Our kiln is operational since 12 years. It is a 64m long 4.15m dia FLS kiln with nominal capacity of 3000tpd. The kiln was upgraded about 1 year ago and now producing about 3800tpd. Recenet measure of kiln shell thicness in Security zone (32 - 40 m) shows a value of about 16 mm against original thickness of 25 mm in this part of the kiln. However, there is no incident of deformation or refractory fall ever occured here.
Should we replace the shell in this portion immediately or we can take some more life from it? In case of replacement, should we go for 25 mm thickness or it needs to be increased due to increased thermal load after upgradation? Do we need to change the composition of kiln shell to take better life after replacement and would you please propose some better material?
Shoaib