Escolar Documentos
Profissional Documentos
Cultura Documentos
by
Y P Sethi, S K Chaturvedi, S N M Khan and M Vasudeva
National Council for Cement and Building Materials, Ballabgarh (India)
1.0 INTRODUCTION
A cement plant, located in one of the Southern States of India, was facing the problem of
corrosion of chimney shell of precalciner string of kiln system. The rotary kiln is equipped with
two strings of preheater; kiln string having four-stage preheater cyclones and precalciner string
having six-stage preheater cyclones. The chimneys in both the preheater and precalciner strings
of kiln circuit were made of mild steel and installed in 1983 and 1998 respectively. The service
life of kiln string chimney was around 20 years. When chimney shell thickness was measured in
July 2007, a high wear rate of the chimney shell of precalciner string was observed that
subsequently led to the state of buckling. The chimney shell was gradually chipped off in the
form of flakes leaving the residual shell thickness as low as 2 mm. National Council for Cement
and Building Materials (NCB) undertook the diagnostic investigations to identify the causes of
buckling of chimney due to corrosion and suggested remedial measures.
2.0 CAUSES OF BUCKLING OF CHIMNEY
The buckling of metallic shell is caused by the progressive deterioration and wear rate of
shell material mainly due to corrosion. Corrosion of metallic shell is influenced by a number of
factors such as composition of the metallic shell, nature of the gases in contact with the shell and
their temperature etc. Steel, when exposed to an industrial atmosphere, reacts to form the
corrosion product (Fe2O3.H2O), which wears out the material gradually.
Corrosion also occur because of condensation of flue gas containing H2O, SO2 / SO3,
NOx and HCl. Massive and rapid corrosion of metal is usually caused by the action of sulphuric
acid formed by the oxidation of sulphur. This condensation of gas occurs on surfaces that are
below its dew point. The dew point of water, nitric acid and hydrochloric acid is much lower
than that of sulphuric acid. Hence, the limiting dew point is that of sulphuric acid. Typically, the
maximum corrosion rate occurs at 15-20oC below the dew point as shown n Figure 1.
Peak Corrosion
CORROSION RATE
Dew Point
E.S.P.
1A FEED 1
G
2
C
1C 1B T
ESP STACK
F 3 FAN
E
E
D
2 4
E.S.P.
PC
G FAN
C
3 5
T
4 6
PC
STACK PH
FAN COAL
TAD
COAL
KILN
PA FAN
SEC. AIR
GRATE COOLER
COOLER FANS
FigFIG.
2 : 2Process
PROCESS Measurements
MEASUREMENTS INin Kiln
KILN Circuit
CIRCUIT
i) O2 and CO levels at the preheater outlet of calciner string were measured and
found to be 2.3-2.4 % and 270 ppm respectively, which indicates satisfactory
combustion in the precalciner. However, O2 level at preheater outlet of kiln string
was found to be 6.3%.