Refractory Lining Problems

Experiences with Refractory Lining at Precalciner

Cement Kilns in Combination with Use of Waste
Fuels

Refractory Lining Problems

Share of Secondary Fuels of the German Cement Industries
Sekundrbrennstoffanteil
40
34,8

35
30.2

30

25.7
22.9

25

18.6

20

15.8

15

10.1 10.7

13.4

7.4

10
4.1
5
0

1987 1990 1994 1995 1996 1997 1998 1999 2000 2001 2002

year
2

Refractory Lining Problems

Ceiling of Gas Duct in Calciner Deflection Chamber

Refractory Lining Problems

Corroded Anchoring and Steel Wall in a Calciner

Refractory Lining Problems

Refractory Lining Problems

Refractory Lining Problems

3-layer installation
107 C

thickness
60 mm
75 mm
150 mm

ceramic anchors

843 C
1164 C

steal plate
insulating plates
insulating monolithics
working lining 30 - 60 % SiC;
gunnite mixes or castables

1200 C
calculated temperature profile

2-layer installation
194 C
thickness
135 mm
150 mm

981 C

alloyed anchors

steelplate
insulating
working lining 30 - 60 % SiC;
gunnite mixes or castables

1200 C
calculated temperature profile
7

Essential Plant Info

Chalk deposit, dry surface mining
Very high CaCO3 portion (94 - 96 %) in chalk requires high

quantities of correction materials for iron, aluminia and silica carrier

Wet process for raw material preparation

De-watering of the slurry in filter presses
Semi-dry process (filter cake 20 % moisture)
Process internal composition of the raw-meal
100 % compound operation with hammer mill flash-dryer
3-stage cyclone gas suspension Pre-heater
Inline Pre-calciner with separate tertiary air duct
Short kiln (2-stations) and three grate clinker cooler

Laegerdorf Plant - Cement Production

Sand Quarry

Sandmill

Mixer

Slurry Filtration
Slurry Tanks

Bagging and
Dispatch

Chalk Quarry

Slurry Preparationl

Flyash Homogenizing
and Storage

Cyklon Preheater
with Calciner

FA-Dome-Silo

Gipsum Storage
AFR Storage

Waste Oil Storage

Coal Mill
Cement Mill 2

Kiln
EP

FlashDryer

Clinker Storage

Cement Mill 1

Clinkercooler

Process Temperatures
140 C
140 C

Gas
Solids

530 C

18
23

850 C

13

12
17
8

140 C

11

700 C

19

20

16

2.000 C

10

14

850 C
1.200 C

21

22
15

160 C

1.450 C

260 C
10

Situation at Lgerdorf - AFR Feeding

Storage

Preheater
Delivery

Dosage Bin

cyclon

Conveyer Scale
Calciner

Belt Conceyer

Screw Conveyer

Kiln

Cooler

11

Situation at Lgerdorf - Kiln 11 (Inline Pre-calciner)

Exhaust gas

Meal input
52 m

34 m

Fullers earth
Animal meal
Tyre chips
other AFRs
Coal dust

Tertiary air

Meal
input

Coal dust
Coal dust
Liquid AF
Clinker

Cooler air
12

Optimization of Process
Fly ash injection

At Lgerdorf fly ash is put directly into the kiln system to

replace clay
Fly ash injection into the calciner resulted in inhomogeneous
clinker (coarse particles inside the clinker lumps)
- Today the fly ash is injected into the flash dryer
- Fly ash injection into the flash dryer also resulted in lower
exhaust gas temperatures

Chlorine and sulphur in hot meal at kiln inlet

Common rule Cl < 2 % and SO3 < 4 % is true for kiln 11

However, when SO3 is very low Cl values above 2 % are
acceptable
13

Original Concept of Refractory Lining

Refractory Lining with Three Layer Design (1 layer calcium silicate

insulation boards, 1 layer insulation castable and 1 layer working castable

(SICTOGUN 60)) at kiln inlet smoke chamber and lower part of calciner

14

Original Concept of Refractory Lining

Refractory Lining with Three Layer Design (1 layer calcium silicate boards, 1 layer insulation

castable and 1 layer working castable (DENCAST SICTO)) at upper part of calciner

15

Original Concept of Refractory Lining

Refractory Lining with Three Layer Design (2 layers of

calcium silicat boards and 1 layer brick lining) at upper

part of calciner and cyclones stage 1

16

Original Concept of Refractory Lining

Refractory Lining with Two Layer Design (1 layer calcium silicate

insulation boards and 1 layer brick lining respectively castable

(SICTOGUN 60)) at gas ducts and cyclones above stage 1

17

Refractory Lining and Corrosion Problems

Short lifetime of brick and castable refractrory lining in

smoke chamber, calciner, cyclones and gas ducts

Corrosion of steel anchors and refractory support rings
Short lifetime of ceramic anchors
Destruction (dissolution) of insulation lining with calcium

silicate plates
Corrosion (inside) of steel shells
Cracks and deformations at steel shells (outside)
Outside corrosion of steel casings in the areas of thermal

bridges (e.g. supporting rings) due to burnt outside coating

18

Cracks at calciner casing

19

Damaged Refractory Lining at Calciner Top

The corroded anchors in the

damaged area are easily
detectable.

20

Damaged Refractory Lining at Caliner Top

Major Shut Down 2000
Platform + 69,0 m

Calciner Top

Damaged 3-Layer

Refractory Lining with

serious Corrosion Attack of
Steel Sheel (Acid
Corrosion)
21

Refractory Lining and Corrosion Problems

Damage mechanisms of refractory lining and steel casing

Rusting and acid corrosion of steel casings and welded metallic

anchors due to 3-layer refractory lining with low temperature at
steel casing
Infiltration of alkali chlorine salts in the refractory lining with
-

alkali spalling at the surface,

increased heat expansion of refractory,
loss of the expansion gaps,
mechanical stress and tear off of anchoring
deformation and cracking of steel casing

High temperature corrosion of metallic anchors due to through the

expansion joints infiltrated alkali chlorine and sulphat containing
kiln gases (chimney effect between working lining and dissolved
calcium silicate plates)
22

High temperature corrosion

SO2 & reducing atmosphere at 400C

Chloride and hydro acid chlorine < 500C

Low melting eutectic mixtures of

. alkali chloride and sulfate salts > 500C

Alkali Chlorides on Cr and CrNiSteel > 600C
Oxidization of steel due to exceeding of application

. .temperature

23

Limits for the application of steel alloys

Steel anchors alloy qualities thermal resistance

versus resistance against chemical attack

Steel quality

AISI 321
DIN 1.4541
AISI 310
DIN 1.4841

Composition

Application
temperature

% Cr
17 - 19

% Ni
9 - 12

C
< 850

24 - 25

19 - 22

< 1150

The higher the Ni content danger of SO2-attack

The higher the Cr content danger of Cl-attack
24

Precast and -tempered monolithic blocks

25

Alkali attack resistant refractory qualities

Refractory with low porosity < 20%

If a monolithic lining required, use low cement

qualities only
SiO2-rich acid fire clay products (Al2O3 < 45%)

When a higher refractoriness is required, then

refractory qualities based on SiC & Mullite
Refractory qualities with low thermal expansion

Application of alkali resistant mortars

26

Alkali attack resistant refractory lining

Installation of two layer refractory lining with alkali resistant refractory

qualities

Insulating firelight bricks, vermiculite or insulating

..
castable

Any installation of CaO-SiO2

boards.
. Exception: only at after
cooling zone of clinker cooler
. and partially at tertiary air duct
Thinner insulating lining to increase the thermal conductivity and permit

higher shell temperatures of

acid corrosion

90-180C to prevent rusting and

to increase thermal conductivity to prevent

overheating of anchors
to prevent rusting and acid corrosion on kiln shell

27

Alkali attack resistant refractory lining

In kiln areas with process temperatures

above 650C:
Flat walls to be lined with a gas tight capsulated
refractory lining only
Refractory support flanges have to be covert
completely by a monolithic lining

28