Kiln Shell Corrosion

Cement

ICTM R. Krischanitz May 2008

Fracture of kiln shell due to corrosion

PC kiln, 4.15 x 58 m, 2450 tpd, <20% alternative fuels:
Fracture of kiln shell at rm 38.5 - despite phosphating it during
previous kiln stops
Kiln shell thickness:
Original thickness
Thickness within fracture area (groove)

20mm
8mm

Average thickness in brick joints

14mm

Thickness below bricks

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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Kiln Shell Corrosion

Corrosion of kiln shell (rm. 65, calcining zone)

Preferred
corrosion below
joints,
condensation of
moisture during
kiln stops

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Kiln Shell Corrosion

Corroded kiln shell within the calcining zone

wet cardboards
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Kiln Shell Corrosion

Kiln shell corrosion (rm. 29, second tyre)

Loss of shell
thickness 6 mm/a
Fuels: Coal + pet
coke, tyres,
palletised sewage
sludge

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Kiln Shell Corrosion

Scales from the kiln shell

Thickness
15 mm

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Kiln Shell Corrosion

Microscopical appearances of scales

Porous layer of hematite and KCl

mag

hem
hem

Dense layer of magnetite and hematite

RHI Technical Centre Leoben, Austria

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Kiln Shell Corrosion

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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[[[

[[[

[[

[[

[[

[
[
[

Evaporation of volatiles in preheating zone

Preheater
Kiln gas

KCl, K2SO4

KCl, K2SO4

KCl, K2SO4

KCl, K2SO4

Kiln Feed / Coating

/LQLQJ

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Kiln Shell Corrosion

Phase diagram KCl K2SO4

Lower melting points of

chlorides in comparison to
sulphates. Eutectic melts
have even lower melting
points. The lower the
melting point the higher
the infiltration depth.
Phase diagram:
acc. to O.S.Dombrovskaya 1933

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Kiln Shell Corrosion

Infiltrated refractory bricks

Spalling of basic bricks

caused by KCl after 3 months
operation
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Kiln Shell Corrosion

Measures to prevent kiln shell corrosion

Reduce chlorine input to the kiln (selection of appropriate raw materials /
substitute fuels, install a by-pass)

Keep evaporation rate of volatile components as low as possible (avoid

reducing operation conditions, use of mineralizers, other process measures)

Reduce permeability of lining (e.g. reduction of joints by use of ISO shapes in

the basic zone, use of mortar lining)

Extension of the basic lining area

Install refractories with low (zero) permeability

Apply gas-tight coatings on the kiln shell (paints, flame / plasma sprayed
metallic or ceramic layers etc.)

Select corrosion resistant steel type for kiln shell

Sacrifice layer

cf also: Jns, E.S. & stergrd, 1999, Investigation into kiln shell corrosion of rotary cement kilns, ZKG International,
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Kiln Shell Corrosion

vol. 52, No. 2, pp. 68-79

Requirements for coatings

Heat resistant up to 400C

Chemical resistance against alkaline salts

Chemical resistance against corrosive gases (H2S, HCl, SO2, CO2 and O2)

Resistance against acids

Abrasion resistant (movement of the lining)

Coating must be applicable on sight

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Kiln Shell Corrosion

Studied types of coating

Materials tested by University of Leoben / RHI
D. Jellen: Verringerung der Ofenmantelkorrosion von Drehrohrfen in der
Zementindustrie durch Beschichtungen
3DLQWLQJV

- polyamide resin with graphite pigments

- silicon resin with FeO pigments and inhibitors
- silicon-modified alkyd resin
- zinc ethyl silicate
- phosphoric acid

0HWDOOLFFRDWLQJ

, flame sprayed: - Al
- NiCr 50/50
- Ni based Cr-B
- Zn, Zn/Al 85/15

&HUDPLFFRDWLQJ

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Kiln Shell Corrosion

, plasma sprayed:

- Al2O3

Performed tests

Ignition test at 400C:

20%
CO2
H2O
10%
SO2
2%
HCl
2%
O2
13%
N2
53%
additionally the specimens were
coated with alkaline-salts
kiln atmosphere:

Low temperature corrosion:

at 40C in an exsiccator which
base has been covered with HCl (21%)

Weight differences were measured over a longer period of time (up to1000 h)
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Kiln Shell Corrosion

Results of investigation

Paintings: embrittlement occurs at moderate temperatures (e.g. 200C),

loss of adhesion on substrate

Phosphate treatment guarantees no protection against corrosion at high

temperatures. After the ignition tests no phosphate detectable anymore.

Metallic coating: protective effect is good / very good (e.g. Al) but
adhesion on substrate is difficult to maintain

Ceramic coating: high porosity of the ceramic layer leads to corrosion of

the substrate and finally spalling of coating

Spray procedure expensive and time consuming (14 days one layer 5rm,
3,8m ), rough surface difficult to clean from mortar

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Kiln Shell Corrosion

Refractories with low (zero) permeability

Fused cast refractories
Zero permeability
Very expensive
Very brittle / low thermal shock resistance

Silica-impregnated alumina bricks (RESISTAL IS)

Reduced open porosity (15-20% less porosity)
Greatly reduced permeability (80-90% less permeability)
Formation of protective reaction layer of alkali silicates at hot face
(reaction sealing)
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Kiln Shell Corrosion

Sacrifice layer against kiln shell corrosion

What is a sacrifice layer?
Method developed in Mexican cement plants (lamina de
sacrificio)
A sheet of stainless steel between refractory lining and kiln shell

Steel type: 1.4301 (AISI 304), 1.4571 (AISI 316)

Dimension:
(A) 900 mm wide endless coil, 0.38 mm thickness, or
(B) 1.220 x 2.440 mm, 0.79 mm thickness, point welded

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Kiln Shell Corrosion

Sacrifice layer (A)

900 mm wide
endless coil,
0.38 mm
thickness

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Kiln Shell Corrosion

Sacrifice layer (A)

Type of
steel
used for
sacrifice
layer
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Kiln Shell Corrosion

Sacrifice layer (A)

Cutting pieces
of 2-3 m length

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Kiln Shell Corrosion

Sacrifice layer (A)

Four sheets
ready for
installation

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Kiln Shell Corrosion

Sacrifice layer (A)

SL installed
between
ANKRAL
bricks and the
cleaned kiln
shell

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Kiln Shell Corrosion

Sacrifice layer (A)

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Kiln Shell Corrosion

Sacrifice layer (B)

Plates of
0.79 mm
thickness
are point
welded to
the kiln
shell
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Kiln Shell Corrosion

Sacrifice layer (C)

wooden bar

Stage 1

magnets

refractory
bricks

vertical overlap:
2 5cm
horizontal overlap: 5 20cm
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Kiln Shell Corrosion

lining rig

stainless steel sheets

1.4301 / AISI 304
0,40 x 1000mm

Stage 2

Effect of sacrifice layer in a PREPOL kiln

4.8 x 75m, 4.800 tpd

Steel shell with sacrifice layer

(rm 30-35): very light corrosion

Steel shell without sacrifice

layer (rm 52): strong corrosion

Fuel: Combustleo + alternative fuels (PET, tyres, industrial waste)

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Kiln Shell Corrosion

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

Jellen, D., 1999, Verringerung der Ofenmantelkorrosion von Drehrohrfen in der

Zementindustrie durch Beschichtungen. Thesis, Montanuniversitt Leoben.

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Kiln Shell Corrosion

Thank you for your attention!

ZZZUKLDJFRP

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Kiln Shell Corrosion