Thermal Treatment

Corrosion-resistant furnaces for the use of secondary fuels

The aim of the project is to investigate the interaction between the fireproof, thermal insulation and metallic components of kiln walls in cement plants and the fuel. This is intended to limit or prevent corrosion and thus extend the service life of the plants. 



Mastering the corrosion problems is the prerequisite for the successful and socially responsible use of secondary fuels (combustible waste) in high-temperature plants instead of conventional fuels. Secondary fuels inevitably import undesirable chemical elements that form aggressive compounds during the operating process and destroy the refractory lining of the plants.  Thus, in addition to its economic effect of lower fuel costs, the research project also has the ecological objective of extending the service life of plants, saving materials, conserving resources and reducing CO2 emissions.

The materials to be developed must be resistant to alkaline corrosion and have a durability of several years in the high-temperature processes in the cement kiln. The following should therefore be developed in the joint project:
- new steels with substitution of nickel (use of nitrogen, aluminium and silicon)
- refractory and thermal insulation materials based on calcium silicates or aluminates
- test methods for the temperature and alkali corrosion resistance of the developed steels and insulating materials
- proof of manufacturability and reproducibility of the developed materials.
After the development phase, the materials are tested in a cement kiln under scientific supervision.

- The lifetime of the test fields could be extended from two to three years in the project. This corresponds to a cost reduction of 30% in relation to the area.
- So far, the installation method has been very complex and time-consuming, which makes it difficult to use it on large areas.

More Project Information

Project title: IKOSEZ - Innovative korrosionsbeständige Ofenwandkonstruktionen von Hochtemperaturanlagen für die Verbrennung von Sekundärbrennstoffen, insbesondere in der Zement- und Kalkindustrie

Reference number: 03X3590G

Project period: 2013 - 2016

Project region: Germany

Project contact: This email address is being protected from spambots. You need JavaScript enabled to view it.

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Source: German National Library of Science and Technology Hannover (TIB)