The replacement cycle of refractory materials in ceramsite sand rotary kiln is affected by many factors, generally about 1 to 3 years. If the raw materials used in ceramsite sand production are highly corrosive, such as containing more acidic or alkaline components, the erosion of refractory materials will be accelerated, and the refractory materials may need to be replaced in about 1 year or even less. If the chemical properties of the raw materials are relatively stable and the erosion of refractory materials is small, the service life of refractory materials may be extended to 2 to 3 years.

During the high-temperature calcination process, if the temperature in the kiln fluctuates greatly and the heating and cooling speed is too fast, the refractory materials will be damaged by cracks and peeling due to thermal stress. In this case, they may need to be replaced in 1 to 1.5 years. If the production process is stable and the temperature control is precise, the refractory materials can be used for about 2 to 3 years.

Damage to refractory materials in ceramsite sand rotary kiln will have serious effects on production in many aspects, mainly including the following points:

Impact on product quality

1. Uneven temperature: After the refractory materials are damaged, the thermal insulation performance of the kiln body decreases, the heat loss increases, and the temperature distribution in the kiln is uneven. This will cause the ceramsite sand to be heated unevenly during the calcination process, and some ceramsite sand may not reach the expected calcination temperature, thereby affecting its physical and chemical properties, such as strength, density, porosity, etc., and reducing the stability and consistency of product quality.

2. Atmosphere change: Damaged refractory materials may affect the atmosphere in the kiln, such as abnormal local oxidation or reduction atmosphere, which will change the chemical composition and crystal structure of the ceramsite sand, resulting in deviations in product color, composition, etc., and fail to meet production standards.

Increased safety hazards

1. Kiln body leakage risk: Damage to refractory materials may cause cracks or holes in the kiln body, causing high-temperature gas, dust, etc. to leak out of the kiln, which will not only cause environmental pollution, but also pose a threat to the safety of operators, such as burns, inhalation of dust, etc.

2. Reduced structural stability: Severe damage to refractory materials may affect the structural stability of the kiln body. Under the dual effects of high temperature and equipment operation, the kiln body may collapse and other serious safety accidents, bringing huge economic losses and casualties to the company.

Reduced production efficiency

1. Increased heat loss: Damage to refractory materials will cause a large amount of heat loss in the kiln body. In order to maintain the calcination temperature in the kiln, it is necessary to increase the supply of fuel, which not only increases the production cost, but also may reduce the production speed of the kiln due to insufficient heat supply, resulting in a decrease in the output of ceramsite sand.

2. Frequent shutdown for maintenance: After severe damage to refractory materials, the machine must be shut down for repair or replacement, which will lead to production interruption, reduce effective production time, reduce equipment utilization and production efficiency, and may also affect the company's production plan and delivery period.

Shortened equipment service life

1. Thermal deformation of the kiln body: After the refractory material is damaged, the kiln body is directly exposed to a high temperature environment, which is prone to thermal deformation, affecting the rotation of the kiln body and the normal transportation of materials, further aggravating the risk of equipment wear and failure, and shortening the service life of the kiln body and other supporting equipment.

2. Aggravated component corrosion: Without the protection of refractory materials, the high-temperature gas and materials in the kiln may directly contact the metal parts of the kiln body, accelerating the corrosion and oxidation of metal parts, and increasing the maintenance cost and replacement frequency of the equipment.