Escolar Documentos
Profissional Documentos
Cultura Documentos
ProtectiveShell
ShellCorrosion
Corrosion
Preventive protection of
Metallic Anchors and
other Components
2006
Protective
ProtectiveShell
ShellCorrosion
Corrosion
Content
1. General contemplation
Corrosion Products
Alkali Circulation
Temperature Profile
Heat flow & salt penetration
2. Metallic Alkali Compounds
Alkali Sulfates
Alkali Chlorines
3. Mechanism of corrosion in cement plants
High Temperature Chlorine Corrosion
Oxidation & Acid Corrosion
4. Preventive shell protection
Process Solutions
Various Lining Solutions for changing the Dew Point Area
Protective coatings
Protective
ProtectiveShell
ShellCorrosion
Corrosion
1.General contemplation
Corrosion Products
Protective
ProtectiveShell
ShellCorrosion
Corrosion
1. General contemplation
Raw Meal
Alkali:
0,5 2,6%
Sulfur:
0,3%
Chlorine:
0,1%
Alkali Circuit
Sulfur Circuit
Input Fuel:
Fuel
Alkali
Sulfur
Chlorine
Oil
---
1-7%
---
Coal
0,8%
0,3-5%
0,4%
Alt. Fuel
7%
15%
30%
Waste Gas
Protective
ProtectiveShell
ShellCorrosion
Corrosion
1. General contemplation
3,632
3,272
2,912
2,552
1,832
1,472
1,112
752
392
32
Bauxite
ACID
Magnesia
Magnesia
Magnesia
Bauxite
Fireclay
ACID
[0F]
2,192
Protective
ProtectiveShell
ShellCorrosion
Corrosion
1. General contemplation
Heat flow & salt penetration
1.40000C / 2,55200F
1.38000C / 2,51600F
1.00000C / 1,83200F
O2, SO2
30000C / 57200F
H2O
Cl-, SO4-, S2-
29500C / 56300F
Protective
ProtectiveShell
ShellCorrosion
Corrosion
2. Metallic Alkali Compounds
Alkali Sulfate
Sulfur (Fuel)
(Fuel)
Combustion
Alkalis (volatile)
(volatile)
Reaction
Condensing
Clinker
Refractory Material
Protective
ProtectiveShell
ShellCorrosion
Corrosion
2. Metallic Alkali Compounds
Alkali Chlorines
Chlorine (Raw
(Raw Mix)
Mix)
Alkali Chlorine (vaporous)
(vaporous)
Reaction
Alkalis (volatile)
(volatile)
Condensing
Sintering
Raw Meal
Protective
ProtectiveShell
ShellCorrosion
Corrosion
2. Alkali Compounds
Compounds
Melting Point or
Decomposition
[0C]
[0F]
KOH
361
682
KCl
768
K2CO3
Compounds
Melting Point or
Decomposition
[0C]
[0F]
NaOH
319
606
1,414
NaCl
801
1,474
894
1,641
Na2CO3
850
1,565
K2SO4
1.074
1,965
Na2SO4
884
1,623
KNO3
337
639
NaNO3
307
584
K2S2O7
>300
>572
Li2SO4
860
1,580
NH4Cl
350
662
NH4NO3
170
338
(NH4)S2O8
120
248
(NH4)2S2O3
150
302
NH4SO3-NH2
131
268
Protective
ProtectiveShell
ShellCorrosion
Corrosion
2. Alkali Compounds
Compounds
Eutectic Reaction
Temperature
[0C]
[0F]
KCL - LiCl
355
671
KCl - NaCl
657
KCl - K2SO4
Compounds
Eutectic Reaction
Temperature
[0C]
[0F]
NaNO3 - Na2SO4
120
248
1,215
NaNO3 - NaCl
298
568
690
1,274
197
387
LiCl - Li2SO4
480
896
NaAlCl4 - KAlCl4
129
264
K2SO4 - Na2SO4
428
802
90
194
Li2SO4 - Na2SO4
591
1,096
110
230
KNO3 - NaNO3
221
430
LiCl AlCl3
10
Protective
ProtectiveShell
ShellCorrosion
Corrosion
3. Mechanism of Corrosion in Cement Plants
1. High Temperature Chlorine Corrosion
11
Protective
ProtectiveShell
ShellCorrosion
Corrosion
12
Protective
ProtectiveShell
ShellCorrosion
Corrosion
13
Protective
ProtectiveShell
ShellCorrosion
Corrosion
3.1. Mechanism of Kiln Shell Corrosion
A) Oxidation - O2 is present (during kiln stop)
4Fe + 3O2 2Fe2O3
(Hematite)
(Hydrochloric Acid)
(Chloride)
14
Protective
ProtectiveShell
ShellCorrosion
Corrosion
800
7720C
Temperature 0C
6770C
600
400
4000C
3850C
2KCl*FeCl2
2900C
200
KCl
3550C
2550C
20
3900C
KCl*FeCl2
40
60
Mol%
80
FeCl2
Protective
ProtectiveShell
ShellCorrosion
Corrosion
[m]:
[m]:
4.8
10.0
Weight
Costs for Steel
Total kiln Shell
Installation
TOTAL
[Kg]:
[/kg]:
[]:
[]:
[]:
35,000
2.8*
100,000
100,000
200,000
* (06/2006)
16
Protective
ProtectiveShell
ShellCorrosion
Corrosion
3.2 High Temperature Chlorine Corrosion
Temperature range at metallic surface 550 8500C / 1,022 1,5620F
Deposit and enrichment of chlorine components on the metallic surface
(Na, K) Cl (gaseous) (Na, K) Cl (solid)
Lack of oxygen underneath the refractory castable / brick (The composition of the
atmosphere is very different at the boundary layer between castable / bricks and metallic
anchors / casing. Deposits and enrichments of condensing chemical components may
occur simultaneously with oxygen reducing reactions)
17
Protective
ProtectiveShell
ShellCorrosion
Corrosion
4. Preventive shell protection
Process Solutions
Objectives
Means
Fuel, Bypass
Burning Condition
18
Protective
ProtectiveShell
ShellCorrosion
Corrosion
4. Preventive Shell Protection
New Refractory Layouts (Dew Point Avoidance)
Lining proposal for ENCI lower cyclone stage T cyclone 8000C / 1,4720F
Existing Lining
40
60
6mm
114
64
Proposal 2
35 6mm
114
40
60
6 30 2mm
114
Proposal 1
Tcasing/out = 730C
Tcasing/out = 1160C
1630F
2410F
Tcasing = 2230C
4330F
Tout = 630C
1450F
Fireclay A40
CS-Board
1800
CS-Board
1500
Cyclone
Casing
19
Ceramic Wool
Plates
Cover
Protective
ProtectiveShell
ShellCorrosion
Corrosion
4. Preventive Shell Protection New Refractory Layouts (Dew Point Avoidance)
Lining proposal for ENCI
Proposal 2:
114
40
60
6 30 2mm
0
Refractory
Refractory lining
lining proposal
proposal 22 (Temperature
(Temperature 800
8000C)
C)
Date
Date
Customer
Customer // project
project
Detail
Detail
Done
Done by
by
Ambient
Ambient temperature
temperature
Surface
Surface temperature
temperature
Heat
Heat transition
transition coefficient
coefficient
Calculation
Calculation formula
formula
Wind
Wind velocity
velocity
Irradiation
Irradiation coeffizient
coeffizient
Solar
Solar irradiation
irradiation
Diameter
Diameter
Transient
Transient heat
heat
Transient
Transient heat
heat tube
tube
Temperature
Temperature flow
flow
Material
Material
Fireclay-A40
Fireclay-A40
CS
CS Board
Board 1800
1800
CS
CS Board
Board 1500
1500
Steel
Steel Casing
Casing
Ceramic
Ceramic Wool
Wool Plates
Plates
Air
Air
Steel
Steel Casing
Casing
14.
14. 10.
10. 02
02
ENCI,
Maastricht
ENCI, Maastricht
Cyclone
Cyclone Stage
Stage 11
Olaf
Olaf Kuehne
Kuehne
inside
inside
800
800
814
814
150
150
outside
outside
20
20
67
67
12,20
12,20
JUERGES2
JUERGES2
11
0,60
0,60
00
5.494
6.000
5.494
6.000
625
572
625
572
10.784
10.784
mm
mm
114
114
40
40
60
60
66
30
30
11
22
unit
unit
C
C (input)
(input)
C
C (calculated)
(calculated)
2
W/m
W/m2K
K
m/s
m/s
--2
W/m
W/m2
mm
mm
2
W/m
W/m2
W/m
W/m tube
tube
W/mK
W/mK
1,265
1,265
0,135
0,135
0,105
0,105
48,3
48,3
0,11
0,11
0,03
0,03
53,633
53,633
border
border
813,8
813,8
758,3
758,3
579,3
579,3
223,2
223,2
220,3
220,3
84,3
84,3
67,2
67,2
mean
mean
785,7
785,7
671,1
671,1
415,5
415,5
223,4
223,4
161,3
161,3
75,2
75,2
67,2
67,2
20
Tin = 8000C
Tcasing = 2230C
Tout= 630C
Protective
ProtectiveShell
ShellCorrosion
Corrosion
4. Preventive Shell Protection New Refractory Layouts (Dew Point Avoidance)
Insulating Castable or
Calcium Silicate Board
Ceramic Felt (short fiber)
Ceramic Blanket
Metallic Clamp
21
Protective
ProtectiveShell
ShellCorrosion
Corrosion
4. Preventive Shell Protection New Refractory Layouts (Dew Point Avoidance)
Protective
ProtectiveShell
ShellCorrosion
Corrosion
4. Preventive Shell Protection Coatings, Paints, Deposit Welding
Gas-tight Coatings / Paints
Polyamide Resin
Silicone Resin
Silicone Alkyd Resin
Deposit Welding by Metallic Powder Gunning
Thermal Spraying with Wire
High Speed Thermal Spraying
Electric Arc Spraying
Phosphating (Bondering)
Phosphoric Acid
23
Protective
ProtectiveShell
ShellCorrosion
Corrosion
4. Preventive Shell Protection
Protective Coatings (Costs are calculated for Rotary Kiln, diam. 4,4m)
Gas-tight Coatings / Paints (2 layer, approx. 350 ml/m 2) not abrasion resistant
Resin based Coating
Polyamide Resin
refractoriness
Graphite Pigments, 75-85%
3000C / 5720F
Polyamide Resin
Silicone Resin
7000C / 1,2920F
24
4250C / 7970F
Protective
ProtectiveShell
ShellCorrosion
Corrosion
4. Preventive Shell Protection (Costs are calculated for Rotary Kiln, diam. 4,4m)
refractoriness
approx. 170/m2 2.400/m
Aluminium wit Ni-Al Wire
8500C / 1,5620F
9500C / 1,7420F
refractoriness
approx. 580/m2 8.200/m
Ni-Cr 50/50
25
9500C / 1,7420F
Protective
ProtectiveShell
ShellCorrosion
Corrosion
4. Preventive Shell Protection (Costs are calculated for Rotary Kiln, diam. 4,4m)
+ PO43- Fe3(PO4)2
26
refractoriness
3500C / 6620F
Protective
ProtectiveShell
ShellCorrosion
Corrosion
4. Preventive Shell Protection
Protective Coatings (not abrasion resistant not suitable for rotary kiln)
Ceramic Mortar (1 layer, approx. 2kg/m2 or 1kg/75anchors)
refractoriness
1.3000C / 2,3720F
approx. 45/kg
(Hoganas - Sweden)
(38% by weight)
27
Protective
ProtectiveShell
ShellCorrosion
Corrosion
5,00 /kg
6,20 /kg
6,30 /kg
Inconel 625
2.4856 AISI 625 NiCr22Mo9Nb
36 40,00 /kg
Stainless Steel:
1.4301 AISI 304 X5CrNi18-10 (V2A)
1.4571 AISI 316 X6CrNiMoTi17-12-2 (V4A)
3,50 /kg
4,80 /kg
28
Protective
ProtectiveShell
ShellCorrosion
Corrosion
4. Preventive Shell Protection
Protective Coatings (not abrasion resistant not suitable for rotary kiln)
Ceramic Mortar (1 layer, approx. 2kg/m2 or 1kg/75anchors)
Coro Tex 5009/3810
refractoriness
1.3000C / 2,3720F
approx. 45/kg
(Hoganas - Sweden)
not coated
Protective
ProtectiveShell
ShellCorrosion
Corrosion
4. Preventive Shell Protection
Refractory
Brick
Steel Plate
Refractory
Mortar
30
Protective
ProtectiveShell
ShellCorrosion
Corrosion
4. Preventive Shell Protection
31
Protective
ProtectiveShell
ShellCorrosion
Corrosion
4. Preventive Shell Protection
32
Protective
ProtectiveShell
ShellCorrosion
Corrosion
33