De-bricking a Contaminated Chromium Kiln with Brokk Robotics

Regular replacement of Kiln and Furnace Refractory Linings incurs Loss of Production Time and, in the past, prior to the development of Robotic Demolition Procedures, necessitated the use of inefficient, hazardous manual demolition operations.

Seven of Gnat's Robots were centre stage in the decommissioning of this major Chromium Chemical Plant, carefully ‘wrecking’ the linings of several vast steel kilns.

Hydraulically operated pecker arms — more at home breaking out heavily reinforced concrete, were used to delicately remove tonnes of contaminated brick linings in a confined-space operation which demanded extreme safety precautions.

At the heart of this process were six rotating cylindrical kilns, up to 100m long, used to heat and mix the various materials. Varying in diameters from 3m to 5m, these horizontal steel kilns had, over the years, built up a thick layer of fine chromic oxide powder known as ‘roast’.

The enclosed kilns were designated as confined spaces, so any proposed lining removal method necessitated a severe health and safety regime. A fine mist suppression system was deployed throughout the works to minimise airborne dust.

GNAT UK's range of Demolition Robots offer varying sized arm reaches and hammer power ideal for tackling all kiln diameters. Access holes were cut in kiln sides and, for the narrowest 3m high vessel some 30m long, Gnat used one of their smaller robots the Brokk 90.

A second opening, cut in the floor of each kiln, allowed bricks and roast powder coating to drop directly into a dump truck standing beneath.

As the six month operation to remove some 200 tonnes of brick and chemical powder contaminant neared its successful end, Elementis’ Bob Armstrong shared his contractor's satisfaction.

Whilst Kiln Stripping procedures may not have changed significantly since 2012, Gnat's continued investment in State of the Art Robotic Technology enables us to confidently tackle the toughest, most demanding refractory wrecking work that the industry can throw at us — More Efficiently, More Safely — And Quicker.

Related context: Brokk 60 Refractory Kiln Strip in a Confined Vessel

Gnat UK — simplifying KILN DeBricking with remarkable ease.

Access to this large Vessel was achieved by cutting through the kiln refractory wall, enabling our Compact Brokk 60 Robot to be craned into the well of the Kiln.

The Brokk 60's small footprint, compact power and excellent manoeuvrability enabled it to systematically and safely de-brick the refractory linings.