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11.

Coating and Ring Formations


In A Rotary Kiln

   


  

A good protective coating on the refractory in the burning zone serves


to prolong the life of the refractory. Frequent replacement of refractory
costs a large amount of money, not only because of the high cost of the
refractory, but also because of the loss in production while the kiln is
down for lining replacement. Needless to say, frequent renewal of refrac-
tory is an undesirable condition in any kiln.
Although refractories in the burning zone have to be replaced from time
to time, a kiln operator nevertheless has the capacity to increase (and
unfortunately also to decrease) the life of the lining by his ability to
control the coating in the burning zone.

Nature of the Coating.

Coating is a mass of clinker or dust particles that adheres to the wall of


the kiln, having changed from a liquid or semiliquid to a solidified state.
The solidified particles adhere to the surface of the coating (CS in Fig.
(or the refractory surface (BS) when no coating exists), as long as
the temperature of the surface of the coating is below the solidifying tem-
perature of the particles. Coating continues to form until its surface
reaches this solidifying temperature. When the kiln operates under such
condition at equilibrium, the coating will maintain itself. This means
THE ROTARY CEMENT KILN

theoretically no new coating is formed. When this temperature is ex-


ceeded, however, the particles on the surface of the coating change again
from a solid to a liquid state, and the coating will start to come off.

DIRECTION I 
-BARREL
LINING

Fig. 11.1 Heat, passing through the shell of the kiln, must be constantly
replenished by the flame in order to maintain a condition of equilibrium
necessary for coating formation.

There is a temperature drop between the coating surface (CS) and the
kiln shell (KS), the heat flowing in the direction indicated by the arrow in
Fig. 11.1. (Heat always travels from a place or body of high temperature
to a place of body of lower temperature.) This heat transfer is governed to
a great extent by the conductivity of the refractory and the coating. The
better the conductivity of the refractory, the better the chance of coating
formation, explained by the fact that the more heat that travels in the direc-
tion of the arrow, the lower the temperature will be at the surface of the
coating. Because the coating consists of particles that have changed from a
liquid to a solid state, the amount that any kiln feed liquefies at clinkering
COATING AND RING FORMATIONS IN A ROTARY KILN

temperature plays a very important role in coating formation. A feed


with a high liquid content at clinkering temperatures is more in
coating formation than a feed low in liquid. Kiln feeds with a high liquid
phase (easy-burning mixes) have a high content of fluxes: the iron, alu-
mina, magnesia, and, alkalies. On the other hand, hard-burning mixes (low
in iron, alumina, magnesia, and alkalies, and high in silica and lime) do
not have a favorable influence on coating formation. Alkalies entrained in
the gas stream promote the formation of coating (unfortunately rings also)
because of their high fluxing characteristics.
Because the surface temperature is probably the most important factor
in the formation of a coating, it is obvious that the flame itself has a
significant effect on coating formation because the shape of the flame
directly governs the surface temperature at any given point in the burning
zone. A flame that is too short, snappy, and wide can erode the coating
because of the great heat released over a short area with this kind of flame.
A long flame is more favorable to coating formation in the burning zone.
In Chapter 6 it was pointed out that short flames are desirable for better
control of the burning operation, but the flame should be shortened only to
the extent that it will not harm the coating.
Once the factors have been taken care of and the foundation for a
good protective coating established, it is then up to the kiln operator to
control the coating during operation of the kiln. It is his responsibility to
form and maintain a good solid coating in the burning zone.

Operating Conditions.

Operating conditions are just as vital for coating formation as all the
other factors mentioned above. Assume that a kiln will be operated from
one extreme of temperature to the other, that is, a cold, a normal, and a
badly overheated kiln; that the same kiln-feed composition is burned in all
three examples; that the solidifying temperature is 2400 F (1315 C); and
that 24% liquid is formed at the point of investigation, under ideal oper-
ating condition.
First, consider the cold kiln (Fig. In this case almost no coat-
ing is formed The coating surface temperature as well as the feed tempera-
ture is too low to produce the necessary amount of liquid matter that would
promote coating formation. The condition in this example is commonly
referred to by kiln operators as the kiln being in a “hole.” This example
also supports the widely known fact that no new coating can be formed
while the kiln is cold.
   

In the normal kiln (Fig. enough liquid (24%) is present to form


a coating. Temperature of the coating when it emerges from the feed bed,
as well as when in contact with the feed, is below the solidifying temper-
ature of the feed particles. The particles will adhere to the wall and solidi-
fy, and will continue to do so as long as the surface temperature of the
coating remains below the solidifying temperature of 2400 F (1315 C).
Whenever the wall reaches this temperature no new coating will form.
The coating is in equilibrium.
In the hot kiln (Fig. because of the extremely high tem-
peratures of the feed and the coating, too much liquid is formed. As all
temperatures are above the solidifying temperature, the coating transforms
from a solid back to a liquid again. In such a condition, coating will come
off, and the feed because of its high liquid content will “ball up.” Needless
to say, this condition is extremely harmful to the kiln and to the
refractory.
Most basic refractories, and especially the dolomite liners, are not able
to withstand prolonged exposure to the high flame temperatures without
this protective coating. As was mentioned in the previous chapter, the
burning zone is divided into three namely the upper-transition,
the sintering, and the lower-transition zones. Because of the lower liquid
content in the feed and because of the frequent temperature changes, the
upper- and lower-transition zones are areas where formation and
maintenance of coating is the most unstable. Shifting burning zone
locations produce a similar shift in the location where coating is formed;
thus, unstable coating conditions are most frequently observed in the upper
and lower end of the burning zone. This is clearly supported by the fact
that most rotary kilns experience the most frequent refractory failures in
these two critical areas. It should be noted that since the upper and lower
burning zones are also within the vicinity of the and second tires,
brick failures am not only the result of variations in burning-zone
conditions but, are also often the direct result of excessive tire clearance
and shell ovality. Both the frequent falling out of coatings in these areas
and the formation of too much coating can lead to troublesome ring for-
mations.
Ring formations in the lower-transition zone (i.e., at the kiln discharge)
are referred to as nose rings. Others refer to these as ash rings when the
kiln is coal Ring formations in the upper-transition zone are referred
to as clinker rings. These ring formations can in many instances be so
severe that they force operators to shut down the kiln and shoot these rings
  

out with an industrial gun. The system has been successfully used
for many years in Europe on several kilns to remove such rings. These
devices affixed to the kiln shell in strategic locations and use
cartridges to blast the rings while the kiln has only to be stopped for a
short interval to load and trigger the cartridges.
Much research work has been done on the probable causes of these ring
formations in the burning zone. The possible causes are many and no one
single factor has yet been found that would be the main cause for all the
rings formed. What seems to be true for one particular kiln might be
wrong for another kiln. This is clearly explained in the fol-
lowing example: On many coal-fired kilns, operators have found a relation-
ship between the fusion temperature of the coal ash and the frequency of
ring formation. There appears to be more ring formation when the fusion
temperature is low, i.e., when the ash contains larger amounts of fluxing
iron and alumina and less silica. However, this could not be the only
cause for such ring formations because natural gas- and oil-fired kilns,
which have no ash deposits in the burning zone, can have just as many
ring problems as the kilns, Hence, solutions for the elimination
of rings in the burning zone are predominantly found by a process of
elimination. First, all probable causes are listed and then each suspected
cause is eliminated or changed until hopefully an answer is found. From
personal experience, the author has found the following factors to be
possible contributors to ring formations in the burning zone:

POSSIBLE CAUSES FOR RING FORMATION


IN THE BURNING ZONE

Coal fineness too coarse.


b) Low fusion temperature of coal ash.
c) Kiln feed high on liquid content (silica, A/F ratios as well as lime
saturation factor low).
d) Incomplete calcination of the feed as it enters the burning zone
(frequent dust flushes into and poor calcining conditions behind
the burning zone).
e) Frequent changes in chemical composition and fineness of kiln
feed,
Excessive dust generation in the cooler and burning zone
(including changes in dust insufflation rates on wet-process
COATING AND RING FORMATIONS IN A ROTARY KILN

g) Kiln speed too slow and feed loading too high in normal
operation.
h) Excessive variations of flame temperature and length during
normal operation.
i) Frequent changes in secondary air temperatures.
j) Excessive frequency of kiln-operating upsets (burning zone
temperature and location varies too frequently and by too large a
range).
k) Increased volatility of, and frequent changes in, alkali and sulfur
contents in the fuel and feed.
Others have found other reasons for ring formation in the burning zone.
Thus, the list could possibly be expanded to over 30.
It is of interest that half of the cited factors can be somehow controlled
by the kiln operator and action taken to stabilize the flame and the kiln
operation that might be beneficial in lessening the frequency of ring
formation.

11.2 COATING AND RING FORMATION


UPHILL OF THE BURNING ZONE

Less frequent but nevertheless equally troublesome are the so-called feed
rings that form in the calcining zone of the rotary kiln. Wet-process kilns
often experience so-called formations in the chain section too.
Finally, many preheater kilns and Lepol kilns experience ring formations
and build-up problems at the feed inlet and in the lower preheat cyclone
stage.
In investigations on this subject it has been found that the majority of
these rings and heavy coatings in dry- and wet-process kilns are associated
with one of the following factors:
a) Internal cycle of the volatile constituents the kiln feed and
fuel (alkalies, sulfur, chlorides).
b) Kiln-feed fineness.
c ) Irregular and insufficient control (frequent fluctuations) of the
end temperature and kiln draft.
d) Excessive dust generation within the rotary kiln proper.
THE ROTARY CEMENT KILN

Analysis of the materials from these rings or excessive coating buildup


invariably showed high contents of calcium sulfates, potassium chlorides,
and/or alkali sulfates. Efforts to alter the internal and external cycle of
volatile components in the gas or feed stream have in many instances
resulted in less frequent ring formations. Although the aforementioned
reasons apply to dry- and wet-process kilns, there have been many reports
by others that have found a similar relationship in preheater and

In one case of a wet-process kiln, it was found that formation


was caused by a large percentage of the coarse fraction in the kiln feed
which contained predominantly free silica. In another case, were
initiated by the kiln operator who did not sufficiently tight con-
trol over the feed-end temperature, i.e, he allowed the temperature to vary
within a large range. Dust insufflation of the introduction of dust through
scoop feeders below the chain section can also be a primary cause for
formations in wet-process kilns. Last but not least,
were also allowed to be formed simply by having the wrong type of
system design or chain-link sixes.

References

1. J. Practical Quality Control Concrete.


New Book Co.
Bogue, 1929. Industrial Engineering Anal. Ed.

3. Lea, F.M. and Parker, T.W. 1935. Building Research, Technical


Paper 16, London.
4. H.1929. 18, 833.
5. Lea, FM. and Desch, C.H. 1935. The Chemistry of Cement and
Concrete; Longmans, Green Co.

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