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    Stack Corrosion: A Serious Problem

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    Kiatchai Ittivikul
    The document discusses stack corrosion in cement plant chimneys. It notes that corrosion has become a more serious problem recently due to factors like higher sulfur fuel, alternative fuels, and more efficient filters. A new material coating called StackGard-255SQW is highlighted as a simple and effective way to prevent and stop corrosion in chimneys. The coating has been successfully used on chimneys in several projects worldwide and provides excellent thermal, mechanical and chemical resistance to extend the life of chimneys.

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    Stack Corrosion: A Serious Problem

    Uploaded by

    Kiatchai Ittivikul
    48 views3 pages
    The document discusses stack corrosion in cement plant chimneys. It notes that corrosion has become a more serious problem recently due to factors like higher sulfur fuel, alternative fuels, and more efficient filters. A new material coating called StackGard-255SQW is highlighted as a simple and effective way to prevent and stop corrosion in chimneys. The coating has been successfully used on chimneys in several projects worldwide and provides excellent thermal, mechanical and chemical resistance to extend the life of chimneys.

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    3L_T_Stacks

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    The document discusses stack corrosion in cement plant chimneys. It notes that corrosion has become a more serious problem recently due to factors like higher sulfur fuel, alternative fuels, and more efficient filters. A new material coating called StackGard-255SQW is highlighted as a simple and effective way to prevent and stop corrosion in chimneys. The coating has been successfully used on chimneys in several projects worldwide and provides excellent thermal, mechanical and chemical resistance to extend the life of chimneys.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    48 views3 pages

    Stack Corrosion: A Serious Problem

    Uploaded by

    Kiatchai Ittivikul
    The document discusses stack corrosion in cement plant chimneys. It notes that corrosion has become a more serious problem recently due to factors like higher sulfur fuel, alternative fuels, and more efficient filters. A new material coating called StackGard-255SQW is highlighted as a simple and effective way to prevent and stop corrosion in chimneys. The coating has been successfully used on chimneys in several projects worldwide and provides excellent thermal, mechanical and chemical resistance to extend the life of chimneys.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 3

    Stack Corrosion:

    A Serious Problem
    Linas Mazeika, 3L&T, USA, describes the company’s method for
    preventing and stopping corrosion in cement plant chimneys.

    Abstract chimney becomes structurally unsafe. Figure 1 illustrates a


    Most chimneys in cement plants are built using carbon steel. case where the top of the chimney fell down.
    In the past, internal corrosion was not a major issue but
    recently it has been getting much worse. The aggressive Corrosion process
    corrosion now observed seems to be related to three It is well known that carbon steel corrodes rapidly when
    current trends: more sulfur in the fuel, an increase in use exposed to the hot, acidic, condensing flue gases produced
    of alternative fuels and better efficiency of the baghouse in a cement plant. Where the plant is close to the coast, the
    filters. There is a new material technology called StackGard- corrosion can be more severe due the additional effect of the
    255SQW that is simple to install, easy to cure and has chlorides present in the atmosphere.
    excellent corrosion protection characteristics. Even if the condensation is not continuous, the effect of
    Several new stacks worldwide have been protected with
    this coating and many other projects are ongoing, including
    a new chimney in Arkansas. Considering the overall
    investment for a new chimney, it is very cost effective to stop
    the corrosion and add more years to its useful life.

    Introduction
    Most chimneys have the ideal conditions for severe internal
    corrosion. The combustion gases consist of acidic compounds
    like SO2, SO3, HCl and NOx, they also contain a large
    amount of moisture. The metal temperatures are, in most
    cases, below the acidic dew point temperature of these gases,
    especially towards the top of the chimney. Additionally, many
    chimneys do not have external insulation and this guarantees
    that there will be significant amounts of acid condensation on
    the internal walls.
    In many cases the corrosion effect is dramatic. After
    4 - 5 years, there is significant wall thickness loss and the Figure 1. Part of a corroded chimney.

    [May 09] worldcement.com 


    corrosion is accumulative. As the thickness of the rust layer
    increases, eventually corrosion flakes disbond from the metal
    surface and the flue gases push them out. This is often visible
    in the neighbourhood of a corroding chimney. Figure 2
    shows these rust scales inside a chimney.

    Corrosion is becoming more severe


    When there is a higher concentration of acidic compounds
    in the combustion gases, corrosion is accelerated. Usually
    there is high sulfur content in the fuel. In many cases, there
    is often significant chloride content in the alternative fuels as
    well as CO2 and NOx emissions from the combustion process.
    Figure 3 shows the effect of chlorides in a coastal location.
    Corrosion is getting worse due to the following factors:
    l Higher sulfur content in the fuel. Fuels like petcoke and
    Figure 2. Rust scales inside a chimney. high-sulfur coal are more common because they are less
    expensive. The sulfur content can be in the 4 – 7% range.
    The combustion of this high-sulfur fuel produces much
    increased amounts of SO2 and SO3.
    l Increase in the use of alternative fuels. Cement plants are
    burning more waste fuels as a way to reduce fuel costs and
    in some cases as an additional source of income. In many
    cases, this waste is a source for additional chlorides. The
    combination of sulfur and chlorides tends to accelerate the
    corrosion of steel and also can damage stainless steel.
    l Better filtration of particles. The new baghouse filters are
    more efficient and can reduce particle emissions to below
    50 mg/t3. This is beneficial for the environment, but a side
    effect is less alkaline dust on the chimney walls and less
    neutralisation of the acid condensation, in other words
    more corrosion.

    Figure 3. The effect of chlorides in a costal location. Corrosion control methods


    Conventional protective coatings
    There are many different types of corrosion protection
    coatings. Most of them can survive either high temperatures,
    aggressive chemicals or high degrees of abrasion, but is very
    difficult to withstand all the above at the same time.
    The failure mode for most coatings is either through
    oxidising degradation at higher temperatures, or by blistering
    and delamination from the steel surface.
    Oxidation damage occurs when the metal surface operates
    above 150 ºC (300 ºF). Delamination, as a result of undercut
    corrosion, occurs when there is coating surface damage or
    imperfection in the surface preparation. It usually starts as
    a small spot, and from there the propagation is relentless.
    Figure 4 shows a chimney where the coating applications did
    not protect it from severe damage.

    New material technology


    Many cement plants complain of corrosion issues and the
    need for a better protection of steel chimneys, and this has led
    3L&T to develop a suitable material.
    The binder is an interpenetrating network made of
    organic and inorganic polymers. This produces a very densely
    cross-linked material with excellent thermal, mechanical and
    chemical resistance.
    The formulation includes several corrosion protection
    mechanisms that are effective within different temperature
    ranges. This is necessary because of the wide temperature
    Figure 4. A severely damaged chimney. difference that is common from the base to the top of most

     worldcement.com [May 09]


    chimneys.
    Additionally, the StackGard-255SQW also has a wide
    temperature range for the final cure, 100 - 180 ˚C. This is
    important because in most chimneys it is very difficult to
    heat the metal at the same temperature.
    This new material is an evolution from the company’s
    FlueGard-225SQC, which has been used successfully in
    many cement plants baghouses, electrostatic precipitators,
    ducts, fans and chimneys worldwide.

    Recent projects
    3L&T has already made several major applications and
    is currently working on new projects in Australia, South
    Africa and the USA.

    Application in Indonesia
    A large cement plant near Jakarta experienced severe
    corrosion in its kiln chimney. This chimney is 6.5 m dia
    Figure 5. The application of StackGuard-225SQW.
    x 100 m high. The top 70 m were rebuilt during January
    2008 in 10 m sections and coated on the ground. Figure
    5 shows the application of StackGard-255SQW on one
    section.

    National Cement, Lebec (CA), USA


    National Cement’s plant, located near Lebec, California
    decided to coat the whole length of its 100 m chimney
    using the StackGard-225SQW. This project was
    completed in April 2008. Figure 6 shows the application
    in progress.

    Cemex Andorra, Spain


    Cemex is building a new cement plant in Teruel,
    Andorra, and decided to coat the chimney to prevent
    corrosion damage. The 10 m sections were coated on
    the ground before assembly. This approach makes the
    application easier, lowers the total cost and facilitates
    quality control of the job. Figure 7 shows the application
    in one section.

    Ash Grove Cement, Foreman (AR), USA Figure 6. Application in progress.


    The kiln chimney at the new Ash Grove cement plant will
    be coated with StackGard-255SQW. The application was
    due to commence in March this year.

    Conclusion
    Corrosion is always a fearsome and costly opponent.
    There are many different components to it and it is
    always a continuous battle to keep it under control.
    In cement plant chimneys, corrosion has been more
    aggressive in recent years. This is due to a combination
    of increased sulfur and chloride content in the gases, and
    fewer dust particles.
    Many plant managers are concerned about the
    deteriorating condition of their chimneys and have
    expressed their worries to 3L&T. This growing market
    need has led the company to develop a new material based
    on the successful previous experience with the FlueGard-
    225SQC material. This new coating, StackGard-255SQW,
    can be cured and operated within a wide temperature
    range which is the normal case in most chimneys. The
    recent StackGard-255SQW applications described in this
    article are just the beginning. The company is pleased to
    Figure 7. Application on one section of the chimney.
    be able to provide an effective soloution. ¸

    [May 09] worldcement.com 

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