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2.02.burning Zone Coating

The coating in the burning zone of a kiln protects the brick and shell from high temperatures and abrasion. Coating forms as hot bricks fuse with clinker particles during startup. Each clinker composition has an equilibrium coating thickness. Hard feed can strip the coating while easy feed builds it up. Loss of coating removes brick, requiring restarting the coating process. Kiln shell scanners detect coating changes, allowing corrective action. Shell fans help induce and control coating formation. Maintaining a stable coating is crucial for long brick life and minimizing kiln downtime.

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0% found this document useful (0 votes)
567 views2 pages

2.02.burning Zone Coating

The coating in the burning zone of a kiln protects the brick and shell from high temperatures and abrasion. Coating forms as hot bricks fuse with clinker particles during startup. Each clinker composition has an equilibrium coating thickness. Hard feed can strip the coating while easy feed builds it up. Loss of coating removes brick, requiring restarting the coating process. Kiln shell scanners detect coating changes, allowing corrective action. Shell fans help induce and control coating formation. Maintaining a stable coating is crucial for long brick life and minimizing kiln downtime.

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JCS
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BURNING ZONE COATING

Coatings and Rings:


The coating is the buildup of clinker and dust on the inside of the kiln generally confined
to the burning zone. The coating is necessary to protect the burning zone brick and kiln
shell from the high temperatures and abrasion that occur in the burning zone.

Coating is formed during the start-up operation and consists of particles of clinker and
dust that combine with the soft surface of the heated bricks. During the kiln heating,
before feed reaches the burning zone, the bricks are heated slowly until the surface
softens. At this time the feed coming down the kiln is also reaching fusion point. The hot
soft bricks and the fusing clinker join and cool to start the coating. Coating continues to
build up until the surface reaches the solidifying temperature. The coating formation is
facilitated with an easy burning mix and it is desirable to use such a mix when starting
with new brick or when the old coating has been removed during a shutdown.

For each clinker composition there is a temperature at which equilibrium is reached and a
thickness of coating developed. The coating should stay in equilibrium if the feed coming
into the burning zone and the flame are in equilibrium. Coating becomes unstable due to
the heating and cooling cycles it goes through as the feed changes in quantity and quality,
and as the flame changes to accommodate these changes. Hard burning feed tends to strip
coating; easy burning mixes tend to build coating.

Each time that the coating falls out it removes a part of the brick and the coating process
must be repeated.

Kiln Shell Scanner:


The shell scanner is a very valuable tool in detecting changes in the coating formation.
Shell scanners monitor the temperature on the outside of the kiln shell on a continuous
cycle and can be invaluable in detecting changes in the coating inside the kiln. Early
detection of weak coating allows you to make changes to the burning zone, and take other
corrective actions.

Kiln Shell Fans:


Shell cooling fans are a very good aid to the formation of coating for kilns that have
unstable coating formations. By cooling the shell and refractory brick we create the
conditions necessary for the coating to form. Many cement plants are now using a long
line of shell fans along the length of the burning zone for the purpose of inducing and
controlling the coating in the burning zone.

Brick Life:
The importance of burning zone coating to the life of the brick can not be overstated, not
only is the re-bricking expensive in terms of brick replacement, more important and even
more costly is the loss of production due to the downtime.
Ring Formations:
Excessive coatings in localized areas are referred to as rings. The temperature profile
along the burning zone and the reaction of various raw meal and dust components
combine to build rings. Alkali components are fluxing agents and when these are present
in cyclic amounts alkali rings are formed. It may be possible to change the flame and thus
the temperature profile to cause the ring to burn out, or to cool and fall out by
contraction. If this is not successful it will be necessary to stop the kiln and shoot out the
ring.
Ash rings and cold rings are often formed when the temperature profile and the ash
contained in the coal combine to freeze and form rings usually below the burning zone at
the exit of the kiln. These rings are can be prevented by pulling the burner back and
reducing the amount of cooling zone at the kiln exit.

The Effects of Ring Formations on Operation:


Ring formations are generally detrimental to the operation of the kiln. A ring forms a dam
and impedes the flow of material and the gasses. Material is held back by the ring and if
the ring forms and falls frequently there will be flushes every time the ring falls. Under
these conditions it is difficult to maintain stable operation.

How to maintain the best coating and get the best brick life:
 Always keep the CO in the gasses to an absolute minimum.
 Maintain free limes between 0.6% - 1.2%. Do not over burn the kiln, when the free
lime is below 0.6% the operator should be taking corrective action to cool the kiln.
 Monitor shell temperatures continually to identify problem areas.
 Use shell cooling fans to promote stable coating
 Maintain stable feed chemistry.

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