History of Development

1. 1996. Indentification of Problem

• Corrosion of kiln, pre-calciner parts observed, together with
wet, yellow refractory bricks.
• Lab. analysis by E+C of brick and metals.
• Identification of corrosion mechanism. Solutions proposed.

2. New Alloy development, 53-606 for this complex

corrosion
3. 2/1997. Plant trials of Solutions
• Workshop and In-situ coating of various parts, with various
alloys and various processes.
4. 1 year and 2.5 year sampling and analysis
5. Successful solutions. Patents, publication and
promotion
 Corrosion Solution

Type of Corrosion

No Universal Solution
• Access
• Equipment availability
• Timing

Process Material
 Corrosion Coating

Composition Bonding
Environment
Temperature

Protectio
Mechanical
TEC, Strength
n Application
In-situ,
Wear
Substrate
3 Corrosion Problems

1
2

3
1. Pre-Calciner Shell
Shell Corrosion
 Pre-Calciner Shell
Plates were Thermal
Spray
Coated in the workshop:

• Range of TS
Processes:
Spray &Fuse + Arc
Wire
• Range of Alloys
53-606 and 45CT

Corroded shell was cut

out and 6 mm plates
 Pre-Calciner Shell

Coated Plates welded in

place with corrosion
resistant electrodes.
Pre-Calciner shell-outside
 Refractory Hangers

Rapid Corrosion of
Refractory Hangers is
Dangerous
 Refractory Hangers

Coated and uncoated

Hangers after 1 year
service

Coated New Hanger

Hanger Hange Thermal Spray

r Process allows
25-20 Suppo coating of Hanger &
rt 25- Support
20
 Kiln Refractory Twigs and
Shell

IN-SITU Spraying of parts

Shell Twigs on kiln, diameter =5.4 m
Kiln Refractory Twigs and
Shell

Twigs welded to shell

with corrosion
resistant electrode
6825.
 Kiln Refractory Shell

Unsprayed and Sprayed Arc Wire

Shell. Spraying with
45CT Wire
 In-Situ Arc Wire Spray

Corrosion
protection of
bridge
Arc Wire Spray Principle Corrosion
protection in
Boilers
 Kiln Refractory Twigs and
Shell

IN-SITU Spraying of
Twigs with 53-606
powder.
 Problem

Alternative Cooler
Shell
Fuels, Cl, S

Hot Gas
Impurities in gas
allow
condensation at
800-900 C higher
temperatures.
Condensation on
cooling
Condensation
300-400 C
 Problem

• at boiling temperature
HCl + H2SO4 • Highly concentrated
acid (pH<1) liquid
+ ~360 C • mixed gas & wet
corrosion. Normally
very different
solutions
• remaining in porous
refractory
 New Alloy Development 53-606

Corrosion
• Ni-based

NiCrMoBSi • High levels of Mo, Cr, Si

Cu • Developed for mixed
corrosion
Spray +
Fuse • Dense due to Fusion
• Best bonding due to
diffusion
• Uniform chemistry
 New Alloy Development 53-606

Mechanical
• Hard, wear-resistant HV
NiCrMoBSi 600
Cu • High hardness at 500 C
Spray + • Smooth surface
Fuse
• TEC matched to base
metal-no cracking
• Best bonding due to
diffusion
 Eutalloy 53-606

0.9 NiCrMoBSi
0.8 Cu
0.7
Spray +
Corrosion (mg/m2h)

0.6
Fuse
0.5
H2SO4
0.4
HCL
0.3
0.2
0.1
0 RT, 10% Acid
12525 17535 12496 12497 53-606 Soln.
 Spray + Fuse

Powder

Protective Gas

Weld Overlay
 Low Dilution with
Substrate
 Dense coating

 Diffusion Bonding
 Practical Experience with 53-606

Hanger History

• Initial trial with 50 hangers and supports.

New, coated in Workshop and installed
2/1997.
• Fully inspected in 1999 (2.5 years). No
corrosion.
• 600 coated and currently installed.
 Practical Experience with 53-606

Kiln Entrance History

• In-Situ coating of shell and twigs in 2/1997.

• Fully inspected in 1999 (2.5 years). No
corrosion.
• Kiln continues to run successfully with
this solution
 Practical Experience with 53-606

Pre-calciner Shell History

• Initial trial with 7 coated test panels
produced in workshop on new 6mm plate.
Installed 2/1997.
• 7 samples cut from inside in 1998 (1 year).
Full E+C laboratory analysis.
• Samples cut in 1999, independent analysis.

Fused 53-606 is best, 45 CT is best of cold

sprayed