Solving the Problem of Build-up on Preheater ID

Fans
 

Greater demands for throughput and efficient use of heat in the kiln have placed greater demands
on kiln induced-draft fans. These fans have been designed with ever-increasing volume and static
pressure requirements, as well as higher process gas requirements. The result has been larger fan
rotors operating at very high tip speeds.

One side effect has been build-up on the impeller. Typically, the build-up is an extremely hard,
brick-like substance, which can break off during operation, causing serious imbalance. Build-up
on preheater ID fans seems to be widespread, with documented cases in Pakistan, India, Saudi
Arabia, Ecuador, Mexico, Texas, and many other areas in the United States.

A study at Robinson Industries, Zelienople, Pa., examined each of the generally postulated
causes of build-up in kiln ID fans. The object was to determine what variables could be adjusted
to control build-up. Findings from the study were applied in the design, building, testing, and
installation of a build-up-resistant preheater fan at the Holnam Texas L.P. plant in Midlothian,
Texas.

Holnam Texas case study Build-up forming on the blades of the preheater ID fan at the Holnam
Texas plant was requiring periodic shutdowns of about 24 hours - 16 hours for the fan to cool
down and another eight to sandblast the blades and remove the build-up.

The original fan at Holnam was obtained from Robinson in the 1980s. Running at its original
design capacity, the fan did well, but the problems developed as Holnam increased production.
By 1994, the fan was running 30% over its intended capacity, and Holnam was having difficulty
tolerating shutdowns, which were increasing in frequency.

Hoping for a solution to the build-up problem, Holnam turned to Robinson Industries, which was
able to design a fan that resists build-up and therefore makes frequent cleaning unnecessary.
Robinson determined that build-up can be reduced by matching the shape of fan blades, as
closely as possible, to particle streamlines, so the impact energy of dust particles is minimized.
Blade angle must be inclined enough to prevent the "hard" buildup on the blade's front surface
and yet radial enough to prevent the "soft" buildup on the blade's back surface. Engineers
determined that the best blade for the Holnam cement plant would be the backward-curved fan.

Robinson also determined that the new fan at Holnam would have to be larger than the old one,
not only to accommodate the plant's increased production but also to accommodate the blade's
new design. To receive the same performance for a given application, a backward-curved fan
needs to be larger than a radial blade fan.

Holnam's parent company, Holder bank, also conducted research on the build-up problem, which
corroborated Robinson's.
Robinson faced three challenges typical in the design of kiln ID fans. The fan would have to: 1)
handle a steady stream of dirty air; 2) tolerate high temperatures; and 3) tolerate fast changes in
temperature, from 450 ºF to 840 ºF. Robinson faced an additional fourth challenge specific to the
Holnam plant, namely that the fan would have to handle extreme stress because of its size.

The original ID fan at the Holnam facility was rated at 3,500 hp and designed for a speed of
1,180 rpm. The new motor, while rated for 4,500 hp, would be designed for 880 rpm.

The size of the fan and its weight (67 tons including the wheel, shaft, housing, inlet dampers,
bearings, and bearing pedestals) presented fabrication challenges. The rotor was welded on a
positioner so the tilt would be perfect for welding at every point. In addition, the fan's size
necessitated splice welds in the shrouds and web plates. All shrouds and web plates were
subjected to X-ray testing.

The fan's plate steel was ultrasonically tested for defects. Before the welds, destructive tests were
conducted on sample plates. After construction, a dry magnetic particle inspection was made of
all final wheel welds. All bolts were ultrasonically tested for defects. The bolts were tested again
during tightening to ensure that they were being stretched to the proper length.

Since the fan's installation in 1997, Holnam has not had to stop production because of build-up
or any other fan-related problem.

Research behind the solution prior to the building of the Holnam backward-curved preheater fan,
Robinson had conducted an extensive study into the problem of build-up in cement factory fans.
The study entailed two approaches: 1) information gathering and 2) a laboratory simulation of
cement plant build-up conditions. In the first case, information from several cement plants was
collected to determine if a pattern of conditions leading to build-up could be identified.

- Theories as to build-up causes can be broken down into the following four primary groups:

1. Thermal: As process gas temperatures have increased over the years (from 350 ºF only a few
years ago to 700 ºF and higher today), so too have build-up problems. Some particles carried by
the gas stream have a lower melting point than others and may become "sticky" above 500 ºF.

2. Chemical: There are several chemical theories. Here are two of the main ones.

a. Some believe the presence of sulphur encourages the formation of gypsum, which is a very
hard and difficult-to-remove material, formed from calcium carbonate in a temperature range
from 700 ºF to 1,800 ºF.

b. Another chemical theory suggests that chlorine reacts with other components in the gas stream
to form lower-melting-point salts such as NaCl, FeCl subscript 3, and KCl.

3. Electrostatic: Since the fan rotor is not grounded (due to the oil film of sleeve-type bearings),
positively charged dust particles may be attracted to a negatively charged fan rotor (or vice-
versa).
4. Mechanical: Build-up could result from fan blade geometry. Some believe that centrifugal
force holds material in place on the back side of airfoil blades, backward-curved, and backward-
inclined centrifugal fan rotor blades. Others believe that build-up results when dust particles
impact the front side of the fan blades, melting or embedding themselves into the surface of the
steel blades.

Laboratory test work a 32 inch diameter rotor was set-up in a closed-loop system at the Robinson
Industries laboratory. The test set-up allowed variations in dust loading, fan speed, temperature,
particle velocities, fan blade shape (rotor design), coatings, and types of steel surfaces. By
controlling most process parameters closely, it was possible to change one variable at a time to
determine its effect on the rate of build-up on the rotor.

The first priority was to see if the field type of build-up could actually be duplicated in the
laboratory. After 168 hours of continuous operation, the rotor was stopped and the fan casing
opened for inspection. A significant build-up (to 11/42 in. thick in some areas) was observed.

The build-up occurred on the leading edge of the blades (pressure side) and at the blade-to-center
plate weld intersection. The build-up was heaviest at areas of high impact between the dust
particles and the rotor surfaces, and along streamlines containing high concentrations of dust
particles. In other words, the location as well as the appearance of the build-up was similar to
that in field sites.

- Each of the possible variables was examined through experiments or field observations to
determine how best to reduce or eliminate build-up:

1. Temperature: The operating temperature was reduced in 50 ºF increments. It was noted that
the build-up was significantly reduced (but not totally eliminated) at temperatures below 500 ºF.

2. Blade shape: Tests were run using radial blade rotors, backward-curved blades, and airfoil-
bladed designs. Results showed that build-up could be reduced with airfoil and backward-curved
blades.

3. Fan speed: As the fan speed was reduced to 1,013 rpm, build-up was reduced. Lower fan
speeds (resulting in lower impact velocities as dust strikes rotor surfaces) appear to reduce build-
up.

4. Surface roughness: The fan rotor had four blades fitted with ground finish 316 SS blade
liners. While stainless steel provides corrosion protection and an ultra-smooth surface, build-up
was virtually unaffected.

5. Coatings: Several coatings were tried including two ceramic coatings, tungsten carbide,
alonized, polished 316L SS and 410 SS and nickel boron. None reduced the amount of build-up
on the fan wheel.

6. Sandblasting: With build-up already on the fan rotor, coarse sand was added to the
recirculation loop, but to no effect. Either the build-up was too hard or the sand was not striking
the fan rotor surface in the same areas as the smaller particle feed dust. Texas Lehigh reports that
this method of cleaning was only marginally successful in the field, with build-up being evened
out (high spots were removed) but not eliminated. Excessive use of sandblasting during
operation can lead to rotor erosion and failure.

7. Sonic horns: Reports from various plants indicate that sonic horns are not an effective means
of preventing build-up on preheater ID fans in cement factories.

8. Electrostatic grounding: A grounding brush was attached to the rotor shaft of a preheater ID
fan at Box-Crow Cement (now Holnam Texas L.P.). The voltage to ground was measured at 0.00
V. This compares to 31 mullivolts static charge when an ungrounded rotor was in operation with
feed dust recirculation at 700 ºF. There was no noticeable difference in the amount of build-up
between these grounded and ungrounded setups.

- Field observations Reports from 20 plant sites have added some interesting insights on the
causes of and possible solutions to preheater ID fan build-up:

 Build-up has occurred on all types of fan blades.

 Build-up has been reduced in some measure by lessening the impact velocity of dust particles
striking the fan rotor. A larger-diameter rotor operating at a reduced speed will acquire less
build-up. Reducing the operating temperature (possible by air dilution upstream from the fan or
water spray in the down corner from the preheater section) greatly reduces build-up on kiln ID
fans. While temperatures below 500 ºF (260 ºC) are necessary to achieve the reduced build-up,
temperatures at or below 392 ºF (200 ºC) increase particle size, causing fan rotor erosion.

 In some cases, a rotor can be sized with an oversized shaft to make it less sensitive to
imbalance caused by uneven build-up. This arrangement allows for longer operating cycles
between shutdowns for cleaning.

 One or two plants have tried water sprays directly onto the 700 ºF rotating fan wheel. Rapid
cooling (quenching) was reportedly effective in removing build-up, but thermal fatigue on the
fan rotor was devastating. In at least one case, a rotor failed catastrophically.

 Conclusions

 Build-up on preheater ID fans is definitely temperature and impact velocity related, which
would support theories about lower-melting-point alkaline forming a sticky compound.

 Sulphur may be ruled out as a cause of build-up on preheater fans since no sulphur was found
in the fuel in the lab test, though build-up still occurred.

 Formation of FeCl subscript 3 resulting from a chlorine reaction with the rotor's steel may
also be ruled out. Build-up occurred even with stainless steel and other protective (non-iron)
coatings on the rotor.
The recommended temperature of gas entering the kiln ID fan is 482 ºF (250 ºC). This
temperature may be achieved with water sprays in the down comer from the preheater tower. The
presence of moisture in itself may minimize build-up.

 The fan rotor should be designed for the smoothest possible flow lines. The backward-curved
and airfoil rotor designs are best for this purpose.

 Fans should be selected to achieve minimum gas/dust particle velocity at the inlet of the fan
rotor. Minimum velocity means minimum impact on the fan rotor. Consider using:

a) Double inlet fans instead of single inlet fans.

b) Larger-diameter and lower rpm fans.

c) A peripheral speed at the rotor inlet opening limited to 15,000 fpm and an inlet velocity not to
exceed 7,500 fpm.

 Oversized shafting should be used to reduce sensitivity to imbalance. The design critical
speed (including effects of bearing oil-film stiffness) should be at least 1.25 times the operating
speed of the fan including the weight of 1-in.-thick (2.54 cm) build-up on all leading surfaces
(pressure side) of the fan rotor blades. Careful attention is required to insure rigidity of the
foundation up to the fan-bearing pedestals.