The document discusses refractory lining problems experienced at a cement plant using waste fuels. It describes damaged refractory linings and corrosion of steel shells in the calciner and cyclones. The original refractory lining design used calcium silicate insulation boards which dissolved from infiltration of alkali chlorine salts, damaging anchors and casings. A new refractory lining design is proposed using alkali-resistant refractory qualities with thinner insulation to prevent corrosion and increase shell temperatures. Precast monolithic blocks and gas-tight capsulated linings are also recommended for high temperature areas above 650°C.
The document discusses refractory lining problems experienced at a cement plant using waste fuels. It describes damaged refractory linings and corrosion of steel shells in the calciner and cyclones. The original refractory lining design used calcium silicate insulation boards which dissolved from infiltration of alkali chlorine salts, damaging anchors and casings. A new refractory lining design is proposed using alkali-resistant refractory qualities with thinner insulation to prevent corrosion and increase shell temperatures. Precast monolithic blocks and gas-tight capsulated linings are also recommended for high temperature areas above 650°C.
The document discusses refractory lining problems experienced at a cement plant using waste fuels. It describes damaged refractory linings and corrosion of steel shells in the calciner and cyclones. The original refractory lining design used calcium silicate insulation boards which dissolved from infiltration of alkali chlorine salts, damaging anchors and casings. A new refractory lining design is proposed using alkali-resistant refractory qualities with thinner insulation to prevent corrosion and increase shell temperatures. Precast monolithic blocks and gas-tight capsulated linings are also recommended for high temperature areas above 650°C.
The document discusses refractory lining problems experienced at a cement plant using waste fuels. It describes damaged refractory linings and corrosion of steel shells in the calciner and cyclones. The original refractory lining design used calcium silicate insulation boards which dissolved from infiltration of alkali chlorine salts, damaging anchors and casings. A new refractory lining design is proposed using alkali-resistant refractory qualities with thinner insulation to prevent corrosion and increase shell temperatures. Precast monolithic blocks and gas-tight capsulated linings are also recommended for high temperature areas above 650°C.
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
