COATINGFORMATION ON REFRACTORY BRICK

RCARY CEMENTKILN

Chromefree dolomitebick offersdistinc't over conventional advantages magnesiachromebick when appliedin the Sintering Zone, or stable coatingregionof the BurningZone. Aside from itshigh refractonness and inherentenvironmentally fiendly composition, dolomitebick possesses a c/osechemical for the cementkilncharge. Thisnaturalcompatibility affinity process withthe cementmanufacturing a//ows kiln linersfo quickly dolamite form a protective coating;a protective coatingwhichaffordslonger seruice life when comparedto magnesia chromebrick. ln orderto obtainmaximum lifefromBurning Zonerefractories, it is important to operate protects of clinker formson thebricks.Thiscoating a cementkilnsuchthata coating the wear,andalsoimproves and abrasive brickworkfrom chemical thermal efficiency of the kilnsystem. is a massof clinker or dustparticles thatadheres to the wallof the kiln,having Coating to a solidstate.As can be seenfromTable from a liquid or semi-liquid V, the changed assemblage of coating resembles that.of clinker. composition andphase closely chemical particles to therefractory firstadhere andcontinue to build as surface clinker Semi-liquid of thecoating is below temperature thesolidifying temperature of the longas the surface particles. Coatingformation will ceasewhen the surfacereachesthis solidifying under equilibrium conditions, willmaintain lf the kilnoperates the coating temperature. itself. kilnis largely dependent cement of the on the consistenry in a rotary formation Coating process. Initial of the burning excessive coating buildup on any kilnfeedandthe stability or "soft" burning mix:lowsilicamodulus, an "easy" reasonable suggests lining refractory liquid (<=98), formation (25o/o) andadequate in theSintering factor Zone. fimesaturation buildup indicates of such a coating a stablekiln operating the maintenance Further, Burning runtime, Zone temperature, control, andflame feedchemistry, mode:consistent

COATING FORMATION BRICK ON REFRACTORY

to namea few. of as littleas three(3) inches(76.2mm) Afterformation of coating, the bncUcoating interface is below temperature the solidifying temperature for CrSand the resultant C.S phaseformed(in the case of a dolomite brick). Thisconfirms that in the case of a dolomite bnck,the brickitself is functional onlyin the initial formation of coating.Further process developmenUloss of coating is strictly related.

brick Coatingformationon a Dolomite by a somewhat different mechanism than ?*u,f in magnesia-chrome refractories,In the Toa." of mag-chrome brick,there are necessary fluxing reactionswhich create liquidsof a transientnaturewith a sub:,eff::, "freezing out" of minerals which react with ano oorfi'ttntLncr. Figure 14 ittusiiatescoating brick. As can be seen, the critical"chrome"and mechanismsfor a magnesia-chrome spinelphasesare fluxedduringcoating MgCrrO./ MgFrOo formationon a Mg-Crbrick. of bonding strength The resultis degration the hostMgO aggregate allowing to assimilate therebycausing into the clinkermaterial increased wear. Underoverheated or constant greatlyand the fluxingprocessis accelerated high temperatureoperatingconditions, of the Mg-Crlining. resultsin "slagging" virtually no fluxingon the surfaceduring On the other hand, dolomitebrickexperiences mechanism for dolomite coatingformation. The primaryreaction is betweenbelite(CrS) free limein the dolomite system(cementclinkercontains in the clinkerbed, and reactive about 20-40% dicalciumsilicate). This reactionis acceleratedby the aluminateand fernteliquidphasesin the clinkermix (namely do not C.A,C.AF,and CrF). Theseliquids participate in the reaction but simply increase the mobility silicate. necessarily of dicalcium liquids mobility facilitated by clinker In such a case, the belite's allowsit to penetrate and formationof C.S reduces hydration subsequent react with the brick. Additionally,

COATING FORMATION ON REFRACTORY BRICK

susceptibility of the brick(inthe caseof a dolomite brick).Figure15 shows thesesteps of coating formation on a Dolomite refractory. Thereare vanous factors whichcan influence the formation and retention of coating on the refractory lining. Someof thesefactors are as follows: 1) Thermal conductivity of the refractory and coating 2) Chemical composition of the feed 3) Changes in flamepattern. flametemperature, and burneralignment 4) Erratic kilnoperation; frequent stopsand starts 5) Changes in cement type 6) Changes in fuel;composition andmultiple fuelsratio
'i.'-! I

As can be seenfromFigure 16,thereis a temperature drobetween the coating surface governed and the kilntfll;*This heattransfer is largely by the thermal conductivity of the kiln linersanUcoating. lf the refractory has a highconductivity, thereis a better formation for coating chance because moreheatwilltravel awayfromthecoating surface reducing hot facetemperature. effectively
that have changedfrom a semi-liquid Since the coatingconsistsof particles to a solid, temperature the liquid contentof the chargeat clinkering has a great effecton coating formation. Kilnfeed havinghigh liquidcontentat clinkering temperatures has a greater tendencyto form coatingthan a feed lower in liquid. The kiln feed with a high liquid phase has a highercontent of fluxes,i.e. FerO., Al2O3, MgO, NarO,and KrO. is an important factorin the formationof coating, Becausethe surfacetemperature it is the flame itselfhas a significant effecton coatingformation. tf a flameis too obvious, short and snappy and wide, it can erode the coatingaway because of the greatheat
i '\;i? f

t t.f tr".'.r.L:

COATING FORMATION BRICK ON REFRACTORY

release overa short long, is prefened slenderflame to promote coatingformation -t133;A in the Sintering Zone, Likewise, a burner whichis out of alignment can causeflame impingement which will erodeaway the coating, and possibly the refractory lining. Maintenance of a good clinkercoating will also be influenced by minimizing kiln shutdowns sincea steadily running kilnwill to a largedegreegovernoverall coating stability.

c:\jhbEoating

TABLEV
TNICAL COATI]IGCHE}TICAIANALYSIS

0xide

Weieht ",1

CaO Mgo si02 Ft2o3 Na^0

L

50-65 1 . 0 - 3. 0 25-30 2 . 5 - 4. 0 0.10-0.50 0. 10-0.50 0.60-1.0

Kzo
SO:

Maior Phases Present in C^S z C^S

J

Coating

- alite beiite alr"ninac,e. prinarily C-,A

C"A

J'3

CaS

ferrite solid solutioa coataining someCrS

cc/C6/LDc

FIGURI 16

PROFII.E COATI}IGFORT,IATION

DIRECTIOT{OF HEAT RAVEL

2000

4 0 0 0F

f_KII.hI

SHELL

F 27oO"
1t+80o C

REFRACTORY LINING

COATING

r 29500 1 6 2 0C "

BRI CK SURFACE

-40

ON NqC COATINGI{EC}Lq}IISU

COATING FORMATION ON
MAGNESITE.CH ROMEBRICK
-+

Maonesite-Chrome Cllnker
r.1 AAJ*tJ\)

CrZO3 41203 FeO

CzS c3s c3A

C4AF Liquio CZS+ C3S+Liquid

Coatlnq Mechanisms ' L i q u i d p enetrati on i nto bri ck.

o C h ro mi u mdi ssol vesi nto l i qui d. . C l i n k e r l i qui d - C hromrte P hase a ) C a l c i um Fernte/C hromrte o C h ro mrumdi ssol vesi n C 3S col ors i t green. . M g O s u sceptabi l i ty to chemi calattack negl i gi bl e. . MgO aggregate broken down as result of attac,( on b o n O o h a se. o F re e z rng out of l i qui dsforms coati ng.