Efficient Corrosion/Erosion-Resistant Linings for Rotary Kilns

Abstract

We studied the service conditions for the lining of the Waelz kilns at the Chelyabinsk Electrolytic Zinc Plant and the Ust’ Kamenogorsk Lead and Zinc Plant, and identified the primary sources of wear on the refractories. Refractory wear inWaelz kilns primarily occurs via a chemical reaction between the refractories and the components of the charge, which is then followed by abrasive wear. PKhPP [periclase-chromite fused grains] and KhPT [chromite-periclase thermal shock resistant] refractories were found to be the most stable under the service conditions in Waelz-kiln linings. The refractories were impregnated with coal-tar asphalt for improved durability. A test batch was produced and tested in the lining of a Waelz kiln. High temperature glue — for Waelz-furnace linings at various non-ferrous metallurgical plants — and mortar — for ceramic joints with better physical and chemical properties throughout the entire lining — were developed. The shape, optimum dimensions, and design of the ceramic products, and brickwork designs based on these products were all studied. The brickwork designs were tested inWaelz kilns at several ferrous and non-ferrous metallurgical plants.