building an industrial kiln using bricks:
- Design and Planning:
- Determine the purpose of the kiln (e.g., ceramic firing, metal heat treatment, drying, etc.).
- Calculate the required internal dimensions, temperature range, and heating/cooling rates.
- Decide on the kiln type (e.g., periodic or continuous) and its fuel source (e.g., gas, electric, oil).
- Plan the kiln's airflow, exhaust system, and control mechanisms.
- Material Selection:
- Choose suitable refractory bricks for the kiln lining. Refractory bricks are designed to withstand high temperatures and thermal shock.
- Select insulating bricks to reduce heat loss from the kiln's outer surface.
- Kiln Construction:
- Build the foundation of the kiln to support its weight and ensure stability.
- Construct the kiln walls using the selected refractory and insulating bricks. Bricks are often arranged in a specific pattern (e.g., straight, herringbone) to enhance structural integrity.
- Install steel reinforcements if needed, especially for larger kilns.
- Create openings for loading and unloading materials, as well as for monitoring temperature and atmosphere conditions.
- Install heating elements, gas burners, or other heat sources as per the kiln's design.
- Lining Installation:
- The interior of the kiln is lined with refractory bricks to protect the kiln structure from high temperatures and chemical reactions.
- Bricks are often laid in specific patterns to provide stability and thermal efficiency.
- Special attention is given to areas prone to high wear and thermal stress, such as the kiln door and areas around burners.
- Insulation Installation:
- The exterior of the kiln is insulated with insulating bricks or fiber materials to reduce heat loss and improve energy efficiency.
- Kiln Firing and Operation:
- Before the initial firing, the kiln may undergo a "drying out" process to remove any remaining moisture in the lining.
- Start the kiln following the recommended firing schedule, gradually increasing the temperature to avoid thermal shock to the bricks.
- Monitor and control the temperature, atmosphere, and other relevant factors throughout the firing process.
- Depending on the kiln's purpose, the firing process may involve multiple stages such as drying, preheating, and sintering.
- Maintenance and Repair:
- Regularly inspect the kiln's bricks, lining, insulation, and heating elements for wear and damage.
- Replace damaged or worn-out bricks to maintain the kiln's efficiency and safety.
- Perform routine maintenance tasks such as cleaning, lubricating moving parts, and checking control systems.
It's important to note that the specifics of the process can vary based on the type of industrial kiln, the materials being processed, and the design considerations. Additionally, proper safety measures and adherence to industry regulations are crucial when constructing and operating industrial kilns.