A CASE STUDY OF TYPES OF FAILURE IN REFRACTORY BRICKS LINING CEMENT KILNS

The failure of refractory bricks lining cement kilns is a costly process not only due to the cost of replacing bricks but also due to the lost in production time during the replacement period. The present work aims to investigate types and causes of failure of refractory bricks in one of Kufa cement factory kilns using chemical analysis and X-Ray diffraction technique. The results showed that there are detrimental components in raw meal and cement clinker like alkalis (K2O, Na2O) and SO3 which tend to react with lining bricks at high temperatures. Cement clinker infiltrated into the hot faces of magnesia bricks resulting in a formation of a coat layer which protect the brick from spalling. When the kiln operates under equilibrium conditions, the coating maintain itself, otherwise coating will start to come off causing brick corrosion.For all Alumina samples, significant ratios of alkalis are infiltrated into bricks during period of service, the amount of infiltration increased with the ratio of alumina content. X-ray diffraction showed formation of detrimental compounds by reaction between alkalis, sulfur and Alumina bricks. Formation of these toxic compounds was associated with increased volume making the brick more brittle and easy to be damaged by thermo-mechanical stresses.