30 REFRACTORIES
Lightweight, high-strength aluminium is as strong as steel and only 40% of the weight, providing a power-to-weight ratio that increases safety, productivity and ROI
Stealing back profits with aluminium bricking machines By Heather Harding* To minimise profit-stealing downtime, plant managers need reliable, efficient maintenance methods that get production back up and running quickly. This requires the right equipment – made from the best materials. Bricking machines, suspended platforms and kiln access ramps safely speed up the refractory installation process, saving thousands of dollars in lost revenue. These useful tools are available from equipment manufacturers but can also be engineered in-house. Small differences in construction and materials can add up, though, so it’s important to thoroughly consider all options. For many cement and lime producers, using their in-house engineers to construct kiln maintenance equipment made from steel is the go-to material because it is readily available. However, there are more efficient materials.
Lightweight, high-strength aluminium, for example, isn’t typically used by inhouse engineers, but offers productivity and safety benefits that make it an ideal choice for kiln maintenance equipment construction. This material is as strong as steel and only 40% of the weight, providing a power-to-weight ratio that increases safety, productivity and ROI. Partnering with an equipment manufacturer that uses high-strength aircraft-grade 6061-T6 aluminium can be the best choice for a facility’s bottom line and efficiency. Here’s how. Get Going Fast With every minute of downtime leading to a loss in revenue, the performance of a bricking machine or kiln access ramp during refractory installation is a manager’s top concern. Setup and teardown times are equally important when it comes to overall productivity. Getting crews in and
out faster requires a machine that is just as easy to put together as it is to remove once the job is done. Much of this comes down to construction materials: heavier materials – like steel – simply take more time and energy to erect. For example, a steel kiln access ramp can take a full crew six to 12 hours to assemble, increasing downtime both before and after maintenance and negatively impacting cost efficiency. The weight of the steel components also requires the use of heavy-duty equipment and complex hoists and rigging methods, increasing cost and risk of injury. A similar ramp manufactured with lightweight, heavy-duty aluminium can be assembled in as little as 1.5 hours – depending on burn floor configuration – with a small crew and only light equipment, such as a forklift. Maintenance equipment that employs a modular design can further increase installation efficiency.
*Bricking Solutions, Managing Director July/August 2022
Bricking solutions.indd 1
Aluminium International Today
06/07/2022 12:57:42
