EXPERIENCE WITH UPGRADING THE LINING OF A DE25/14 BOILER
I. V. Tropinova
, A. M. Tropinov
, V. P. Buglak
, and A. A. Kirilyuk
Translated from Novye Ogneupory,No.6,pp.6–8,June, 2009.
Original article submitted April 27, 2009.
In the period 1997 – 1999, members of the DSK-3 ZZhBI Corporation repaired the lining of two DE25/14
boilers with materials from the Alineka Company. Operation for five years confirmed that the repair was reli
able and reduced the consumption of energy from the use of these lining materials.
Keywords: DE25/14 boilers, substrates, burner stones, flame zone, refractory concrete, thermal-insulating
material, thermal stability, energy saving.
The crisis time for the economy is characterized by a fall
in industrial production and weakening in the financial
sphere: reduction in national tax yields, and increased costs
and difficulty in obtaining credit. Under these conditions it
has been problematic to introduce new energy-saving tech-
nology of foreign origin on account of the lack of adequate
working capital and availability of credit. Industrial organi-
zations in this time have tended to optimize (reduce) produc-
tion costs, namely performing repairs to equipment reliably
to give a long working life and is possible by the use of en-
ergy-saving components on account of the constantly in-
creasing prices for energy resources. This is why scientific
organizations having available technologies providing long
working lives and energy-saving elements have become pop
ular and have introduced their materials that partially resolve
problems in industrial production.
In 1997 – 1999, stage repairs were performed on two
DE25/14 boilers. The first repairs were to the burner stones,
and then to the furnace lining. The results from this repair
were examined after five years of operation in the repaired
boilers. The correct choice of repair technology provided
long working life and reliability in the furnace lining.
For an industrial organization such as DSK involved in
making block ferroconcrete, it is important that the steam
plant works in a stable fashion. Usually, such plant is
equipped with boilers of old design: DKVr, DE, and BG
(which have been in operation for 40 – 60 years), and which
have a high fuel consumption for producing1tofsteam.
Also, unauthorized electricity disconnection causes the
boiler automatics to shut down. When the refractors in the
burner device are built around shaped firebrick refractories
of type ShA with low thermal stability, the latter may crack,
which interferes with the mode of action of the burner de-
vices: there are resulting leaks of air, increasing fuel con-
sumption, and reduction in efficiency (55 – 65%). Operation
in such a state for 1 – 2 weeks led to melting in the firebrick
refractory for the burner device and replacement of it. On the
other hand, reliable repair to the burner stone requires certain
specifications to be met in the design of the burner and the
The constructional specifications for the burner device
are as follows:
1) the burner stone should be made of a plastic material
enabling one to prepare a monolithic component of compli
cated geometry with the minimum number of compensating
2) the burner should be mounted in such a way that the
geometrical axes of the burner and the burner stone coincide;
3) the flame zone should be strictly defined (deviations
not permitted) in accordance with the burner maker’s specifi
4) the zone where the burner stone joins the furnace lin
ing should be monolithic and not be subject to burning and
melting, since the latter results in the intrusion of air, flame
deviation, and subsequent melting of the burner stone.
The lining material should differ from ShA firebrick re
fractory in having a higher temperature of use in order to ex
tend the working life, higher thermal stability, and higher
hardness, which increases the working life on account of the
increased resistance to mechanical effects from combus
tion-product particles, while having adequate residual
strength in the presence of pulsations and flicker in the flame
in the furnace, as this increases the working life, and also im
proves the gas sealing to exclude leakage of air.
Refractories and Industrial Ceramics Vol. 50, No. 3, 2009
1083-4877/09/5003-0166 © 2009 Springer Science+Business Media, Inc.
NPF Alineka Private Company, Kiev, Ukraine.
DSK-3 ZZhBI Corporation, Kiev, Ukraine.