Lining thickness measurement

Lining thickness measurement in industrial kilns

Quick, easy and practically non-invasive – lining thickness measurement with ElektroPhysiks StratoTest C

Measuring the lining thickness of rotary kilns is an important process in the industry, especially in cement production. The lining of a rotary kiln consists of refractory material that has to withstand high temperatures and chemical stresses to ensure a smooth production process. The thickness of the lining is of great importance because it has a direct influence on the efficiency, safety and service life of the rotary kiln. Measuring the lining thickness is therefore an important and fundamental aspect when it comes to the safety of rotary kilns.

Why measuring the lining thickness of rotary kilns is important

Service life and operational safety: The lining protects the rotary kiln from extreme temperatures and chemical reactions inside. Sufficient thickness ensures that the furnace lasts longer and is less susceptible to damage or failure caused by wear or erosion.

Thermal insulation and energy efficiency: An intact lining of the rotary kiln contributes to the efficient insulation of the kiln, which minimizes heat loss. This increases the energy efficiency of the rotary kiln and reduces energy consumption.

Product quality: In certain industries, such as cement production, the lining of the rotary kiln has a direct impact on product quality. A worn or uneven lining of the rotary kiln can lead to undesirable chemical reactions that affect the product composition.

Maintenance and servicing: Regular monitoring of the lining thickness of the rotary kiln enables operators to assess the condition of the kiln and plan any maintenance measures in good time. Regular inspection of the rotary kiln can prevent expensive repairs and longer downtimes.

Occupational safety: A damaged rotary kiln lining can lead to uncontrolled cracks or fractures, which in turn endangers the safety of employees. By regularly measuring the lining thickness, potential hazards can be identified and avoided.

Measuring the lining thickness in the rotary kiln Traditional versus non-invasive method

Today, the lining thickness is measured using specialized measuring instruments. There are different ways of measuring. With the traditional method, up to 200 small holes have to be drilled into the rotary kiln in order to determine the thickness of the lining. However, the borehole method has significant disadvantages. Firstly, the outdated measuring method is tedious because simply drilling the holes takes a lot of time. Secondly, the measurement results are not accurate because only the boreholes can be used to determine the lining thickness – the spaces between the boreholes are not taken into account. In addition, the many drill holes – even if they are closed again after the measuring process – can permanently weaken the lining of the rotary kiln and make it more susceptible to damage.

Non-invasive lining thickness measurement with StratoTest 4500 C

Measuring the lining thickness with our device, the StratoTest 4500 C, offers decisive advantages over the invasive borehole method. Instead of drilling up to 200 holes, our measuring method only requires a single hole to be drilled in order to determine the lining thickness of the entire rotary kiln. This method provides more comprehensive information about the thickness distribution with less effort, without disturbing the furnace operation or damaging the lining. Lining thickness measurement with StratoTest 4500 C is more efficient, safer and provides a better basis for informed maintenance and repair decisions. Learn more about StratoTest 4500 C here.