Selection of Refractory Bricks for Use in Lime Sludge Kilns

Selection of Refractory Bricks for Use in
Lime Sludge Kilns
Corrosion in Pulp and Paper Mills and Biorefieries
November 13-14, 2015
Georgia Tech
By:
J. Peter Gorog
www.HoughtonCascade.com
253.670.2867
11104 SE 283rd St, Auburn, WA, 98092-­‐4026 Outline
• 
• 
• 
Function of the refractory lining
Selection of refractory bricks
Recommended refractory linings
Selec9on of Refractory Bricks 2 Key Factors to Optimize Performance of the Refractory Lining
Operating
Conditions
Material
Selection
Burner
Design
Optimized
Refractory
Lining
Selec9on of Refractory Bricks 3 Function of the Refractory Lining
• 
A kiln cannot be operated without the use of a refractory lining to insulate the metal
shell. This is because the temperatures required for calcination are so high that a bare
metal shell would be destroyed.
• 
The most important physical characteristics of the refractory lining are its ability to
withstand high temperatures and direct chemical attack by the sodium compounds that
are introduced into the kiln with the mud.
• 
The secondary role of the refractory lining is to reduce heat losses through the shell so
that the kiln can be operated with the highest energy efficiency possible.
Selec9on of Refractory Bricks 4 Kiln Refractory Linings
Single Brick Lining
Dual Brick Lining
Metal Shell
Refractory Brick
Refractory Brick
Insulating Brick
Modern kilns typically use a dual lining consisting of a high temperature brick at the inner
hot surface backed by an insulating brick next to the steel shell. The intent of the dual
lining is to minimize shell heat losses.
Selec9on of Refractory Bricks 5 Factors to Consider in Selecting Refractory Materials
•  Resistance to chemical attack (solids and gases)
•  Abrasion resistance
•  Thermal conductivity
•  Resistance to spalling
•  Fusion and softening temperatures
•  Strength
•  Cost
Selec9on of Refractory Bricks 6 Refractory Zones in the Lime Kiln
Burning Zone
(~10 diameters)
©2014 Houghton Cascade
Castable
Selec9on of Refractory Bricks High Duty
Fireclay
(40-50% Al2O3)
High Alumina
(60-70% Al2O3)
7 Kiln Diameter, Dk
Height Dam, hd
Discharge Dam
hd = kDk where k = 0.15 to 0.25
• 
Dams are installed at the discharge of the kiln to increase the depth and heat
transfer to the bed, increase the residence time of the solids, and help to protect the
refractory lining from being overheated in the hottest region of the kiln.
• 
The heights of dams vary between 15 to 25 percent of the inner diameter of the kiln.
More recently, the trend has been to install shorter dams.
Selec9on of Refractory Bricks 8 Cup Tes9ng High Alumina Refractory Bricks Cut test bricks into 5
cm blocks
Selec9on of Refractory Bricks Drill 25.4 mm diameter hole to a
depth of 25.4 mm
9 Cup Testing High Alumina Refractory Bricks
Fill with 50 grams of dried mud
Heat samples to 1500°C and
hold for 4 hours
cool for 12 hours
Section for
examination
Selec9on of Refractory Bricks 10 Cup Testing High Alumina Refractory Bricks
Cross-sectional area used
measure the extent of
chemical reaction
Selec9on of Refractory Bricks 11 Typical Composition of Lime Mud
Mill
Location
Al
(ppm)
Fe
Mg
(ppm) (ppm)
Mill #1
807
506
Mill #2
726
753
Mill #3
92
120
Mill #4
742
691
Mill #5
1010
795
Mill #6
763
1310
Mill #7
1900 2150
Mill #8
376
1040
Average
802
921
†Below limit of detection
Selec9on of Refractory Bricks 2870
3710
1760
2350
5470
2700
6600
5410
3859
Mn
Na
(ppm) (ppm)
43
117
158
81
98
260
210
305
159
7800
8500
7200
5800
6200
11000
7900
7800
7775
P
(ppm)
Si
(ppm)
Total S
(%)
5000
3000
1070
827
2230
2460
6790
7440
3602
910
860
<200†
1300
990
1000
1100
1100
1037
0.09
0.18
0.06
0.12
0.17
0.31
0.33
0.18
0.18
12 Cross-Sections Showing Impact of Mud Compositions on Penetration
70% High Alumina Brick
Mill #1
Mill #5
©2014 Houghton Cascade
Selec9on of Refractory Bricks Mill #2
Mill #3
Mill #4
Mill #6
Mill #7
Mill #8
25 mm
13 Mill$#8$
Mill$#7$
Mill$#6$
Mill$#5$
Mill$#4$
Mill$#3$
Mill$#2$
Mill$#1$
Impact of Mud Composition on Penetration
• 
No relationship between penetration depth of reaction and mud
composition and the area of penetration.
• 
Mud from Mill #1 was used for the cup tests reported here.
Selec9on of Refractory Bricks 14 Cross-Sections for 70% High Alumina Bricks
70%High
HighAlumina
Alumina Brick
70%
Bricks
Brick #2
Brick #1
Brick #4
©2014 Houghton Cascade
Selec9on of Refractory Bricks Brick #3
Brick #5
25 mm
15 Cross-Sections for 60% High Alumina Bricks
60% High Alumina Bricks
Brick #6
Brick #11
Brick #8
Brick #7
Brick #12
Brick #9
Brick #13
Brick #10
Brick #14
©2014 Houghton Cascade
Selec9on of Refractory Bricks 16 Penetration (cm 2)
4
2
0
3
4
5
Selec9on of Refractory Bricks Nike
60 AR
Brick&#11&
Resisto
605
Brick&#12&
Refralusit
Brick&#13&63
Tuff
Zone
Brick&#14&
8
6
7
9
Sample&
Sample Number
Ufala
Brick&#10&
8
Seneca
Brick&#9&60
Mizzou
Brick&#8&
10
Arco 60
Brick&#7&
12
GM 60 D
Brick&#6&
CBBrick&#5&
70 D
2
GMBrick&#4&
70 DE
1
Arco 70
Brick&#3&
Alusa
Brick&#2&
6
Kruzite
Brick&#1&
Penetration for 60% and 70% High Alumina Bricks
70% Alumina Brick
Avg. 8.71 cm2
60% Alumina Brick
Avg. 5.61 cm2
10
11
12
13
14
17 Photomicrograph Showing Unreacted Matrix for High Alumina Bricks
70% High Alumina Brick
60% High Alumina Brick
Brick #1
Brick #12
©2014 Houghton Cascade
A
©2014 Houghton Cascade
M
M
M
M
M
A
M
M
A
M
100 mm
A
M
M
100 mm
M
M Mullite (3Al2O3•2SiO2) A Corundum (Al2O3)
• 
• 
Brick #1 (70% alumina) is made using bauxite and corundum (to meet alumina content).
Brick #12 (60% alumina) is made using Andalusite (naturally occurring mineral that
transforms to mullite when heated above 1000˚C during manufacturing).
Selec9on of Refractory Bricks 18 Impact of Corundum Content on Penetration
Brick
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Classification
70% Alumina
70% Alumina
60% Alumina
60% Alumina
Selec9on of Refractory Bricks Penetration
(cm2)
Corundum
Content
(%)
7.55
8.38
10.38
9.03
8.19
7.61
7.61
5.68
5.74
5.29
4.58
4.19
5.16
4.84
18
18
23
21
18
22
12
8
4
0
0
Trace
Trace
Trace
Corundum is used as starting
material in the manufacture of
these bricks.
19 Cross-Sections for 70% High Alumina Plastics 70% High Alumina Plastics
Plastic #1
Plastic #2
Plastic #3
©2014 Houghton Cascade
In terms of chemical reaction with mud, plastics offer no advantage over bricks.
Selec9on of Refractory Bricks 20 Impact of Temperature on Reaction of Mud with High Alumina Bricks
Test Temperature
Material
1400˚C
1450˚C
1500˚C
70% High
Alumina Brick!
!
!
!
60% High
Alumina Brick
(<10% corundum)
©2014 Houghton Cascade
For high alumina bricks, the mud reacts with the brick to form liquid calcium
alumino-silicates above 1450°C. Once formed, these liquids can readily penetrate
deep into the matrix of the brick leading to rapid erosion and failure of the lining.
Selec9on of Refractory Bricks 21 Chemical Reactions of Soda with Alumina and Silica
Na2O + 2 SiO2 + ≤0.2 Al2O3
Natrosilite (Na2Si2O5) + Liquid
Na2O + 2 SiO2 + ≥0.2 Al2O3
Nepheline (Na2O⋅Al2O3⋅2SiO2) + Liquid
Na2O + ≥0.4 Al2O3 + ≥3.5 SiO2
Albite (Na2O⋅Al2O3⋅6SiO2) + Liquid
Na2O + ≤0.5 Al2O3 + ≤1.5 SiO2
Na2SiO3 + Liquid
Na2O + ≥0.5 Al2O3 + ≥1.5 SiO2
Nephelite (Na2O⋅Al2O3⋅2SiO2) + Liquid
The hot-face temperatures of the bricks are thought to approach 1500oC
which enables the formation of new sodium silicate phases accompanied
by liquid.
Selec9on of Refractory Bricks 22 Lime Coating Protects Refractory Lining
Metal Shell
Refractory Lining
Lime Coating
•  In some kilns a coating of material buildups on the inner refractory wall.
•  These coatings are typically between 2 and 10 cm thick.
Selec9on of Refractory Bricks 23 Temperatures Profiles for the Refractory Lining
38mm 38mm 1600
Shell Backup
Hot Face 180mm
Coating 50.8mm
Above 1450˚C the mud reacts with the
alumina and silica in the brick to form
liquids (rapid erosion)
1400
Temperature (˚C)
1200
1000
800
Maximum working Temperature
Diatomite based insulating bricks are
950˚C
600
No Coating
400
50mm Coating
200
0
0
50 100 150 200 250 300 350
Refractory Lining Thickess (mm)
The presence of a coating helps in keeping both the hot face and insulating bricks
below their maximum working temperatures.
Selec9on of Refractory Bricks 24 1600
Production = 290 t/day
5
1550
4
1500
3
1450
2
1400
1350
1300
66
1
Carbonate
Temperature
Residual Carbonate (%)
Peak Refractory Temperature (˚C)
Impact of Production Rate and Residual Carbonate on the Peak
Refractory Temperatures
0
68
70
72
74
Firing Rate (GJ/tonne)
76
Increasing the firing rate increases peak temperatures of the refractory lining. The
increase in temperature is more pronounced once all carbonate has been completely
calcined.
Selec9on of Refractory Bricks 25 Localized Overheating of the Refractory Lining
Examples of concave heating pit formation (commonly referred to as "duck
nesting") in refractory linings caused by flame impingement on the lining.
Selec9on of Refractory Bricks 26 Cross-Sections for Magnesia Bricks Magnesia Bricks
Romag X
Basic
Narco#1
!
Magnel
BasicWalker
#2 !
Harbison
Radex A
Basic
Radex#3
!
Almag 85
Basic #4 !
Refractechnik
©2014 Houghton Cascade
Magnesia bricks do not react with mud to form liquids at the operating temperatures in
lime sludge kilns.
Selec9on of Refractory Bricks 27 Comparison of Shell Temperatures for Refractory Linings Made Using
Basic and High Alumina Bricks
Shell Temperature (˚C)
600
Uninsulated Basic
500
Insulated High Alumina
400
300
200
100
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Distance Along Kiln (x/kiln length)
0.8
0.9
1
The shell temperatures of the kiln lined with the basic brick are nearly double those
for the kiln lined with insulated high alumina brick.
Selec9on of Refractory Bricks 28 Comparison of Shell Heat Loss for Refractory Linings Made Using
Basic and High Alumina Bricks
Uninsulated Basic
20.0
Insulated High Alumina
2
Heat Flux
Flux (kW/m
Heat
(kW/m)2)
25.0
15.0
10.0
5.0
0.0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Distance Along Kiln (x/kiln length)
0.8
0.9
1
Since the heat transfer due to radiation is proportional to the fourth power of
temperature, the corresponding shell heat losses for kilns lined with uninsulated
basic brick can be as much as four times higher than those lined with insulated high
alumina brick.
Selec9on of Refractory Bricks 29 Infiltration of Basic Refractory Bricks by Volatile Components
Basic refractories do not react with lime mud to form liquids at the operating temperatures
in lime sludge kilns. Physical infiltration of sodium and potassium salts and condensation
is possible. The salt condensation leads to densified horizons in the basic bricks which
become brittle. If the lining is exposed to thermo or mechanical loads, the salt infiltrated
horizons can spall off.
Selec9on of Refractory Bricks 30 Examples of Refractory Bricks Used in Lime Kilns
Density
(gm/cm3)
Thermal
Conductivity
(W/m˚K)
2.8
3.1
2.7
1.7
60% Al2O3
2.6
1.6
40% Al2O3
Super Duty
2.2
1.1
2.1
1.1
1.6
0.6
2.3
1.7
1.6
0.6
0.9
0.2
Classification
Zone
Hot Face Lining
Basic
70% Al2O3
30% Al2O3
High Duty
Burning
Preheating
<30% Al2O3
Low Al2O3 Fireclay
Low Cement Castable
Drying
Backup Lining
<30% Al2O3
Low Al2O3 Fireclay
Diatomite
Selec9on of Refractory Bricks Burning
Preheating
31 Commonly Used Refractory Linings in Lime Sludge Kilns
Conventional Dual Brick Lining
Burning
Dam Outlet Outlet
Preheating
60% Alumina Brick
Super Duty
Drying
High Duty
Castable
Bare Shell
Insulating Brick
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
Dam Outlet Dual Brick Lining with Single Layer of Low Alumina Fireclay in Preheating Zone
60% Alumina Brick
Low Alumina Fireclay
Castable
Bare Shell
Insulating Brick
0
0.1
0.2
Selec9on of Refractory Bricks 0.3
0.4
0.5
0.6
Distance Along Kiln (x/Lk)
0.7
0.8
0.9
1.0
32 Wear Rate (cm/yr)
Brick Thickness Measurements for 60% High Alumina Bricks
Mill #8 Brick #12
Mill #5 Brick #8
Distance Along Kiln (x/D)
• 
The burning zone refractory lining should go 2 to 3 years between major
repairs.
• 
Paying more for bricks does not always improve performance (Brick #12 is
three time more expensive than Brick #8).
Selec9on of Refractory Bricks 33 Refractory Lining for Heavily Loaded Lime Sludge Kilns
Dual Lining Using Magnesia and High Alumina Bricks in the Burning Zone
Burning
Dam Outlet Outlet
Magesite Brick
Preheating
60% Alumina Brick
High Duty
0
0.1
0.2
Selec9on of Refractory Bricks Super Duty
Drying
High Duty
Castable
Bare Shell
Insulating Brick
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
34 Shell Temperature Monitors Should be Used When Making Changes to
the Refractory Lining
Thermal Imaging System
Benefits of Monitoring Shell Temperatures
• 
• 
• 
Detect hotspots on the kiln shell due to refractory lining loss, damage or wear
Detect ring formation
Extend service life of kiln shell and refractory lining
Selec9on of Refractory Bricks 35 Sample Output from Shell Scanner
Temperature Increase Due to
Magnesia Brick upto150°C
Access Door
Access Door
1st Tire
Magnesia Brick
Selec9on of Refractory Bricks 2nd Tire
36 Conclusions
• 
Kilns could not be run without refractory linings because the temperatures required to
calcine the mud are so high they would destroy the metal shell.
• 
Most kilns use a dual brick lining to reduce shell heat losses in burning and preheat
zones.
• 
Insulating the refractory lining can reduce heat consumption by 1.5 GJ/t CaO.
• 
High Alumina (60% or 70% Al2O3) refractory bricks are the most commonly used
materials in hot face of the burning zone.
• 
The use of single component low alumina fireclay refractory bricks in the preheat zone
is gaining more acceptance within the industry.
• 
Magnesia bricks can be use as a means to extend the working life of the refractory
lining in the burning zone for heavily loaded kilns.
Selec9on of Refractory Bricks 37 Final Comments
• 
Optimizing the performance of the refractory lining is an ongoing process.
• 
Care must the take to keep good records
–  Installation (type of refractory and location).
–  Inspection (wear patterns and thickness measurements).
• 
Careful planning of schedule maintenance (avoid patchwork of odds and ends).
• 
Work with the brick suppliers and contractors to insure the refractory lining is properly
installed.
Selec9on of Refractory Bricks 38