REFRATECHNIK

Report No. 55
Wear phenomena of refractory linings in
the burning zone of cement rotary kilns
M. Künnecke, R. Gocht

Refratechnik Cement GmbH

Rudolf-Winkel-Strasse 1
37079 Göttingen
Germany
Phone +49 551 6941 0
Fax +49 551 6941 104
refra@refra.com
www.refra.com
Published by:
Refratechnik Cement GmbH,
Göttingen

All rights reserved.

Reproduction in any format – including extracts –
is only permitted with the approval of the publisher.
Report No. 55
Wear phenomena of refractory linings
in the burning zone of cement rotary kilns
M. Künnecke, R. Gocht

©Refratechnik Cement GmbH 1

Photo 1: Perfect burning conditions

©Refratechnik Cement GmbH 2

Introduction
Depending on the cement clinker production process type, the average lining life of burning zone refractories is
10-12 months being equivalent to approx. 500 g of refractories per ton of produced clinker. If your lifetime is more than 1 year
or the ­specific consumption is less than 500 g, you can be happy.

Photo 1 shows a perfect, clear flame, good protective coating and satisfactory process conditions. If your kiln looks similar,
you may relax.

If the lining performance however is less than 6 months and brick consumption is more than 800 g, the following case
­histories of damaged bricks and linings will hopefully contribute to an improvement.

Refractory bricks installed in the burning zone of cement rotary kilns are considered as ­working lining and are thus sub­
jected to continuous wear through thermal, chemical and ­mechanical stresses.

Numerous stresses of that kind do overlap in the kiln due to the interaction of kiln feed, flame, and kiln shell deformation
as per Fig. 1. Refractories are sensitive ceramics and should be handled with care because: There is no cement without
refractories!

redo
l shock x
a
rm
he
t

cli
nk
er m
l
ma

infiltr
ther

elt
chem
overheating

ation

stresses on
ical
alkali salts

refractory linings

va mechanical
se

li l
o

rm ty ca o
de

ni
lla

cha ng c
fo

a ti me
on therm o ti
coa
stoppages

Fig. 1: Stresses on the refractory lining in cement rotary kilns

©Refratechnik Cement GmbH 3

First of all we have to look at the various responsibilities and influences regarding the lining performance (Fig. 2).

user’s responsibility
thermal chemical
stress stress

installation of
refractories service
conditions

dry storage mechanical

stress

lifetime of
selection refractories

installation quality of quality of

drawing production raw materials

producer’s responsibility

Fig. 2: Responsibilities or influences regarding the lifetime of refractories

©Refratechnik Cement GmbH 4

Generally, extensive investigations are necessary to evaluate complica­ted cases of premature wear.

Nevertheless, some typical kinds of lining damage can already be identified on site ­immediately after having stopped the
kiln by comparing the present lining situation in your kiln with the following case histories.

The attached photos of lining damages were collected during i­nspections of kiln linings which showed premature wear due
to different reasons. If you recognize such types of damage during shutdown of your kiln (Photo 2), you might be able to
avoid future problems by taking appropriate improvement measures.

The following photos and figures are examples for typical damages due to mechanical, thermal, and ­chemical overstresses:

1. Mechanical wear
1.1 Convex spalling Photo 3 / Fig. 3
1.2 Concentric stress cracks Photo 4 / Fig. 4
1.3 Spiralling Photo 5 / Fig. 5
1.4 Ovality Photo 6 / Fig. 6
1.5 Formation of grooves Photo 7 / Fig. 7
1.6 Pinch at retaining rings Photo 8 / Fig. 8

2. Thermal wear
2.1 Concave melting pits Photo 9 / Fig. 9
2.2 Lava-like coating Photo 10 / Fig. 10
2.3 Excessive thermal load Photo 11 / Fig. 11
2.4 Thermal shock Photo 12 / Fig. 12

3. Chemical wear
3.1 Infiltration of alkali salts Photo 13 / Fig. 13
3.2 Corrosion of chrome ore Photo 14 / Fig. 14
3.3 Redox bursting Photo 15 / Fig. 15
3.4 Hydration cracks Photo 16 / Fig. 16

©Refratechnik Cement GmbH 5

Photo 2: Lining inspection during a kiln stop

©Refratechnik Cement GmbH 6

 1. Mechanical wear

1.1 Convex spalling

1.2 Concentric stress cracks

1.3 Spiralling

1.4 Ovality

1.5 Formation of grooves

1.6 Pinch at retaining rings

©Refratechnik Cement GmbH 7

Photo 3: Convex spalling

©Refratechnik Cement GmbH 8

 phenomena: symptoms:
convex spallings in longitudinal direction axial pressure generated by dilatation,
of the kiln, so-called cobblestones brick resistance is exceeded thus causing
spalling

convex spalling

reasons: improvements:
• insufficient clearance in the expansion joints • insertion of cardboard ­spacers according
• installation without card­board spacers to installa­tion drawings
• s toppage of ­operation during heating up, • use of bricks with pre­attached
after cardboard spacers burnt off cardboard spacers like all basic qualities
from Refratechnik

Fig. 3: Mechanical wear 1

©Refratechnik Cement GmbH 9

Photo 4: Concentric stress cracks

©Refratechnik Cement GmbH 10

 phenomena:
concentric stress cracks in 3-5 cm
depth around the circumference
concentric stress cracks
reasons:
• s teel plates oxidize and react with the
bricks forming a monolithic horizon
of magnesioferrite with significant
volume increase
Fig. 4: Mechanical wear 2
symptoms:
cracks in the reaction zone of steel plate-lined
bricks and in bricks in the keying section
improvements:
• lining without steel plates
(mortar or clench lining)
• correct keying of the brick rings
©Refratechnik Cement GmbH 11
Photo 5: Spiralling

©Refratechnik Cement GmbH 12

 phenomena:
spiralling, tilting and edging,
cold face wear from friction
against the kiln shell
spiralling
reasons:
• loose installation
• increased kiln shell ovality
• expansions and contractions
due to frequent kiln ­s toppages
• changing coating ­formation
• deformation of the kiln shell
Fig. 5: Mechanical wear 3
symptoms:
lining displacements and stress marks
on the brick's cold face due to relative
­movements between kiln shell and lining
improvements:
• uniform kiln operation
• repair of bulged kiln shell
• measuring the ovality by means
of the REFRA-Shell II equipment
• p roper and tight ­installation with
staggered lining and REFRA-Rig II
• kiln alignment measurement
©Refratechnik Cement GmbH 13
Photo 6: Ovality

©Refratechnik Cement GmbH 14

 phenomena:
deep spalling of single bricks, inbetween
completely perfect brick sections
ovality
reasons:
• worn tyre shoes increase the clearance
causing excessive ovality
• limit for the ovality max. 1/10 of kiln
diameter, e.g. 0.5% for a 5 m dia. kiln
• maximum migration between kiln shell
and tyre 25 mm
Fig. 6: Mechanical wear 4
symptoms:
high kiln shell ovality in the tyre area
(squeeze and release) during each rotation
stressing the brick's hot face
improvements:
• permanent monitoring of migration
between kiln shell and tyre
• measuring the ovality by means
of the REFRA-Shell II equipment
• kiln alignment measurement
• insertion of new tyre pads
• best flexible lining with mechanically
enhanced refractory brick grades, like
PERILEX® CF, TOPMAG® A1 or ALMAG® A1
• mortar installation
©Refratechnik Cement GmbH 15
Photo 7: Formation of grooves

©Refratechnik Cement GmbH 16

 phenomena:
parallel grooves (2-4 bricks wide) with deep
spalling appear­ing along the kiln axis
formation of grooves
reasons:
• keying of the rings with excessive tightness
• damaged bricks in the keying section
­c aused by jack hammer
• more than one metal shim per joint or shims
on both sides of one brick
Fig. 7: Mechanical wear 5
symptoms:
orientated premature wear channels
within uniform, unaffected lining
improvements:
• correct keying of brick rings
• uniform insertion of liners in
the whole joint
• one steel plate per joint only
• use of max. 2 mm thick keying shims
©Refratechnik Cement GmbH 17
Photo 8: Pinch at retaining rings

©Refratechnik Cement GmbH 18

 phenomena: symptoms:
collapse of brick rings against retaining ring horizontal cuts and cracks of bricks
or outlet segments due to pinch spalling at the upper edge of retaining rings
and t­ ranspassing nose ring s­ egments

pinch at retaining rings

reasons: improvements:
• thrust and oscillations ­generate shear • solid kiln shell
cracks and grinding • use of appropriate retaining rings
• flexing kiln outlet or ovality accelerate with max. 50 mm height
the damage • use of highly abrasion resistant brick grades
• loose brick lining like KRONAL® 63 AR

Fig. 8: Mechanical wear 6

©Refratechnik Cement GmbH 19

©Refratechnik Cement GmbH 20
 2. Thermal wear

2.1 Concave melting pits

2.2 Lava-like coating

2.3 Excessive thermal load

2.4 Thermal shock

©Refratechnik Cement GmbH 21

Photo 9: Concave melting pits

©Refratechnik Cement GmbH 22

 phenomena:
concave wear, so-called duck nesting (looking
like eutectic melting of ­alumina bricks)
concave melting pits
reasons:
• coating-free operation of standard grade
bricks with ­moderate ­refractoriness
• flame impingement on the lining
• misalignment of the burner
Fig. 9: Thermal wear 1
symptoms:
overheating of bricks ­weakens the
structure of bricks at their hot face
improvements:
• adjustment of burner
• limits for silica modulus: SM < 2.6
• cross section load
< 5.0 x 106 kcal/m2h
• use of refractories with high
­thermochemical resistance, like
ALMAG® AF with magnesia-­
fused spinel or MAGNUM® E, the
­magnesia-zirconium oxide brick grade
with balanced elastification
©Refratechnik Cement GmbH 23
Photo 10: Lava-like coating

©Refratechnik Cement GmbH 24

 phenomena:
lava-like coating solidly adhering to the bricks
and cracks behind the ­densified surface
falling coating takes off ­densified brick heads
lava-like coating
reasons:
• overheating of clinker with formation of
increased liquid clinker phase ­infiltrating
the hot face, e.g. peaks of ferritic phase
during production of SRC
Fig. 10: Thermal wear 2
symptoms:
overheating of clinker with liquid phase
­infiltration and densification of the hot
face of bricks, loss of mechanical flexibility
improvements:
• avoidance of burning conditions with
increased liquid phase LPh < 26% (L & P)
• uniform operation ­conditions
• best possible homogeneity of raw
­materials
• use of refractories with high
­thermochemical resistance, like
ALMAG® AF with magnesia-
fused spinel or MAGNUM® E, the
­magnesia-zirconium oxide brick grade
with balanced elastification
©Refratechnik Cement GmbH 25
Photo 11: Excessive thermal load

©Refratechnik Cement GmbH 26

 phenomena: symptoms:
change from uniform brick matrix with round structural fatigue of high-quality bricks
grain to periclase needles with brittle structure at coating-free operation due to high
­temperature

excessive thermal load

reasons: improvements:
• overheating above 1700 °C • uniform and continuous ­operation
without liquid phase ­conditions
• thermotactic recrystal­lisation • use of refractories with high
­thermochemical resistance, like
ALMAG® AF with magnesia-
fused spinel or MAGNUM® E, the
­magnesia-zirconium oxide brick grade
with balanced elastification

Fig. 11: Thermal wear 3

©Refratechnik Cement GmbH 27

Photo 12: Thermal shock

©Refratechnik Cement GmbH 28

 phenomena: symptoms:
split-like spallings in 2-3 cm thin layers sudden changes in ­temperature
generate thermal tensions that
cause horizontal cracks

thermal shock

reasons: improvements:
• quick heating up • rational heating-up at 50 °C/h
• sudden cooling down • slowly cooling down
• coating losses • uniform operating ­conditions
• s table coating
• use of optimally elastified brick grades
with high thermal shock resistance
of ≥ 80 cycles, such as PERILEX® CF,
TOPMAG® A1, and ALMAG® A1

Fig. 12: Thermal wear 4

©Refratechnik Cement GmbH 29

©Refratechnik Cement GmbH 30
 3. Chemical wear

3.1 Infiltration of alkali salts

3.2 Corrosion of chrome ore

3.3 Redox bursting

3.4 Hydration cracks

©Refratechnik Cement GmbH 31

Photo 13: Infiltration of alkali salts and corrosion of kiln shell

©Refratechnik Cement GmbH 32

 phenomena:
a cut through the brick shows infiltration
­horizons, and the inner kiln shell is attacked
by corrosion
infiltration of alkali salts
reasons:
• deposits of mainly K 2SO4 in the lower
­transition zone and burning zone, along
with KCl in the upper transition zone
Fig. 13: Chemical wear 1
symptoms:
gaseous alkali salt c­ ompounds migrate
into the bricks, filling the brick pores,
­condensating and solidifying them
improvements:
• alkali salt content to be reduced
• alkali/sulphate ratio to be balanced
in a range of 0.8-1.2
• use of brick grades with improved infiltration
resistance: PERILEX® CF, REFRAMAG® AF,
TOPMAG® AF or ALMAG® AF
• cleaning of the kiln shell and use of
­REFRACOAT® for protection of the kiln shell
• installation of sacrificial steel plates
©Refratechnik Cement GmbH 33
Photo 14: Corrosion of chrome ore

©Refratechnik Cement GmbH 34

 phenomena: symptoms:
yellow-green discoloration and brittle surface with excessive alkalis the chrome ore is
with cracks ­attacked and corroded, and toxic hexavalent
alkali chromates are formed

corrosion of chrome ore

reasons:
• with free K 2O, Na2O ­formation of K 2CrO4, Na2CrO4
• loosening of the brick structure by dissolving
of the chrome ore
improvements:
• alkalis to be reduced and alkali/sulphate ratio
to be balanced (refer to 3.1)
• u se of chrome ore-free bricks: PERILEX® CF or
REFRAMAG®, TOPMAG® or ALMAG® grades

Fig. 14: Chemical wear 2

©Refratechnik Cement GmbH 35

Photo 15: Redox bursting

©Refratechnik Cement GmbH 36

 phenomena:
bleaching of dark brown basic bricks to
cappuccino colour and bursting of the structure
carbon deposits in the joints ­and on the
kiln shell and in the pores of the bricks
redox bursting
reasons:
temporarily reducing ­atmosphere due to:
• insufficient combustion
• use of fuels rich in ashes
• course grain coal or ­petcoke
• use of alternative fuels
Fig. 15: Chemical wear 3
symptoms:
repeated change from ­oxidizing to reducing
­atmosphere (so-called redox) causes volume
­change ­between trivalent (red) and ­bivalent
(green) iron
improvements:
• min. of 1.5% of O2 for complete combustion
• improvement of coal/petcoke fineness
(max. residue 50% on 90 micron mesh
of volatile ­content
• use of a chrome ore-free brick grades
with lowest iron content: ALMAG® AF,
ALMAG® 85, and ALMAG® A1
©Refratechnik Cement GmbH 37
Photo 16: Hydration cracks

©Refratechnik Cement GmbH 38

 phenomena:
spider web cracks propagating from the
surface into the bricks, even disintegration
hydration cracks
reasons:
• MgO reacts with water to brucite Mg(OH)2
under ­significant volume increase
Fig. 16: Chemical wear 4
symptoms:
CaO and MgO are sensitive to humidity.
Magnesite bricks are by far less sensitive
than ­dolomite bricks, but should be ­protected
against ­seawater, rain and humid air, especially
in ­subtropical climates.
improvements:
• dry storage under roof
• recommended storage time
6 months in subtropical climate
• ventilated storage
• max. ignition loss of humid
bricks 0.3%
• use of REFRAPACK seaworthy packing
with double pre-shrunk ­plastic foil
©Refratechnik Cement GmbH 39
Recommendations
• Optimize uniformity of raw meal feed.
• Try to obtain and maintain stable coating conditions in the burning zone.
• Control kiln shell ovality in the tyre areas and kiln alignment periodically.
• Balance thermal load.
• Avoid frequent kiln stoppages.
• Heat-up and cool down the kiln slowly.
• A pply a suitable installation method with your permanent crew
or a reliable ­subcontractor.
• Do carefully select appropriate brick grades with Refratechnik.

Basic bricks for burning zones

MAGNUM® E magnesia- lower transition zone subject to extremely high thermal load
zirconium oxide with cement clinker attack and redox ­conditions prevailing;
also recommended for use in lime, ­dolomite and magnesite
kilns, chrome ore-free
ALMAG® AF magnesia-fused spinel upper and lower transition zones subject to ­extremely high
thermo­chemical load in kilns using alternative fuels, ­
chrome ore-free

TOPMAG® AF magnesia-fused spinel upper and lower transition zones subject to high
thermo­chemical load in kilns using alternative fuels,
chrome ore-free

ALMAG® A1 magnesia-fused spinel upper transition zone, tyre section subject to high thermo­
mechanical load with redox conditions and extreme alkali
and ­sulphate attack, chrome ore-free

TOPMAG® A1 magnesia-fused spinel upper transition zone, tyre section subject to high mechanical
load with redox ­conditions prevailing and extreme alkali attack,
chrome ore-free

ALMAG® 85 magnesia-spinel upper and lower transition zones ­sub­ject to severe ­service
­conditions with alkali attack and redox conditions prevailing,
chrome ore-free

REFRAMAG® AF magnesia-spinel upper and lower ­transition zones as well as burning zone
­subject to ­thermochemical load in kilns using alternative fuels,
chrome ore-free

FERROMAG® F1 magnesia-spinel burning zone and upper transition zone subject to severe
(fMA spinel) ­service conditions, good coatability, chrome ore-free

PERILEX® CF magnesia-spinel burning zone as well as upper transition zone, good coatability,
(fMA spinel) chrome ore-free

PERILEX® 83 magnesia-chromite burning zone as well as upper and lower transition zones
subject to severe ­ser­vice conditions, low chrome ore ­content

PERILEX® 80 magnesia-chromite burning zone as well as upper and lower transition zones
sub­ject to normal service conditions, low ­chrome ore ­content

©Refratechnik Cement GmbH 40

Photo 17: Kiln without Refratechnik services

41
Refratechnik Cement GmbH
Alte Münzesheimer Strasse 13
76703 Kraichtal/Gochsheim
Germany
Phone +49 7258 9112 0
Fax +49 7258 9112 27
produktion2@refra.com

Refratechnik Ibérica S.A.

Clot del Torrent, s/n.
08729 Gornal/Barcelona
Spain
Phone +34 977 16705 0
Fax +34 977 16705 4
rtiberica@refra.com

Refratechnik Italia S.r.L.

Corso Casale 360
13039 Trino
Italy
Phone +39 0161 801213/801074
Fax +39 0161 804207
refraitalia@refra.com

Refratechnik México S.A. de C.V.

Shakespeare No. 30 - 11° Piso
Col. Nueva Anzures
C.P. 11590,
Del. Miguel Hidalgo
México, D.F.
Mexico
Phone +52 55 525074 66
Fax +52 55 525074 67
reframex@refra.com.mx

Refratechnik North America, Inc.

530 Maryville Centre Drive
Suite 320
St. Louis, Missouri 63141
USA
Phone +1 314 336 0634
Fax +1 314 336 0639
rtnorthamerica@refra.com

Refratechnik Asia Limited

Suites 3107-09, 31st Floor
Tower 1 The Gateway
Harbour City, Kowloon
Hong Kong
Phone +852 3920 5000
Fax +852 3920 5050
refra@rtasia.hk
www.rtasia.hk
Ce 1-020-10/2014