Corrosión de la virola – medidas preventivas

Seminario de refractarios para UNACEM

Atocongo, Perú, 7-9 noviembre de 2017
Agenda

Phenomena of kiln shell corrosion

Preventive measures
Agenda

Phenomena of kiln shell corrosion

Preventive measures
Phenomena of kiln shell corrosion
Different kinds of kiln shell corrosion

Corrosion of the kiln during kiln operation resulting in scaling of the kiln shell by
oxidation of the metallic iron at elevated temperature (high temperature corrosion)
Rusting during kiln shutdowns caused by condensation or adsorption of humidity
(moist air, water)
Phenomena of kiln shell corrosion
Different kinds of kiln shell corrosion

Corrosion of the kiln during kiln operation resulting in scaling of the kiln shell by
oxidation of the metallic iron at elevated temperature (high temperature corrosion)
Rusting during kiln shutdowns caused by condensation or adsorption of humidity
(moist air, water)
Phenomena of kiln shell corrosion
Corroded kiln shell samples (high temperature corrosion)
Phenomena of kiln shell corrosion
Different kinds of kiln shell corrosion

Corrosion of the kiln during kiln operation resulting in scaling of the kiln shell by
oxidation of the metallic iron at elevated temperature (high temperature corrosion)
Rusting during kiln shutdowns caused by condensation or adsorption of humidity
(moist air, water)
Phenomena of kiln shell corrosion
Corroded kiln shell samples (rusting during longer kiln shutdowns)
Phenomena of kiln shell corrosion
Cause of kiln shell corrosion

Composition of the kiln gas atmosphere

Content of volatile components
Alkalis, chloridic-, sulphur- and vanadic compounds, water vapour etc. are the main
volatile components
Combustion of other fuels and especially waste fuels and waste material increases the
concentrations of volatile and harmful compounds within the kiln system accelerating
shell corrosion
Phenomena of kiln shell corrosion
Corrosion of the Metallic Shell (Mechanism)

K2O + SO3/SO2 + H2O + Cl- + (Cr6+, V5+) + O2

Sheet-iron shell

Cr 6+ and V 5+ + O2 from kiln gas

as O2 donors + OH- in the form of
or catalysts water vapour
FeO Fe(OH)2 + Cl- from hydrolysis of KCl
Fe2O3 Fe(OH)3
Fe3O4 + S- from SO2/SO3/SO4 (redox)
+ OH- (hydrolysis)
Alpha-FeOOH
FeS2, FeS, FeSO4, Fe2(SO4)3
Gamma-FeOOH
Corrosion of shell, covering with scale (during operation) and rust (when inoperative)
Phenomena of kiln shell corrosion
Fe-S-O ternary system in the temperature range between 250 °C and 550 °C

250 < T < 550 °C Fe

Troilite/Pyrrhotite (FeS)
Magnetite (Fe3O4)
Hematite (Fe2O3)
Pyrite/Markasite (FeS2)

O SO2 S
AT.%
Agenda

Phenomena of kiln shell corrosion

Preventive measures
Preventive measures
Reducing or preventing kiln shell corrosion

Phosphatizing is one way reducing kiln shell corrosion, but with moderate success.
Brick grades with lower apparent porosity, and mortared
REFRACOAT, an aluminium containing resin, which forms an inorganic alloy layer with
the thermally loaded steel components.
Stainless steel plates as sacrificial anode (sacrificial sheet metal)
Preventive measures
Reducing or preventing kiln shell corrosion

Phosphatizing is one way reducing kiln shell corrosion, but with moderate success.
Brick grades with lower apparent porosity, and mortared
REFRACOAT, an aluminium containing resin, which forms an inorganic alloy layer with
the thermally loaded steel components.
Stainless steel plates as sacrificial anode (sacrificial sheet metal)
Preventive measures
Steel Sheets, exposed to temperature and volatile components
Uncoated Coated with REFRACOAT

exposed to NaCl/H2O
Temperature: 100 °C

exposed to NaCl/H2O
Temperature: 300 °C
Preventive measures
Supply and consumption as well as application of REFRACOAT

REFRACOAT is supplied in 5-litre and 12-litre drums.

The consumption of REFRACOAT is about 100 to 130 g/m2 per coat.

Application:
Painting with a lambskin roller or brush, spraying,
dipping or pouring is possible.
Kiln shell or other metal surfaces have to be cleaned,
dry and rust-free.
A twice application is recommended.
Before lining of refractory materials, the REFRACOAT coating must be dry.
Preventive measures
Reducing or preventing kiln shell corrosion

Phosphatizing is one way reducing kiln shell corrosion, but with moderate success.
Brick grades with lower apparent porosity, and mortared
REFRACOAT, an aluminium containing resin, which forms an inorganic alloy layer with
the thermally loaded steel components.
Stainless steel plates as sacrificial anode (sacrificial sheet metal)
Preventive measures
Installation of the sacrificial sheet metal

Thickness of the sacrificial sheet metal should

width: 1.5 m max.
have no more than 1.024 mm.
The width of the roll should be less than 1.5 m.
A thicker sheet will cause problems as air bubbles
may form between kiln shell, sheet metal and
bricks (poor contact).
A roll of a bigger width will be difficult to place,
especially in the top centre of the kiln.
Preventive measures
Installation of the sacrificial sheet metal (Step 1)

The first part of the sheet metal will be installed in the lower centre of the kiln, and
has to cover a little bit more than half of the circumference.
In case of diameters of more than 4400 mm it is recommended to proceed in two steps
for a better workability.
Preventive measures
Installation of the sacrificial sheet metal

Leave a gap of 20-30 mm between

the sections to avoid overlapping.
Preventive measures
Installation of the sacrificial sheet metal (Step 2)

The following two sheets metals have to be supported to ensure full contact with the
kiln sheet while installing the bricks.

Support with wooden beams

First step Second step

Preventive measures
Installation of the sacrificial sheet metal (Step 2)

The following two sheets metals have to be supported to ensure full contact with the
kiln sheet while installing the bricks.

Wooden supporting
beams

First step Second step

Preventive measures
Installation of the sacrificial sheet metal (Step 3)

The last sheet metal will be installed in the key section and also supported to ensure
full contact with the kiln shell.

First step Second step Third step

Preventive measures
Installation of the sacrificial sheet metal (Best results)

The best protection of the kiln shell against corrosion is obtained with a combination
of REFRACOAT and sacrificial sheet metal.

REFRACOAT

Sacrificial sheet metal

Thank you for your attention!