Strategies for reducing cement kiln baghouse corrosion problems

Abstract

The costs associated with corrosion of cement kiln baghouses can be as much as $100000 to $500000 per year for each kiln baghouse, depending upon the severity of the problem. Corrosion is caused by acid attack on carbon steel, resulting from the presence of acid producing compounds in raw material, fuels and additives. These compounds typically contain sulfur and chloride. However, weak acids such as carbonic acid can cause slow corrosion over a long period of time. The costs of baghouse corrosion include: repair of tube sheets and bag collars; repair of walls/hopper; cost of new, replacement dust collector; kiln downtime; bag replacement; environmental permit noncompliance fines; reduced production; personnel morale due to unpleasant task of bag replacement; safety hazards; and management distraction from making cement This paper explores the causes and costs of cement kiln baghouse corrosion. Typical system arrangements are discussed with a focus on identifying key problem areas for each unique system. Ways to identify the cause of the corrosion as well as strategies to reduce corrosion are elaborated on. Finally, four case studies are discussed to detail real world problems and solutions.