NEW GRUPPA MAGNEZIT CHROMITE-PERICLASE REFRACTORIES
FOR A ZINC PRODUCTION WAELZ KILN
T. V. Yarushina,
V. V. Smertin,
D. Yu. Yazovskikh,
I. G. Maryasev,
A. I. Aparin,
and Yu. P. Shlemov
Translated from Novye Ogneupory, No. 6, pp. 114 – 121, June 2011.
Original article submitted May 12, 2011.
Results of research work performed by Gruppa Magnezit are provided for prolonging the campaign of a zinc
production Waelz kiln. Research into the corrosion resistance of refractory objects by a charge, consisting of
ore and coke, is used to select the substance composition and development of technology for chro-
mite-periclase refractory production that is inert towards Waelz material components. Service tests show that
use of new refractories within the reaction zone of a Waelz kiln lining provides stable performance for the pro-
duction process with high productivity and an increase in the time between repairs.
Keywords: Waelz kiln, reaction zone, zinc-containing clinker, chromite-periclase refractory.
Waelz kiln lining refractories for the production of zinc
oxide concentrate operate under chemical and abrasive con-
ditions of the charge being treated. In a Waelz kiln there are
four zones: drying, sulphate decomposition, reaction, and
The main reasons for wear and breakdown of refractory
objects in a Waelz kiln are mechanical loads, which arise
during kiln rotation and deformation of its body, wearing by
Waelz material, periodic thermal shocks (heating with an
open flame, stoppage of a hot kiln) and heating of material,
and chemical action of a reaction mass.
Chamotte objects are used for lining a kiln in drying and
sulphate decomposition zones. In order to make the working
layer of the reaction zone lining, within which temperature
reaches 1300°C, and in zones of clinker formation of a Waelz
kiln 5 m in diameter and 75 m long, the Waelz workshop for
zinc cake of TOO Kaztsink traditionally uses refractory ob-
jects grade KhPTU produced by OAO Kombinat Magnezit.
Since in operation there is a change in chemical and mineral
composition, not only of the Waelz charge, but also lining
refractories, and also their physicomechanical properties
(thermal conductivity, abrasive wear resistance, etc.), then
the service life of a chromite-periclase lining is normally
limited and is from 250 to 320 days.
In order to increase the service life of a Waelz kiln lining
for zinc production, with guidance of technological develop-
ments of Gruppa Magnezit scientific research work has been
carried for choice of refractory, most resistant to the action of
Waelz charge components.
STUDY OF WEAR OF STANDARD KhPTU OBJECTS
IN A REACTION ZONE AND IN THE ZONE
OF WAELZ KILN CLINKER FORMATION
In order to study the nature of reaction of zinc-containing
clinker with chromite-periclase objects after installation in a
Waelz kiln for repair from the 16
(reaction zone) to the 29
meter (clinker formation zone) specimens of KhPTU
refractories, used traditionally for lining, were selected.
Petrographic analysis of objects was carried out, whose re-
sults make it possible to assess the chemical nature of lining
A study of refractory corrosion in a Waelz kiln showed
that lining wear over the length of a kiln is uneven: wear in
the clinker formation zone exceeds the degree of wear in the
reaction zone. This is due to the fact that at 1100 – 1250°C
fayalite and matte components are in a liquid phase, their
density is higher than coke fines, and therefore melt within
the reaction zone falls to the layer adjacent to the lining, and
A change in the skull thickness over the kiln length
points to a change in clinker consistency from a flowing liq
uid with inclusions of iron metal in the 16
meter to ductile
Refractories and Industrial Ceramics Vol. 52, No. 3, September, 2011
1083-4877/11/05203-0216 © 2011 Springer Science+Business Media, Inc.
OOO Gruppa Magnezit, Satka, Chelyabinsk Region, Russia.
TOO Kaztsink, Ust’-Kamenogorsk, Kazakhstan.