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Cement
ICTM R. Krischanitz May 2008
29 Kiln Shell Corrosion
PC kiln, 4.15 x 58 m, 2450 tpd, <20% alternative fuels:
Fracture of kiln shell at rm 38.5 - despite phosphating it during
previous kiln stops
Kiln shell thickness:
Original thickness 20mm
Thickness within fracture area (groove) 8mm
Average thickness in brick joints 14mm
Thickness below bricks 17mm
Ref: DAVILA, J.C. et al., 1995, Influencia del Refractario en la Corrosion de la Coraza del Horno Rotatorio para
Cemento, ALAFAR XXIV Congreso, Cartagena, pp 157-183
Fracture of kiln shell due to corrosion
3 29 Kiln Shell Corrosion
Preferred
corrosion below
joints,
condensation of
moisture during
kiln stops
Corrosion of kiln shell (rm. 65, calcining zone)
4 29 Kiln Shell Corrosion
wet cardboards
Corroded kiln shell within the calcining zone
5 29 Kiln Shell Corrosion
Loss of shell
thickness 6 mm/a
Fuels: Coal + pet
coke, tyres,
palletised sewage
sludge
Kiln shell corrosion (rm. 29, second tyre)
6 29 Kiln Shell Corrosion
Thickness
15 mm
Scales from the kiln shell
7 29 Kiln Shell Corrosion
RHI Technical Centre Leoben, Austria
Dense layer of magnetite and hematite
mag
hem
Porous layer of hematite and KCl
hem
KCl
Microscopical appearances of scales
8 29 Kiln Shell Corrosion
Composition of scales
<@W A B C D E F G
Fe
2
O
3
44 90 88 17 56 n.a. 81
SO
3
11 7 5 1 1 -
K
2
O 24 - 2 43 16 6
Na
2
O 4 - - - 2 1
Cl
-
6 1 4 36 11 6
F
-
7 - - - - -
PbO - - 1 - - -
Fe
3
O
4
777 777 7 77 777 77
Fe
2
O
3
777 7 77 777
FeS 77 77 7 7 77
FeS
2
77
Fe(OH)
2
7
FeSO
4
.H
2
O 7
K
2
SO
4
77
KCl 77 7 777 77 77 77
Na
2
SO
4
7 7
NaCl 7
NaF 7
Pb
2
(SO
4
)O 7
W (wt.%)
WW W g7
9 29 Kiln Shell Corrosion
Kiln Feed / Coating
Kiln gas
KCl, K
2
SO
4
KCl, K
2
SO
4
KCl, K
2
SO
4
KCl, K
2
SO
4
Preheater