We have a kiln of 5 m of diameter and 82 m of length. Our thermanl loading in the main burner is 5.3 Gcal/m2/h. I read that increasing the percentage of precalcination and reducing the thermal loading in the main burner the refractory performance can be increased, reaching more than 310 days/year. In our kiln condition, which is a normal performance in days/year?. We use gas as fuel and we have a new burner.

you should be achieving in excess of 320 days/year.the degree of calcination can be increased to bring down the thermal loading. but there is a limitation for the % firing and degree of calcination in your calciner.

If u r facing severe problems of refractory failure inspite of your efforts, then check the burner settings.

Maximum thermal loading in the dimension kiln can be 5.4Gcal/hr/m2.Higher thermal loading certainly put thermal stress in kiln refractory but refractory solution present for high thermally loaded kilns such as magnesia-zirconium oxide brick for lower transition zone.Optimum degree of calcination we may achieve 90-95%.More than 95% calcination may create jamming prone tendency.We may use 60-65% fuel firing in calciner.Our practical experience indicate that we may achieve kiln running more than 345 days per year. Regards, R.M.Sahu, INDIA