2.02.burning Zone Coating
2.02.burning Zone Coating
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.
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.
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.