New Brokk solution to demolish crust and refractory from preheating towers

Brokk , a global leader in the manufacture of remote-controlled demolition robots, presents the new Brokk Descaler: a solution specifically designed for the demolition of refractories, linings, and build-up in various areas of preheating towers, primarily in cement and alumina plants. With a telescopic arm offering outstanding reach and remote control operation with the same precision as robots, the Brokk Descaler revolutionizes the method of extracting material from preheating towers.

Health and safety are a constant challenge and a major issue for cement plants worldwide. The hazardous work of removing refractory material and its accumulation in cement kilns and coolers has historically endangered many workers… but by using remotely controlled Brokk robots, safety has improved dramatically. Similar problems with refractory and lining material in the upper areas of preheating towers have also existed for years, due to the lack of a safe and efficient solution.

Conventional methods often involve a manual pre-inspection before sending workers onto scaffolding with hand tools, making the work time-consuming and critical. In this respect, the Brokk Descaler offers many advantages, particularly in terms of productivity. With quick setup, faster demolition, and no need for scaffolding, downtime is significantly reduced. And since the Brokk Descaler doesn't require personnel to enter the tower, work can begin in temperatures up to 80°C.

Today, workers are not only exposed to the risk of falling debris, but also from silica dust entering the body and skin. Additionally, vibration from hand tools is a known problem causing the 'white fingers' symptom. The Brokk Descaler keeps operators at a safe distance and therefore risks such as these are eliminated or significantly reduced.

“Brokk robots have replaced manual labor for removing linings and refractory material in cement kilns worldwide for years. With this solution, we can also protect workers in the preheater tower, where the risk of falling debris is as high as in a kiln ,” says Joakim Furtenback, International Sales Director at Brokk AB, Sweden.

The Brokk Descaler was evolved from a standard Brokk robot and modified to suit the preheat tower application without compromising power. The telescopic arm is extensible in one or two sections that allow the development of demolition work in installations up to 9,5 m in diameter.

As preheater towers are of different designs and accumulation appears in various places depending on design, material and other factors, a flexible solution is required. The Brokk Descaler is carefully designed for use in a wide variety of installations and is easy to move anywhere in the tower as it can be transported in most elevators. Installation can be completed in less than three hours and once installed, the operator can safely control the work from the outside through windows, allowing for precise and controlled demolition.

The operator can safely control the work from the outside through windows, allowing precise and controlled demolition.

“Once you have seen the benefits of using the Brokk Descaler, there is no going back to the dangerous methods used previously,” concludes Joakim Furtenback.

Hundreds of tons of refractory can be removed with zero physical contact and at a much faster rate than manual labor. This guarantees high productivity and safety for workers. In short, a safer and more efficient workplace.