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Refractories and Industrial Ceramics Vol. 49, No.

2, 2008

ROTARY KILN CORROSION-EROSION-RESISTANT LININGS

V. V. Slovikovskii1

Translated from Novye Ogneupory, No. 4, pp. 13 – 17, April 2008.

Original article submitted October 30, 2007.

The properties of magnesia refractories are studied with the aim of determining the possibility of their use for
lining rotary kilns. Periclase-chromite refractory PKhPP has been developed with an increased Cr2O3 content,
whose use combined with a laying cement, operating by the principle of self-propagating high-temperature
synthesis, in a developed “slotted” single-layer lay-up of the furnace reaction zone, made it possible to
increase the lining life of industrial rotary kilns by a factor of 1.5 – 1.8.

The most worn lining of a rotary furnace is that of the – shear of refractory components due to variable thermal
Waelz kiln due to the severe operating conditions: high tem- loads and the considerable heating and cooling rate of the
perature (1400 – 1500°C), corrosive charge (considerable lining, and also occurrence of the zonality of refractory com-
amount of FeÎ, Fe2O3, Fe3O4, SiO2, Pb, Zn, etc.), low ponents as a result of impregnation of them with molten
viscosity of the liquid melt, presence of gas-phase Pb, Zn; reagents of the charge to a depth of 150 mm. At the boundary
there is a liquid phase in the reaction zone during furnace of the zone cracks form, parallel to the surface of the lining,
operation. Therefore use of linings that operate satisfactorily due to the different linear thermal expansion coefficients of
in rotary cement furnaces, as practice has shown, is the refractory;
undesirable in Waelz kilns. In Waelz kilns it is necessary to – formation in the reaction zone of crusts weighing up to
use refractory components of metallurgical grades: PKhS, 1500 kg as a result of impregnation of the lining with readily
KhPT, PKhP, etc. melting components of the charge followed by separation of
The lining of any Waelz kiln is the most critical part of crusts from the lining which leads to failure of the output area
its construction. The duration of a campaign and the main of a kiln and sometimes failure of the loading pouring devices;
technical and economic indices of processing depend on – use of oxygen in burner devices.
lining quality. Currently the duration of a campaign is from In order to increase lining life it will be necessary to
one to three months, as a result of which it is necessary to study the behavior of different highly resistant refractory
carry out partial repair using a considerable amount of components applied to service conditions in rotary furnaces,
expensive refractory materials and a considerable proportion to develop compositions and manufacturing technology of
of manual labor for highly qualified masons. special refractories for Waelz kilns, and also to select diffe-
The main reasons for the short life of linings of Waelz rent combinations of refractories for lining and creation of
kilns are: lining structures for Waelz kilns of different sizes. The pro-
– corrosive wear as a result of chemical reaction of perties of a number of refractories were studied that are fun-
charge reagents with refractory materials during operation; damental in operating the lining of rotary kilns (see Table 1).
– abrasive wear caused by the considerable amount of Analysis of the thermomechanical properties of refrac-
charge being processed; tory materials in the range 20 – 1300°C has shown that
– breakdown of the working layer of the lining due to its refractory composition, its structure and heating rate have a
small thickness (230 mm), a small throw of articles (3 – 4 marked effect on properties (Figs. 1 and 2). The elasticity
mm) as a result of which a refractory component falls from modulus of refractories based on fuzed granular material is
the lining after wear of about 30 – 40%;
much higher (by a factor of 1.5 – 2) compared with this
– wear of the heat insulating chamotte layer of a lining as
index for sintered refractories of similar composition, and
a result of its rotation with respect to the working layer and
this points to the possibility of low heat resistance during
the body of the furnace due to the small weight of the lining,
service of refractories based on fuzed material (type PKhP
and also comparatively low mechanical strength of chamotte
modifications PKhPP and PKhPU).
components;
The dependence has been established of deformation for
refractories of magnesia composition on stress before and
1
GOUVPO UGTU–UPI, Russia. after service in a kiln (Fig. 3). Analysis of the dependence

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1083-4877/08/4902-0099 © 2008 Springer Science+Business Media, Inc.
100 V. V. Slovikovskii

TABLE 1. Properties of Refractory Components


Ultimate strength Heat resistance Linear thermal Elasticity
Open porosity, Wear resistance, Refractory wear
Component in compression, 1300 – 20°C, water expansion coefficient modulus E,
% g/cm2 rate v, 10–2 m/h
MPa thermal cycles aav, 10–6 °C–1 103 MPa
KhP 20 – 23 25 – 26 3–5 6.9 19.3 0.36 – 0.68 0.029
MKhS 21 – 22 26 – 28 3–5 8.9 17.2 0.38 – 0.51 0.015
PKhS 16 – 20 30 – 34 4–6 9.5 12.5 0.4 – 0.9 0.012
KhPT 18 – 20 25 – 30 6–8 9.1 14.6 0.2 – 0.29 0.011
PKhPP 14 – 15 39 – 42 3–4 10.0 11.4 0.18 – 0.20 0.010
MPM 14 – 17 50 – 60 1–3 12.1 46.2 0.44 – 0.48 0.031

Fig. 1. Change in elasticity modulus E of chromite-magnesite re- Fig. 2. Change in elasticity modulus E of periclase-chromite re-
fractory in relation to test temperature t and its heating rate m. fractory made from fuzed materials in relation to t and m.

showed that an area of refractories impregnated with molten MgSO4, Al2O3, etc.) with the aim of increasing the content of
reagents, at below 800°C, is converted into a rigid monolith Cr2O3 in a grain to 25% instead of 16 – 18% [1]. The in-
having increased elastomechanical properties. It has also creased Cr2O3 content raises the heat resistance of PKhPP
been revealed that with one-sided action of temperature on components to 7 – 8 thermal cycles, which is very marked
refractory components the temperature gradient formed during operation in Waelz kilns in which there is formation
causes thermal stresses within them. The zone of greatest of a considerable temperature drop with each kiln rotation.
microcracking for a component is placed at a distance of There is also a reduction in impregnation of the lining by
1/3 – 1/5 of its length from the working surface. The higher molten reagents from 100 – 150 mm for PKhS to 5.6 mm for
the heating rate for a component, the greater is the change in PKhPP, that excludes crust formation.
its uniformity (Fig. 4). In OAO Kombinat Magnezit an industrial batch of
The author of this article have performed studies of slag magnesia components (600 tons) has been produced that has
and abrasion resistance for different forms of refractory com- been used for lining melting furnaces Waelz kilns of the
ponents over a wide temperature range (see Table 1). It has Ust-Kamenogorsk Lead-Zinc Combine. With respect to
been revealed that the best indices of these properties with component life it is possible to arrange them in the following
respect to processed product in Waelz kilns is exhibited by order: PKhPP – KhPT – PKhS – MKhS – KhP – MPM. The
periclase-chromite components based on fuzed material with most resistant to processing products in Waelz kilns are
an increased Cr2O3 content (up to 25%). The refractories periclase-chromite components based on fuzed material
have been developed by the author in performing work in (PKhPP, PKhPU).
OAO Kombinat Magnezit. These studies have made it possible to develop a number
Melting of periclase-chromite was carried out by a spe- of improved lining schemes for rotary kilns using highly
cial regime using special additions (MgCO3 instead of efficient refractory materials. Use of single-layer linings

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