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    Cement Corrosion 1

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    Simelemon Tolomeo
    1. In 1996, corrosion was identified in kiln parts and refractory bricks at a plant. Testing identified mixed acid corrosion as the mechanism. 2. A new alloy, 53-606, was developed in 1997 for this complex corrosion and tested through plant trials with coatings applied both in workshops and in-situ. 3. After 1 and 2.5 years of sampling and analysis, the 53-606 coating solutions were found to be successful in protecting pre-calciner shells, refractory hangers, and kiln shells and twigs from the mixed acid corrosion.

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    Cement Corrosion 1

    Uploaded by

    Simelemon Tolomeo
    28 views25 pages
    1. In 1996, corrosion was identified in kiln parts and refractory bricks at a plant. Testing identified mixed acid corrosion as the mechanism. 2. A new alloy, 53-606, was developed in 1997 for this complex corrosion and tested through plant trials with coatings applied both in workshops and in-situ. 3. After 1 and 2.5 years of sampling and analysis, the 53-606 coating solutions were found to be successful in protecting pre-calciner shells, refractory hangers, and kiln shells and twigs from the mixed acid corrosion.

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    1. In 1996, corrosion was identified in kiln parts and refractory bricks at a plant. Testing identified mixed acid corrosion as the mechanism. 2. A new alloy, 53-606, was developed in 1997 for this complex corrosion and tested through plant trials with coatings applied both in workshops and in-situ. 3. After 1 and 2.5 years of sampling and analysis, the 53-606 coating solutions were found to be successful in protecting pre-calciner shells, refractory hangers, and kiln shells and twigs from the mixed acid corrosion.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    28 views25 pages

    Cement Corrosion 1

    Uploaded by

    Simelemon Tolomeo
    1. In 1996, corrosion was identified in kiln parts and refractory bricks at a plant. Testing identified mixed acid corrosion as the mechanism. 2. A new alloy, 53-606, was developed in 1997 for this complex corrosion and tested through plant trials with coatings applied both in workshops and in-situ. 3. After 1 and 2.5 years of sampling and analysis, the 53-606 coating solutions were found to be successful in protecting pre-calciner shells, refractory hangers, and kiln shells and twigs from the mixed acid corrosion.

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    © All Rights Reserved
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    Download as ppt, pdf, or txt
    of 25

    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

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