Shell Corrosion

7/21/2019 Shell Corrosion

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Protective Shell Corrosion


1

Preventive protection ofPreventive protection of

Metallic Anchors andMetallic Anchors andother Componentsother Components

20062006





Content

1. General contemplation

•Corrosion Products

•Alkali Circulation

•Temperature Profile

•Heat flow & salt penetration

2. etallic Alkali Compounds

•Alkali Sulfates

•Alkali Chlorines

!. echanism of corrosion in cement plants

•Hi"h Temperature Chlorine Corrosion

•#$idation & Acid Corrosion

%. Preventive shell protection

•Process Solutions

•arious 'inin" Solutions for chan"in" the (ew Point Area

•Protective coatin"s





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1.General contemplation

• Corrosion Products





4

)aw eal

* a s t e G a s


• The Salt Circulation

+nput )aw eal,

• Alkali, 0,5 – 2,6

• Sulfur, ≤0,3

• Chlorine, ≤ 0,1

+nput -uel,

-uel Alkali Sulfur Chlorine

#il !!! 1!" !!!

Coal 0,# 0,3!5 ≤0,4

Alt. -uel ≤" ≤ 15 ≤ 30

Alkali Circuit

Sulfur Circuit





5


Temperature Profile )otar/ 0iln3,632

3,2"2

2,$12

2,552

2,1$2

1,#32

1,4"2

1,112

"52

3$2

32

[ 0 F ]

au$ite a"nesia a"nesia a"nesia au$ite -irecla/

AC+( 34T)A' ... A'0A'+3 AC+(



Protective Shell CorrosionProtective Shell Corrosion

"

()lf)r*')el+

()lf)r*')el+

()lf)r -ide*vaporo)s+

()lf)r -ide*vaporo)s+

Al.ali ()lfate *vaporo)s+ Al.ali ()lfate *vaporo)s+

Com/)stionCom/)stion

eactioneaction Al.alis*volatile+

Al.alis*volatile+


• Alkali Sulfate

efractor Materialefractor Material

CondensinCondensin

Clin.er Clin.er




#

Chlorine*a Mi-+

Chlorine*a Mi-+

Al.ali Chlorine *vaporo)s+ Al.ali Chlorine *vaporo)s+eactioneaction

Al.alis*volatile+

Al.alis*volatile+


• Alkali Chlorines

a Meala Meal

CondensinCondensin

Al.ali Chlorine *vaporo)s+ Al.ali Chlorine *vaporo)s+ (interin(interin




$

Compounds eltin" Point or (ecomposition

89C: 89-:

Compounds eltin" Point or (ecomposition

89C: 89-:

0#H 361 6#2 a#H 31$ 606

0Cl "6# 1,414 aCl #01 1,4"4

02C#! #$4 1,641 a2C#! #50 1,565

02S#% 1%0"4 1,$65 a2S#% ##4 1,623

0#! 33" 63$ a#! 30" 5#4

02S2#; 300 5"2 'i2S#% #60 1,5#0

H%Cl 350 662 H%#! 1"0 33#

<H%=S2#> 120 24# <H%=2S2#! 150 302

H%S#!7H2 131 26#

2. Alkali Compounds




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Compounds 3utectic )eactionTemperature

89C: 89-:

Compounds 3utectic )eactionTemperature

89C: 89-:

0C' 7 'iCl 355 6"1 a#! 7 a2S#% 120 24#

0Cl 7 aCl 65" 1,215 a#! 7 aCl 2$# 56#

0Cl 7 02S#% 6$0 1,2"4 -eCl2 7 AlCl! 7 -eCl! 1$" 3#"

'iCl 7 'i2S#% 4#0 #$6 aAlCl% 7 0AlCl% 12$ 264

02S#% 7 a2S#% 42# #02 0Cl ? aCl ? AlCl! $0 1$4

'i2S#% 7 a2S#% 5$1 1,0$6 'iCl ? AlCl! 110 230

0#! 7 a#! 221 430

2. Alkali Compounds




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!. echanism of Corrosion in Cement Plants

1% ih emperat)re Chlorine Corrosion 2% -idation 7 Acid Corrosion




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15

%999C!>@9C !99C

!@@9C

299C

2@@9C

20ClB-eCl2

0ClB-eCl2

D D

E;;9C

;;29C>99

E99

%99

299

29 %9 E9 >9 -eCl20ClolF

T e m p e r a t u r e

9 C

Phase (ia"ram for Hot Corrosion

!.1. echanism of 0iln Shell Corrosion

C) ot Corrosion (during kiln operation)




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3$ample for )eplacin" of a 0iln Shell Section,

:iln >iameter ?m@ 4%#

:iln (hell (ection ?m@ 10%0

Beiht ?:@ 35,000

Costs for (teel ?&.@ 2%#D

otal .iln (hell ?@ 100,000

Enstallation ?@ 100,000

T#TA' 8:, 2996999

D (06/2006)

!.1. echanism of 0iln Shell Corrosion

d) Costs for !eplacing of corroded "iln Shell Sections




1"

!.2 Hi"h Temperature Chlorine Corrosion

•Temperature rane at metallic s)rface @@9 ? >@99C & 1,022 – 1,5620'

•(eposit and enrichment of chlorine components on the metallic s)rface

*;a, :+ Cl *aseo)s+ *;a, :+ Cl *solid+

•'ack of o$/"en )nderneath the refractor casta/le & /ric. *he composition of the

atmosphere is ver different at the /o)ndar laer /eteen casta/le & /ric.s and metallicanchors & casin% >eposits and enrichments of condensin chemical components ma

occ)r sim)ltaneo)sl ith o-en red)cin reactions+




1#

%. Preventive shell protection

• Process Solutions

#Iectives 7 eans

•ed)ction of Chlorine and ()lph)r Enp)t ! ')el, Fpass

•F)rnin Atmosphere ith hih o-en

s)rpl)s ! F)rnin Condition

•Preventive (hell Protection

;e efractor =ao)ts *>e Point Avoidance+

Coatins, Paints, >eposit Beldin

Beldin of (teel Plates on :iln (hell




1$

'irecla A40 C(!Foard C(!Foard Cclone Ceramic Bool Cover

1#00 1500 Casin Plates

%. Preventive Shell Protection

;e efractor =ao)ts *>e Point Avoidance+

'inin" proposal for 3C+ ? lower c/clone sta"e Tc/clone >999

C 16%;29

-

Tout J E!9C

1%@9-

> e 3

P o i n

t A r e a

11% %9 E9 Emm 11% E% !@ Emm 11% %9 E9 E !9 2mm

3$istin" 'inin" Proposal 1 Proposal 2

Tcasin"out

J ;!9C

1E!9-

Tcasin"out

J 11E9C

2%19-

Tcasin"

J 22!9C

%!!9-




20

)efractor/ linin" proposal 2 <Temperature >999C=

(ate 1%. 19. 92

Customer proIect 3C+6 aastricht

(etail C/clone Sta"e 1

(one / #laf 0uehne

inside outside unit

Amient temperature >99 20 GC *inp)t+

Surface temperature #14 6" GC *calc)lated+

Heat transition coefficient 150 12,20 B&m2:

Calculation formula HIJKJ(2

*ind velocit/ 1 m&s

+rradiation coeffiKient 0,60 !!

Solar irradiation 0 B&m2

(iameter 5%4$4 6%000 mm

Transient heat 625 5"2 B&m2

Transient heat tue 10%"#4 B&m t)/e

Temperature flow

aterial mm *m0 order mean

'irecla!A40 114 1,265 #13,# "#5,"

C( Foard 1#00 40 0,135 "5#,3 6"1,1

C( Foard 1500 60 0,105 5"$,3 415,5

(teel Casin 6 4#,3 22!62 223,4

Ceramic Bool Plates 30 0,11 220,3 161,3

Air 1 0,03 #4,3 "5,2

(teel Casin 2 53,633 E;62 6",2

)efractor/ linin" proposal 2 <Temperature >999C=

(ate 1%. 19. 92

Customer proIect 3C+6 aastricht

(etail C/clone Sta"e 1

(one / #laf 0uehne

inside outside unit

Amient temperature >99 20 GC *inp)t+

Surface temperature #14 6" GC *calc)lated+Heat transition coefficient 150 12,20 B&m

2:

Calculation formula HIJKJ(2

*ind velocit/ 1 m&s

+rradiation coeffiKient 0,60 !!

Solar irradiation 0 B&m2

(iameter 5%4$4 6%000 mm

Transient heat 625 5"2 B&m2

Transient heat tue 10%"#4 B&m t)/e

Temperature flow

aterial mm *m0 order mean

'irecla!A40 114 1,265 #13,# "#5,"

C( Foard 1#00 40 0,135 "5#,3 6"1,1

C( Foard 1500 60 0,105 5"$,3 415,5

(teel Casin 6 4#,3 22!62 223,4

Ceramic Bool Plates 30 0,11 220,3 161,3

Air 1 0,03 #4,3 "5,2

(teel Casin 2 53,633 E;62 6",2

Proposal 2,

11% %9 E9 E !9 2mm

Tin J >999C T

casin" J 22!9C

Tout

J E!9C

%. Preventive Shell Protection ;e efractor =ao)ts *>e Point Avoidance+ 'inin" proposal for 3C+




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%. Preventive Shell Protection ;e efractor =ao)ts *>e Point Avoidance+

Ceramic lanket LMCeramic lanket LM

Ceramic -elt <short fier=Ceramic -elt <short fier=

+nsulatin" Castale or+nsulatin" Castale orCalcium Silicate oardCalcium Silicate oard

Ceramic Anchor rickCeramic Anchor rick

etallic Clampetallic Clamp




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%. Preventive Shell Protection ;e efractor =ao)ts *>e Point Avoidance+

)efractor/ Solutions for avoidin" Chimne/ 3ffects




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%. Preventive Shell Protection Coatins, Paints, >eposit Beldin

Gas7ti"ht Coatin"s Paints

•Polamide esin

•(ilicone esin

•(ilicone Al.d esin

(eposit *eldin" / etallic Powder Gunnin"

•hermal (prain ith Bire

•ih (peed hermal (prain

•Jlectric Arc (prain

Phosphatin" <onderin"=

•Phosphoric Acid




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• Protective Coatin"s <Costs are calculated for )otar/ 0iln6 diam. %6%m=

Gas7ti"ht Coatin"s Paints <2 la/er6 appro$. !@9 mlm2= ? not arasion resistant

)esin ased Coatin" refractoriness

Pol/amide )esin Kraphite Piments, "5!#5

Polamide esin !999

C @;29

-

Silicone )esin 65 'e – Piments *appro-% !9m2 ≈ @99m+

oranic hdrocar/on ;999C 16229-

(V.M. CORPRATION, Mumbai, India or Refratechnik)

Silicone Alk/d )esin =ead and non!chromate

containin Piment Coatin %2@9C ;;9-




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%. Preventive Shell Protection <Costs are calculated for )otar/ 0iln6 diam. %6%m=

• Protective Coatin"s <arasion resistant=

(eposit *eldin" / etallic Powder Gunnin" <1 la/er6 thickness appro$. 1.999Nm=

Power -lame Spra/ Coatin" refractoriness

Thermal Spra/in" with *ire appro-% 1;9 &m2 ≈ 2.%99 &m

Al)mini)m it ;i!Al Bire >@99

C 16@E29

-

Hi"h Speed Thermal Spra/in" appro-% !29 &m2 ≈ %.@99 &m

special allo ;iCrMoC)F(i @99C 16;%29-

*http&&%frmetals%com&+

3lectric Arc Spra/in" refractoriness

Arc *eldin" with Sealin" appro-% @>9 &m2 ≈ >.299 &m

;i!Cr 50&50 @99C 16;%29-




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%. Preventive Shell Protection <Costs are calculated for )otar/ 0iln6 diam. %6%m=

• Protective Coatin"s <lo cost sol)tion – not a/rasion resistant+

Phosphatin" <onderin"= <2 la/er6 appro$. 299mlm2= refractoriness

Phosphoric Acid *3P4 "5+ appro-% > &m2 ≈ 129 &m !@99C EE29-

'e23 8 P43! 'eP4

'e 8 P43! 'e3*P4+2

'e(2 8 P43! 'e3*P4+2




2"


• Protective Coatin"s <not a/rasion resistant – not s)ita/le for rotar .iln+

Ceramic ortar <1 la/er6 appro$. 2k"m2 or 1k";@anchors= refractoriness

Coro Te$ @99!>19 appro-% %@k" 1.!999C 26!;29-

*oanas ! (eden+ Coro e- 500$ – Poder *62 / eiht+

Coro e- 3#10 – =iL)id *3# / eiht+

Pot!life at 200C a/o)t 2hrs

C)rin ime a/o)t 2 – 3hrs

>ensit 1%# .&dm3

(helf life

Coro e- 500$ ! )nlimited

Coro e- 3#10 – 5 months




2#

Costs for heat resistant Allo/s <1299E=

1%4#2# – AE(E 30$ – 15Cr;i(i20!12 5,00 &.1%4#41 – AE(E 314 – 15Cr;i(i25!20 6,20 &.

1%4#45 – AE(E 310 – 12Cr;i25!21 6,30 &.

Enconel 625

2%4#56 – AE(E 625 – ;iCr22Mo$;/ 36 – 40,00 &.

(tainless (teel1%4301 – AE(E 304 – 5Cr;i1#!10 *N2A+ 3,50 &.

1%45"1 – AE(E 316 – 6Cr;iMoi1"!12!2 *N4A+ 4,#0 &.




2$


• Protective Coatin"s <not a/rasion resistant – not s)ita/le for rotar .iln+

Ceramic ortar <1 la/er6 appro$. 2k"m2 or 1k";@anchors= refractoriness

Coro Te$ @99!>19 appro-% %@k" 1.!999C 26!;29-

*oanas ! (eden+

etallic Components after 1 /ear of operation <E.@99tpd=

coated ith Coro e-

not coated




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• *eldin" of Steel Plates on the 0iln Shell

ild Steel6 SiKe appro$. 2 $ 2m6 @ 7Emm thick

Service 'ife of Steel Plate, 1 ? 2 /ears <depends on Corrosion Pro"ress=

efractorFric.

efractorMortar

(teel Plate




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Stainless Steel6 SiKe appro$. 26%% $ 1622m6 96;mm thick

Steel "rade, 2A <1.%!916 A+S+ !9%= or %A <1.%@;16 A+S+ !1E=





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Stainless Steel6 SiKe, endless 99mm Steel )oll6 96!>mm thick

Steel "rade, 2A <1.%!916 A+S+ !9%= or %A <1.%@;16 A+S+ !1E=





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Shell Corrosion

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