Refractory in Cement Industry Wear Phenomena

Wear
Phenomena

Refractory In Cement Industry

Wear of refractories,
particularly when using
waste fuels and their
influence on the brick
life

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Refractory in Cement Industry Wear Phenomena

Influences on the part of

the cement producer Refractory
Installation

storage Thermal

Kiln Chemical
Lifetime of Burning
Refractory Refractory Conditions
selection

Mechanical

installation Raw Influences on the

draw Production Material part of the producer
Quality Quality

Thermal Influences

Typical burning conditions

Clinker melt infiltrations
Concave / Sloping
erosion
Thermal shocks

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Refractory in Cement Industry Wear Phenomena

Typical burning
conditions

Clinker Melt Infiltration

Densification of the brick‘s hot face caused by clinker melt

infiltration
 increased thermal influences
 variations of the kiln feed composition

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Refractory in Cement Industry Wear Phenomena

Concave/sloping/smooth hot surfaces

(brickwork erosion)
 constant thermal overloading of the brickwork lava-like
coating

Concave/sloping erosion
(brickwork erosion)
 direct flame impact

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Refractory in Cement Industry Wear Phenomena

Thermal Shock
Influences Too fast heating up or cooling
down
Loss of coating

Optimizing:
 Taking heating procedure
into consideration/
 cooling down slowly

Chemical Influences

Salt infiltration
Corrosion of chrome spinel
Silicate corrosion
Redox burning conditions
“Alkali Spalling“
Corrosion of the kiln shell
Hydration of basic bricks

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Refractory in Cement Industry Wear Phenomena

Salt infiltration:
Volatile elements and their Principal Compounds
(without heavy elements)

Sulphur compound
SO2 , SO3 , S2-

Potassium Oxide
K2O

Chorine
Cl2 , Cl-

Salt infiltration : alkali sources

Kiln feed raw material

 Clay and mica minerals

 Feldspar minerals (Na,K)AlSi3O8
 Additives (ashes, bentonite, etc.)
 Alternative combustibles

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Refractory in Cement Industry Wear Phenomena

Salt infiltration : Chlorine sources

Coal 0.1 – 0.3 % Cl

Lignite 0.1 - .013 % Cl
Animal meal 0.6 – 1.6 % Cl
Plastics “ PVC” 20% of the worldwide production of Plastics
CH2 = CHCl 30% Cl

Salt infiltration : Sulphur sources

Kiln feed raw material: FeS2 , PbS, ZnS, CaSO4 , CaSO4 ·H2O
Oil 0.2 – 2.5 %
Pitch/Tar 1–6%
Coal 0.1 – 12 % So3 in the ash
Petrol coke 5–8%
Lignite 0.2 – 15 % SO3 in the ash

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Refractory in Cement Industry Wear Phenomena

Concentrations of salts in the cement kiln

system
Circulation of volatile compounds

alkalis + Cl- alkalis + So2 / SO3

Calculation of the alkali-sulphate modulus

{ASM} In the cement Clinker

1< 1 <1

KCl + K2SO4 + SO 3 Free KCl + K2SO4 KCl + K2SO4 + K2O Free

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Refractory in Cement Industry Wear Phenomena

Salt infiltration, balanced alkali-sulphate modulus (ASM ~1)

 Densification of different brick horizons
 Infiltration of gaseous alkali chloride and/or sulfate
components, condensation and densification of the brick
texture
 Sulfate salts mostly in the lower transition zone and burning
zone together with alkali chlorides in the upper transition zone

Salt infiltration, balanced alkali-sulphate

modulus (ASM ~1)

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Refractory in Cement Industry Wear Phenomena

Salt infiltration, balanced alkali-sulphate

modulus (ASM ~1)

Chrome spinel corrosion, surplus of alkalis in kiln atmosphere

(ASM >1)
 Corrosion of chrome spinel in the presence of free alkalis at
higher temperature
 Formation of toxic, hexavalent alkali chromate sulfate
 (yellow efflorescences = water soluble)
 Contamination of ground water, mason eczema

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Refractory in Cement Industry Wear Phenomena

Silicate corrosion, sulphurs of sulphur in kiln atmosphere

(ASM <1)

Silicate corrosion reduces the

refractoriness and the structural
flexibility

Possibly operational difficulties in the kiln system & to

the clinker composition (ASM <1)

Formation of coating rings

and/or build-ups in the calcining
zone, inlet section, cyclones etc.
caused by the formation of
anhydrite (CaSO4 ), double
sulfate salts(calcium langbeinite,
syngenite),and spurrite phases
(sulfate spurrite).

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Refractory in Cement Industry Wear Phenomena

Possibly operational difficulties in the kiln system and to

the clinker composition (ASM <1)

Sulphur will be retained as sulfates in the clinker (approach or

exceed 2 %), reducing the add of gypsum at the clinker grinding
stage. The retarding of hydration and setting of cement will be
changed.

Formation of dusty clinker Reduction of the viscosity of clinker

melt and the surface tension of the liquid phases, which results
in clinker structure loosening, and a greater proportion of clinker
dust is formed.

Redox burning conditions

Local reduction and/or redox burning conditions caused by
incomplete combustion of fuels (coarse coal, ashes on the
lining’s surface)
Basic brick grades with alpine magnesia (crystalline magnesia)
are sensitive to the high Fe2O3 content

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Refractory in Cement Industry Wear Phenomena

“Alkali Spalling“

Thin hot face spallings due to brittleness of the brick texture

Alkalis react with the brick components from fireclay and high
alumina bricks forming alkali alumina silicates (feldspar,
feldspathoids). This formation is accompanied by volume
increase.

alkali spalling due to the

wear by alkalis
formation of new
minerals

alumina content, refractoriness, mechanical

resistance

Kiln shell corrosion

Migration and efflorescences of salts between brickwork and

kiln shell
Chemical attack of salts under kiln operating conditions (high
thermal corrosion)
Depending on the alkali-SO3 -ratio and oxygen partial pressure
bi- and trivalent iron oxides and/or iron sulphides are formed.

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Refractory in Cement Industry Wear Phenomena

Hydration

Cracks from the brick surface into the brick‘s internal texture
Basic bricks are sensitive to humidity and must be stored and
protected against humidity, rain and sea water.
MgO reacts with water to brucite (Mg(OH2) ) which is
accompanied by volume increase (~ 53%).
Tropical/sub-tropical climate conditions accelerate this reaction.

Hydration

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Refractory in Cement Industry Wear Phenomena

Mechanical Influences

Thermal expansion
Loosenings of the lining
Kiln shell deformation (ovality)
Groove in the lining
Pressure loads on the kiln
retaining ring

Thermal Expansion

Convex spallings on the

longitudinal joints
Too little allowance for
expansion leads
to higher pressure within the
brickwork.
Convex spallings finally occur.
Insufficient expansion space
Frequent kiln stops after the
burnout of the cardboards

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Refractory in Cement Industry Wear Phenomena

Loosenings of the lining

Loosenings of the brickwork due to brickwork movements
Spiral twisting, tilting of bricks, shearing cracks, abrasion
marks on the brick‘s cold face
Wrong installation, frequent kiln stoppages, kiln shell
deformations and ovalities

Kiln shell deformation (ovality)

Local strong spallings in the tire section, the surrounding
brickwork is intact. Increased ovality in the tire section
causes tensions and loosenings of the lining.
The brick‘s hot face is more loaded (spallings).

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Refractory in Cement Industry Wear Phenomena

Groove formation
Increased wear parallel to the kiln axis caused by groove
formation, the other brickwork is intact (spallings of 2 - 3
brickwork width)
Brickwork rings are closed too tightly, damage of the key bricks
using a wrong hammer
More than one iron plate within the brickwork rings

High pressure on the retaining ring section

Increased pressure of the brickwork onto the retaining ring.
Shearing tensions occur within the brickwork leading to cracks
and spallings of brick parts.
Instable, deformed kiln shell or ovality increases this wear.

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Refractory in Cement Industry Wear Phenomena

Wear Influences onto

the Monolitic lining

Vapour explosion

monolithic Thermal
wear
influences
Mechanical
influences

Chemical
influences

Wear Influences onto the

monolitic lining
Vapour explosion (100 °C to ~600 °C)
 Too fast heating up during setting/hardening and after heating up
of the monolithic lining

Thermal influences
 Thermal shocks, thermal overloading, thermal spots

Chemical influences
 Reaction with the kiln feed (clinker dust), thermochemical attack
by harmful components (alkali and sulfur compounds)

Mechanical influences
 Abrasion, dust erosion (clinker dust), influences due to anchor,
kiln shell and metallic construction

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Refractory in Cement Industry Wear Phenomena

Vapour explosion (100 °C to ~600 °C)

Riser shaft to
Cooler banks
calcinator/inlet chamber

Thermal influences

Cooler banks
(tension cracks caused by thermal shock)

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Refractory in Cement Industry Wear Phenomena

Chemical influences

Kiln hood back wall

(alkali attack -> alkali spalling)

Chemical influences

Corrosion of metallic anchors

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Refractory in Cement Industry Wear Phenomena

Mechanical influences

Damper in the tertiary air duct

(high abrasion caused by strong air stream)

Mechanical influences

Embrittlement of metallic anchors

(formation of sigma phase)

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Refractory in Cement Industry Wear Phenomena

Thermal, chemical and mechanical influence

Burner lance

A change of refractory wear, particularly when

using alternative or waste fuels in the cement
rotary kiln

Fuel oil and gas as primary energy since approx. 1960

Changeover to coal after the petroleum crisis in 1973/74
Use of alternative fuels since mid eighties

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Refractory in Cement Industry Wear Phenomena

Lining and coating zone of kilns using oil & gas

Outlet Burning Safety

zone zone zone

Coating in the burning zone

The magnesia-chromite bricks used in the hot zones and the
high alumina and fireclay bricks in the other sections perform
good regarding lifetime and wear resistance

A change of refractory wear, particularly when

using alternative or waste fuels in the cement
rotary kiln

Fuel oil and gas as primary energy since approx. 1960

Changeover to coal after the petroleum crisis in 1973/74
Use of alternative fuels since mid eighties

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Refractory in Cement Industry Wear Phenomena

Lining and coating zone of kilns using coal & Fuel oil

Outlet Lower Upper Safety

Burning
zone Transition Transition zone
zone
zone zone

Coating in the burning zone and particularly in the transition

zones
Magnesia-chromite bricks in the burning zone showing a usual
wear
Reduced service life of the magnesia-chromite lining in the
transition zones (salt infiltration, formation of alkali chromates,
redox burning conditions)

Salt infiltrations, alkali chromate formation and reducing

burning conditions in case of magnesia-chromite bricks

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Refractory in Cement Industry Wear Phenomena

Development of magnesia -Spinel & Magnesia-Zirconia Bricks

MAGPURE®93/95 ALMAG®A1 ALMAG SLC® REFRAMAG®85

ALMAG®85

FERROMAG®90

MAGNUM®95 MAGNUM®S

Main properties:
 high resistance to alkali attack (no corrosion of the MA spinel
or the zirconia)
 insensitive to reducing or redox conditions

A change of refractory wear, particularly when

using alternative or waste fuels in the cement
rotary kiln

Fuel oil and gas as primary energy since approx. 1960

Changeover to coal after the petroleum crisis in 1973/74
Use of alternative fuels since mid eighties

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Refractory in Cement Industry Wear Phenomena

Lining and coating zone using fuel with 50% & 50%
alternative fuel

Outlet Lower Transi Safety

Burning tion Burning Transition
zone Transition zone zone zone
zone zone
zone

Complex and instable coating situation and various flames

Lining lifetime clearly reduced, particularly in the transition
zones(massive salt infiltrations, local overheating, local redox
burning conditions)

Influence of secondary fuels on the refractory lining

and kiln system

Stronger chemical and physical attack against the basic bricks

Risk of irregular temperature profile in the kiln (local thermal
overload)
Risk of formation of local reducing atmosphere
Stronger chemical attack against the aluminous and fireclay
bricks
Stronger attack against the kiln/cyclone shell and the anchor
system

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Refractory in Cement Industry Wear Phenomena

Percentage of the different wear types

Up-to-date studies show that more than 60 % of the wear
cases are caused by salt infiltrations (alone or in combination
with other attacks)

23 % thermochemical Influences & Salts

23 % mechanical / thermomechanical % 60 <

influences and salts

17 % salts

23 % overheating
8 % mechanical/thermomechanical influences
1 % redox conditions
5 % other

Quaternary System : K2So4 – CaSO4 , KCl – CaCl2

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Refractory in Cement Industry Wear Phenomena

Increase of salt infiltrations and accumulation of other

harmful substances in the structure, balanced alkali-
sulphate modulus (ASM ~1)

Increase of salt infiltrations and accumulation of other

harmful substances in the structure, balanced alkali-sulphate
modulus (ASM ~1)

Use of alternative additives with the kiln feed

(e. g.: condensation of lead sulfide (PbS))

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Refractory in Cement Industry Wear Phenomena

Silicate corrosion , Surplus of sulphur in kiln

atmosphere (ASM <1)

refractoriness and the structural

flexibility are reduced

Influence of secondary fuels on the refractory lining and

kiln system

Stronger chemical and physical attack against the basic bricks

Risk of irregular temperature profile in the kiln (local thermal
overload)
Risk of formation of local reducing atmosphere
Stronger chemical attack against the aluminous and fireclay
bricks
Stronger attack against the kiln/cyclone shell and the anchor
system

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Refractory in Cement Industry Wear Phenomena

Local overheating and redox burning conditions

Redox burning condition & salt infiltration

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Refractory in Cement Industry Wear Phenomena

Strong reducing and redox burning conditions

carbon disintegration, Boudouard reaction (CO + C <-> 2CO)
2

carbon
horizon

Influence of secondary fuels on the refractory lining

and kiln system

Stronger chemical and physical attack against the basic bricks

Risk of irregular temperature profile in the kiln (local thermal
overload)
Risk of formation of local reducing atmosphere
Stronger chemical attack against the aluminous and fireclay
bricks
Stronger attack against the kiln/cyclone shell and the anchor
system

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Refractory in Cement Industry Wear Phenomena

“Alkali Spalling“ in the aluminous bricks

Structural embrittlement and spalling of thin layers.
The alkalis react with the components of fireclay and
aluminous bricks under formation of alkali containing alumina
silicates (feldspars, feldspathoids).
This formation is accompanied by a volume increase.

Influence of secondary fuels on the refractory lining

and kiln system

Stronger chemical and physical attack against the basic bricks

Risk of irregular temperature profile in the kiln (local thermal
overload)
Risk of formation of local reducing atmosphere
Stronger chemical attack against the aluminous and fireclay
bricks
Stronger attack against the kiln/cyclone shell and the anchor
system

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Refractory in Cement Industry Wear Phenomena

Effect of kiln shell corrosion and cyclone steel shell

Corrosion of metallic anchors (refractory areas installed with

castables), formation of alkali chromate (K2 CrO3 ), surplus of
alkalis in kiln atmosphere (ASM >1)

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Refractory in Cement Industry Wear Phenomena

Alkali chromate consideration in magnesia spinal lining

Arcanite
(blue efflorescences)

Arcanite
(green efflorescences)

alkali
chromate

Requirements to refractory material and its installation

In Cement Rotary Kilns fired with secondary fuels

Minimization of infiltration and corrosion of refractory

components
Optimization of the structural texture by higher flexibility and
high structural strength
Renewable sealing of the refractory’s hot face
Optimization of installation technology, especially in the static
area of cement kiln system including a flexible and fast
installation of high grade refractory concretes and bricks
Innovative insulating and protection options for the anchoring
system and steel shell to reduce or even prevent different
corrosion mechanism of shell and anchor

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Refractory in Cement Industry Wear Phenomena

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