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Kiln Shell Corrosion PDF
Kiln Shell Corrosion PDF
Cement
20mm
8mm
14mm
17mm
Ref: DAVILA, J.C. et al., 1995, Influencia del Refractario en la Corrosion de la Coraza del Horno Rotatorio para
Cemento, ALAFAR XXIV Congreso, Cartagena, pp 157-183
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Preferred
corrosion below
joints,
condensation of
moisture during
kiln stops
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wet cardboards
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Loss of shell
thickness 6 mm/a
Fuels: Coal + pet
coke, tyres,
palletised sewage
sludge
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Thickness
15 mm
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mag
hem
hem
KCl
Composition of scales
6DPSOH
n.a.
81
&KHPLFDODQDO\VLV
(wt.%)
Fe2O3
44
90
88
17
56
SO3
11
K2O
24
43
16
Na2O
Cl
36
11
PbO
[[[
[[[
[[
[[
0LQHUDO3KDVHV;5'
Fe3O4
Fe2O3
[[[
FeS
[[
FeS2
[[
[[
Fe(OH)2
[[
KCl
[[
Na2SO4
NaCl
Kiln Shell
Pb2Corrosion
(SO4)O
[[[
[[
K2SO4
NaF
[[
FeSO4.H2O
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[[[
[[[
[[
[[
[[
[
[
[
KCl, K2SO4
KCl, K2SO4
KCl, K2SO4
KCl, K2SO4
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Apply gas-tight coatings on the kiln shell (paints, flame / plasma sprayed
metallic or ceramic layers etc.)
Sacrifice layer
cf also: Jns, E.S. & stergrd, 1999, Investigation into kiln shell corrosion of rotary cement kilns, ZKG International,
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Chemical resistance against corrosive gases (H2S, HCl, SO2, CO2 and O2)
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0HWDOOLFFRDWLQJ
, flame sprayed: - Al
- NiCr 50/50
- Ni based Cr-B
- Zn, Zn/Al 85/15
&HUDPLFFRDWLQJ
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, plasma sprayed:
- Al2O3
Performed tests
Weight differences were measured over a longer period of time (up to1000 h)
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Results of investigation
Metallic coating: protective effect is good / very good (e.g. Al) but
adhesion on substrate is difficult to maintain
Spray procedure expensive and time consuming (14 days one layer 5rm,
3,8m ), rough surface difficult to clean from mortar
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900 mm wide
endless coil,
0.38 mm
thickness
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Type of
steel
used for
sacrifice
layer
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Cutting pieces
of 2-3 m length
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Four sheets
ready for
installation
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SL installed
between
ANKRAL
bricks and the
cleaned kiln
shell
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Plates of
0.79 mm
thickness
are point
welded to
the kiln
shell
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Stage 1
magnets
refractory
bricks
vertical overlap:
2 5cm
horizontal overlap: 5 20cm
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lining rig
Stage 2
References
Davila, J.C. et al., 1995, Influencia del Refractario en la Corrosion de la Coraza del
Horno Rotatorio para Cemento, ALAFAR XXIV Congreso, Cartagena, pp 157-183
Jns, E.S. & stergrd, 1999, Investigation into kiln shell corrosion of rotary cement
kilns, ZKG International, vol. 52, No. 2, pp. 68-79
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ZZZUKLDJFRP
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