Successful kiln repair enhances reliability at Mannok cement plant

Critical repair to heavy shell section ensures continued reliability and efficiency of the kiln

DURING the planned maintenance shutdown at Mannok’s cement factory, a critical repair was undertaken to replace the heavy shell section and drive tyre at kiln pier 2. This proactive work was essential to address cracking in the heavy shell section and to realign the kiln tyre, which was no longer in the correct position.

Although the cracking had not yet caused a stoppage, it posed a significant risk of future operational disruption or even catastrophic failure. Addressing these issues during the scheduled downtime ensured the continued reliability and efficiency of the kiln.

The repair project was a collaborative effort, with Mannok’s trusted partners FLSmidth serving as the main contractor. Portuguese specialists Simetrexial and Mannok’s in-house team also played crucial roles in completing the task.

The replacement process began with removal of the damaged shell section, achieved using automated gas-cutting equipment. This precision method ensured accuracy in cutting and minimal disruption to surrounding components.

Given the scale of the operation, a 100-tonne lift plan was prepared for the removal of the damaged section and to position the new one. For this, a 700-tonne crane was brought in from Dublin Crane Hire, whose collaboration was instrumental in the project’s success.

The new section was carefully lifted, positioned, and secured using sub-arc welding. This advanced welding technique, which involves using a submerged arc to heat and join the metal, provided strong and durable welds, crucial for the integrity of the kiln.

The entire project was completed in 27 days, from start to finish, and went exactly to plan with no delays or complications. The kiln is now operating flawlessly, demonstrating the success of the maintenance work and the effectiveness of the team’s efforts.

This essential repair has not only resolved immediate concerns, but also enhanced the long-term reliability of the kiln.

Paul Carron, Mannok’s engineering manager - decarbonization, said: ‘This project was executed exactly as planned, staying on schedule and without any issues. The FLSmidth team delivered their usual excellent and professional service, complemented by the expertise of Simetrexial. With the work now complete, we can look forward to significantly enhanced reliability in our operations.’