Wear Mechanism

in Cement Rotary Kilns

Wear Mechanisms
Chemical wear
 Alkaline salt infiltration
 Clinker melt infiltration (due to improper raw meal
composition)
 REDOX Reactions
 Hydration

Thermal wear
 “Overheating” (mostly of kiln feed – clinker melt infiltration,
rarely of brick)
 Thermal shock

Mechanical wear
 Kiln shell deformation
 Excessive ovality
 Lining thrust
 Abrasion by clinker
2 Improper Installation
 Mechanical
conditions Factors Influencing the
Refractory Performance

- Ovality
- Deformed kiln shell Mechanical
condition
of kiln
Refractory

Process Process
Refractories

- Burnability of kiln feed

- Kiln system
- Selected material - Fuel(s), burner
- Quality of product Refractory Lifetime - Production programme
- Bricks vs castables - Process Instabilities
- Installation - etc.
Wear
3 Mechanisms
 Predominant Wear Mechanisms
in Rotary Kilns
Outlet/LTZ CBZ UTZ SZ CZ IZ

most critical areas

most critical areas

thrust
mechanical load
abrasion

thermal load / overheating

thermal load
(no coating)

thermal shocks (unstable coating)

chemical load (alk. salt infiltration)

chemical load (alkali bursting)

Chemical wear
Wear Relevant Elements
Periodic Table of the Elements

 alkalise Na2O, K2O

 SO3
 Cl

Wear
6 Mechanisms
Enrichment of Volatile Elements
by evaporation / condensation between kiln and preheater originating from:
 Raw meal
SO3:
as sulphate: gypsum CaSO4 x 2H2O and anhydrite CaSO4
as sulphide: pyrite FeS2, organic compounds
Cl-:
introduced by alkaline salts as halite NaCl or sylvine KCl

Alkalis (Na2O, K2O):

as interlayer cations in clay minerals and in feldspars
endmembers orthoklas KAlSi3O8, albit, NaAlSi3O8, anorthit CaAl2Si2O8
plagioclase solid solution Ab-An
alkalifeldspars solid solution Or-Ab

 Or fuel 
Wear
7 Mechanisms
Wear Relevant Elements of
Alternative Fuels
cal. value wear-relevant elements
Fuel
[MJ/kg] Sulfur Chlorine Alkalis Phosphorous
Light oil 42 +
Heavy oil 40 ++
Natural gas 37
Rubber waste 36 ++ 0
Anthracite 34 +
Waste oil 30 - 38 ++ + +
Petcoke 33 ++ 0
Hard coal 30 ++ +
Waste tires 25 - 32 + +
Petrochemical residue 16 - 22 +
Lignite 16 - 21 ++ 0 +
Landfill gas 16 - 20
PVC 19 + + +
Fuller's earth 13 - 18
Asphalt sludge 16 ++ 0
Scrap wood, sawdust 16 + +
Rice husks 16
Domestic refuse 15 + ++ ++
Cardboard, paper waste 15 +
Dried sewage sludge 10 + + + ++
Waste wood (contaminated) 7 - 20 ++
Hazardous waste 4-8 + ++
Oil shale 2 - 16 + Alternative fuels tend to
Animal meal
(++) high input of wear-relevant elements
0 + ++ ++ increase the input of wear
(+) considerable input of wear-relevant elements relevant elements into the
(0) minor input of wear-relevant elements
Wear
8 Mechanisms
system!
Kiln Cycles

Wear
9 Mechanisms
Consequences of Alkaline Salt
Infiltration
There are two effects in case of alkaline salt infiltration
1. Densification of the microstructure  Reduction of structural flexibility
2. Depending on alumina sulphur ratio (ASR) corrosion of brick bonding – loss
of bonding strength
ASR > 1 ASR ~ 1 ASR < 1
Dens. + loss Corrosion Dens. + loss Corrosion Dens. + loss Corrosion
of flexibility of flexibility of flexibility

Magnesia spinel X X x X X
Magnesia X
chromite X X X x X
Alumina /
Fireclay
x X x x x

Na 2O K 2O Cl
 
Balanced alkali/sulphur ratio ASR  62 94 71
1) Corrosion of chromite SO3
ASR ~0,8 to 1,2
Effects
10 of AF use 2) Alkali bursting 80
 ASR - Alkali Sulphur Ratio
The substitution of fossil fuels by alternative fuels can significantly change the
alkali sulphur ratio and lead to increased volatilization as well as corrosion and
attack of refractory materials.
Ideal range:
 balanced ratio – saturated compounds
 reduced volatilization (partly extraction with of
Alkalisulphate with clinker)
 reduced refractories attack

Sulphate overload:
 corrosion of ceramic
bonding of magnesia bricks Alkali overload:
 increased volatilization  risk of alkali bursting
 formation of  increased volatilization
encrustations.  formation of encrustations.

Na 2O K 2O Cl
 
Balanced alkali/sulphur ratio ASR  62 94 71
ASR ~0,8 to 1,2
SO3
80
Effects
11 of AF use
Wear Process:
Alkaline Salt Infiltration

Wear
12Mechanisms
Alkaline Salt Infiltration
Chemical analysis:
MgO 81,90% K2O 2,01%
Al2O3 9,41% Na2O 0,26%
SiO2 1,55% SO3 2,15%
CaO 3,22% Cl 0,05%

MgO 77,90% K2O 7,04%

Al2O3 7,46% Na2O 0,45%
SiO2 0,32% SO3 7,79%
CaO 0,62% Cl 0,05%

MgO 88,90% K2O 0,26%

Al2O3 8,72% Na2O 0,05%
SiO2 0,42% SO3 0,52%
CaO 0,78% Cl 0,05%
 densification of the microstructure and loss
of thermo-mechanical brick properties (flexibility)
crack formation at the interface between
Wear
13Mechanisms
infiltrated and not infiltrated brick area
Corrosion of Brick Bonding

Wear
14Mechanisms
Corrosion of Calcium-Silicatic
Brick Bonding
2Ca2SiO4 + SO3 + MgO Ca3Mg(SiO4)2 + CaSO4
Ca3Mg(SiO4)2 + SO3 + MgO 2CaMgSiO4 + CaSO4
CaMgSiO4 + SO3 + MgO Mg2SiO4 + CaSO4

The corrosion of the calcium-silicatic brick bonding leads to a severe

loss of the bricks bonding strength. The new formed phases are
present as isolated particles within the pores and do not contribute to
the brick bonding.
The consequences are crack formation and finally spalling of hot
face brick parts.

Wear
15Mechanisms
Infiltration Spall

Wear
16Mechanisms
Ovality Spall

Wear
17Mechanisms
ASR > 1:
Alkali Attack on Alumina Bricks
Physical attack:
- Deposition of alkali compounds in the open pores
(densification of microstructure)

Chemical attack: DV up to + 36%

- Incorporation of alkali oxides into glassy phase up to saturation
(fireclay bricks)
- Reaction with cristobalite, quartz and mullite at T > 600°C, formation
of orthoklase (KAS6), albite (NAS6), leucite (KAS4) and nepheline
(NAS2) at T > 930°C: Volume increase up to 36%
- Formation of b-alumina (KA11) and K2O.Al2O3 at T 1000-1050°C:
Volume increase up to 20%
- Spalling of shells even at small temperature changes due to the
increased thermal expansion of the reaction layers in
comparison to mullite.
 nepheline ~ 3  mullite
Wear
18Mechanisms
ASR > 1:
Alkali Attack on Alumina Bricks

Wear
19Mechanisms
Examples of Alkali Spalling
 Alkaline spalling of
andalusite bricks in
the cooler front wall
after 1 month.

Alkaline spalling of
castables 
Wear
20Mechanisms
Alkali Attack:
Failure of Steel Shell due to Expansion of Alumina Refractory

The strong volume

increase related with
alkali bursting can even
lead to damages of the
steel shell.

Calciner lifted by 15cm

Wear
21Mechanisms
Thermal load
Clinker Melt Infiltration

Increased clinker melt due to unfavourable clinker composition or

overheating of the kiln feed. Clinker melt infiltration is observed
only at the hot face, mostly adjacent to a thick clinker coating. The affected brick
microstructure is severely densified and the matrix heavily corroded. Often also a coagulation
of the matrix and the formation of coarse pores can be observed. The loss of thermo-
mechanical properties leads to crack formation and finally spalling.
Wear
23Mechanisms
Wear Process:
Clinker Melt Infiltration

Wear
24Mechanisms
Overheating of High Alumina Bricks
in the Outlet Zone
High alumina bricks after 7 months in
operation. Formation of gehlenite C2AS,
anorthite CAS2, nepheline NaAlSiO4
and other low melting Ca-alumosilicatic
phases at the hot face in reaction with
the kiln feed.

Wear
25Mechanisms
Overheating of SiC Mullite Bricks
in the Safety Zone

Wear
26Mechanisms
Wear Process:
Effect of Frequent Thermal Shocks

Wear
27Mechanisms
Thermal Shocks
An increased load by thermal shocks occurs mostly in the initial phase of kiln
operation, when the operation condition are not stabile yet.

Thermal shocks can effect the lining only in case of missing coating,
particularly in case of loss of a thick coating area. The fall off of clinker
coating always implies also a certain mechanical load, which is
superimposed by the thermal-shock stress.
Spalling of hot face brick parts are the consequence.

Thermal shocks are especially severe in case that the microstructure has
been pre-damaged or degenerated by thermo-chemical influences, as
infiltration of clinker melt or alkaline salts.

Wear
28Mechanisms
 Overstress at
Too Fast Heating Up hot face!

Open gap
at cold face

Spalling of brick heads of magnesia-chromite

bricks due to too fast heating up.

Wear
29Mechanisms
 Combination of Wear Mechanisms
CBZ after 5 months
In practice there is often a combination Overheating at the
of several wear mechanisms as this hot face:
example demonstrates Chemical analysis:
0.09% Cl,
0.67% SO3,
1.44% K2O,
2.08% Na2O,
2.08% CaO,
0.74% SiO2,
5.09% Al2O3

Alkaline salt attack

behind the hot
face (black, etched
by water).
Chemical analysis:
0.77% Cl,
2.47% SO3,
3.00% K2O,
1.28% CaO
Wear
30Mechanisms
Mechanical load
Reasons for Mechanical Load
• Kiln shell torsions or
deformations 

• and instable
Scratch marks on kiln shell
lining 

• Excessive lining thrust 

Wear
32Mechanisms
Kiln Shell Deformations:
Reversible Deformation Due to too High Clearance

Wear
33Mechanisms
Kiln Shell Deformations:
Kiln Shell Constriction Due to too Low Clearance

Too low gap can lead to strangulation of the kiln shell within the tire during the
heating up procedure. Therefore it is important to monitor the tyre creep during
the heating up procedure. To avoid any risk of kiln shell constriction and lining
damage, keep tyre creep above 8 mm/rev during heating up and the
temperature difference between shell and tyre above 150°C.
Wear
34Mechanisms
Recommended Tyre Creep and
Ovality
The ovality of the kiln shell depends on the tyre clearance, the
distance between kiln shell and tyre. The higher the clearance the
higher also the ovality. The acceptable clearance depends on the
diameter of the kiln.
Ideal situation under hot conditions (on the example of a 4,8m Ø kiln):
max. clearance = kiln Ø [mm] /1000
(4800mm Ø  4,8mm clearance)
rec. creep = tyre clearance x  (4,8 x PI = 15,1)
The ideal creep value for a 4,8m diameter kiln should be around
15mm/rev.

Wear
35Mechanisms
Possible Consequences

Increased ovality values and the thereby caused excessive mechanical load
can lead to severe damages of the refractory lining (crack formation, spalling
and spiralling).

Wear
36Mechanisms
Influence of Tyre Ovality

Higher mechanical stresses within the tyre section lead to significantly lower
residual thicknesses especially in case of simultaneous present chemo-
thermal load, as often present ion the UTZ.
Wear
37Mechanisms
Reasons for Mechanical Load
Wrong Installation

Wear
38Mechanisms
Signs of Mechanical Overload

Formation of vertical cracks

(white and red arrows) and a
crumbly microstructure
(circles) at the cold face as
well as scratches (yellow
lines) at the cold face are
clear signs of increased
mechanical load.
Wear
39Mechanisms
Hydration of bricks
Maximum Shelf Life
Fireclay and alumina bricks are not susceptible to hydration and
can be stored indefinitely.
Mortar should not be stored at customer´s warehouse for more
than 12 months.
Magnesia bricks are susceptible to hydration and should
therefore not be stored for more than 12 months. Risk of
hydration is higher tropical conditions and for bricks made from
high purity, synthetic sintered magnesia. Under such conditions
a further reduction of storage time can be necessary.
Basic bricks should be installed shortly before kiln heat up,
earliest 4 weeks before heat up.

41
Hydration
Hydration of Magnesia Bricks

The damage by hydration of unused magnesia bricks is characterized by one or

several cracks in the brick and may lead to its partial sandlike decomposition.
42
Hydration
Hydration of Magnesia Bricks
Bricks with radial cracks have
lost their mechanical strength
and must be discarded

When knocked with a steel

hammer, hydrated bricks sound
dull and break easily
43
Hydration
 Hydration
 Hydration of periclase (MgO), key factors:
 High humidity
 Temperature range of 40°C to 120°C
 Time
 Transformation of periclase to brucite Mg(OH)2
under increase in volume of 115%

MgO + H2O  Mg(OH)2

Brucite crystals on top of periclase (SEM)

Installation
44 of Rotary Kiln Bricks
How to Check for Hydration

Typical indications:
 network like cracks (radial)
 bulged surface (ruler test)
 dull sound (sound test with hammer)
 loose or crumbly structure

45
Hydration
Lab Test:
Differential Thermogravimetry (DTG)
File: 2562.TG
Gewicht, Abdampfrate vs. Temperatur Datum: 01.16.2003
0 10 Nummer: 4154-6
Probe: ANKROM-B65-R1

-0,05 Einwaage (mg): 8233

0 Meßbereich (g): 0,2
Bemerkung: 1K/min 10l Luft/h
-0,1

-10
-0,15

Abdampfrate in ppm/min
-20
-0,2
Gewichts%

Lossofofwater
Loss water 100°C
at 100° C

-0,25
-30 Loss
Lossofofcristallwater at about
crystal water at about
350°
350°C,C, due
dueto to
degeneration
degenerationof
of brucit Mg(OH)2.
-0,3 of brucit Mg(OH)2
-40

-0,35

-50
-0,4

-0,45 -60
0 100 200 300 400 500 600 700 800 900 1000
Grad Celsius

difficult to detect because already low amounts of brucite,

46
Hydration which is analytically difficult to identify, can lead to formation of cracks
Wet Bricks

 Magnesia bricks which have become wet, must be

stacked openly and ventilated at ambient air
temperatures until dried completely.
 Do not use hot air, do not expose wet bricks to the heat
radiated from the kiln shell.
 After drying, check bricks carefully for crack formation.

47
Hydration
Wet Lining Sections

New lining sections which have become wet have

48
Hydration
to be removed and replaced by dry bricks.
New Lining with Wet Spot

49
Hydration
Loss of Strength over 1 x 2 Meters due
to Hydration

Magnesia
hercynite,
lower
transition
zone

50
Hydration
Measures to Avoid Hydration

 Stick to the RHI storage recommendations (storage under roof

in well ventilated areas).
 Avoid long storing in countries with critical climate, supply of
basic lining material if possible just in time shortly before lining.
 Avoid shipments during rainy season.
 Special brick packing with use of desiccants.

51
Hydration
 Thank you for your attention!

www.rhi-ag.com
RHI AG, Business Unit Cement & Lime
Wienerbergstrasse 9, 1100 Vienna, Austria

DI Roland Krischanitz : Tel: +43 (0)50213-6720, E-Mail: roland.krischanitz@rhi-ag.com

DI Erich Schachenhofer: Tel: +43 (0)50213-6752, E-Mail: erich.schachenhofer@rhi-ag.com

Important notice by RHI Corporate Communications: Elke Koch Tel: +43 (0)50213-6160, E-Mail: elke.koch@rhi-ag.com

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