Anchor systems in castable or brick linings of different

cement plant vessels

Klaus Kassau

1.

introduction

- chemical load
- corrosion

- history of anchoring

2.

- general consideration
- task of anchoring

3.

- salt attacks

functionality of anchoring

load conditions in process

- survey of load conditions
- thermal load

4. alloys
- general view
- alloy testing

5. examples
- load profile

- oxydizing

- fixed anchoring with metal anchors

- strength

- metallic / ceramic anchoring

- embrittlement

- suspended ceiling construction

- mecanical load
- mecanical load in wall structure
- reasons of mecanical load
- mineralogical effects

- bullnose
- burner lance

6. discussion

1. introduction

history of anchoring

2. functionality of anchoring

general consideration of anchoring

question
ceramic anchors

metallic anchors

fix anchoring

movable anchoring

or

round cross section

rectangular cross section

casted anchor

bended anchor

austenitic / ferritic alloy

inconel / Ni-master alloy

knowledge
the best anchoring is that provides
the best performance

task of anchors
1.) ... shall fix the monol. working lining as long as possible
2.) ... shall resist mechanical constraints
3.) ... shall resist heat constraints
4.) ... shall resist chemical constraints
5.) ... shall easily be installed during installation
(easy handling)
6.) ... shall easily be removed during break out
7.) ... shall be economical (low investment)
8.) ... shall be easily available (delivery time)

3. load conditions in process

survey of load conditions

present situation

mechanical
load

thermal
load

past situation

mechanical
load

thermal
load

chemical load
chemical load

thermal load
1.) oxydizing
metal + O2 + high temp.

2.) lost of strength

limit of creep rupture strength [N/mm]

3.) embrittlement

oxydizing
Fe2O3

Fe2O3
FeO

FeO
Fe3O4
O2+T

increase of volume
!

lost of strength
T

tensile stress

tensile stress

tensile stress

t i m e
1000

10000

100000

hours

creep rupture strength

200
180
160
140
120
N/ mm

ferritic steel
1.4828

100

1.4841
2.4856

80
60
40
20
0
500

600

700
t (in C)

800

900

embrittlement

Fe

iron carbide
Fe

Fe
Fe

double effect:
(sigma phase embrittlement)

cubic body entered lattice

-lattice

Fe Fe

(without alloying elements)

F
e

Fe
Fe
Fe
Fe
Fe
Fe
Fe

Fe
Fe

Fe

chromium
carbide

(without alloying elements)

Fe
Fe

Fe

face centered cube lattice

lattice > 900C

Fe

transition lattice structure

(with alloying elements)

Fe
Fe
Fe

frequent and slow temperature

change around 900C

intercrystalline corrosion
grain

grain

grain boundaries with

carbide embrittlement
(chromium carbide)

reasons of mecanical load

1.) to small designed expansion joints

2.) process temperature clearly higher as expected

3.) mineralogical effects

4.) manufacturing / design

mineralogical effects

mecanical load in wall structure

new installed lining

used lining
anchor cracks

anchor cracks

Mechanical load factors

supporting anchor
20C
RCY40LCC-114MM
RT102SP-100MM

91C

1000C

936C

tripple effect

definition of corrosion
attack and destruction of material due to chemical
and electrochemical reactions

wet corrosion

hot gas corrosion

cold areas < 500C

hot areas > 500c

electrochemical reaktion

chemical reaktion

with electrolytic medium

without electrolytic medium

salt attacks
KCI
(772C)

NaCI (801C)

K2CO3 (897C)
NA2SO4
(852C)

CaSO4 (1397C)

K2SO4 (1074C)

4. alloys

general view
condition
high
temperature
high sulpher
content
high content
of chloride
high C + Co
presence

problem

best
measure

oxydisation

Cr and Cr+Ni

sulphidizing

Mn+C
no Ni

salt attack

Ni

carbonisation

Ni+Si

constrictions
- -crystal
- -embrittlement 700-900C
- embrittlement due to aging
< 800C
- -embrittlement 700-900C
- sulpher sensativity
- price
- sulpher sensativity
- price

dilemma of anchoring material

compromise !
ferritic alloys

austenitic alloys

Ni-master alloys

attack of chloride at appr. 800C

(oxydising atm.)
1.482
8

1.430
1

1.476
2
2.485
6

2.485
1

1.484
5
1.484
1

attack of K2SO4
(oxydising atm.)
1.4828
1.4301
2.4856
1.4762

2.4851

1.4845
1.4841

attack of K2SO4
(reducing atm.)

attack of K2SO4
(reducing atm.)

5. examples

loadload
profile
profile

fixed anchoring

metallic / ceramic anchoring

suspended ceiling construction

bullnose

burner lance

6. discussion