PSI - Issue 37

ScienceDirect Structural Integrity Procedia 00 (2019) 000 – 000 Structural Integrity Procedia 00 (2019) 000 – 000 Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceD rect Available online at www.sciencedirect.com ScienceDirect

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

Procedia Structural Integrity 37 (2022) 533–539

© 2022 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of Pedro Miguel Guimaraes Pires Moreira Abstract The main objective of the paper herein presented is to analyze an equipment failure in a cement production line, namely the existence of cracking of the concrete inside the cyclone towers (with the fall of this coating). The observed failures are recurrent and responsible for reducing the period between stops of the production line. The equipment is a double cyclone that makes up the fourth stage of a preheating tower; this is composed of a set of cyclones arranged at various levels, which use the hot exhaust gases from the kiln to pre-heat and partially decompose the raw material before it enters the kiln. Cyclones are exposed to high temperatures; for this reason, their metallic structure is covered with an insulating material and a refractory material (concrete). It was identified that the refractory material cracks and falls due to its thermal degradation and due to the temperature gradients, which range from 24ºC to 750ºC. Also, repeated thermal cycling could affect the bond strength between the concrete and the steel reinforcements. One solution passes by developing a new brick support layout that replaces the concrete, taking advantage of the internal steel framework of the cyclones. © 2022 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Abstract The main objective of the paper herein presented is to analyze an equipment failure in a cement production line, namely the existence of cracking of the concret inside the cyclone towers (with the fall of this coating). Th observed failures are recurrent and r sponsible for reducing the p riod between stops of he p oduc ion line. The equipme t is a dou l cyclone that makes p the fourth stage of a preheating tower; this is composed of a set of cyclones arranged at various levels, which use th hot exhau t gases rom the kiln to pre-heat and partially decompose the raw material before it enters the kiln. Cyclones ar exposed to high temperatures; for this reason, their metallic structur is covered with n insulating material and a refractory material (concrete). It was identified that the refractory material cracks and falls due to its thermal degradation du to he temper ture gradi nts, hich range from 24ºC to 750ºC. Also, repeated thermal cycling could affect the bon strength between the concrete and the steel reinforcem nts. One solution passes by developing a new brick support layout that replac s t e concr te, taking adva tage of the internal ste l framework of the cyclones. © 2022 Th Authors. Publis d by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of Pedro Miguel Guimara s Pires Moreira Keywords: Failure Analysis ; Cement Industry ; Preheating tower ; Double-cyclone 1. Introduction Cement production begins in the quarry where limestone and other raw materials are extracted through explosion and drilli g operation; then, the materi l is reduc d to a dimension of less than 40 mm using hammer cr s rs. * Corresponding author. Tel.: +351 212 948 567 E-mail address: rfspm@fct.unl.pt ICSI 2021 The 4th International Conference on Structural Integrity Failure Analysis of a Double-Cyclone located in a Cement Production Line Alexandre Fragoso a , Rui F. Martins b,* , António César Soares c a Nova School of Science and Technology, Department of Mechanical and Industrial Engineering, Campus de Caparica, 2829-516 Monte de Caparica, Portugal b UNIDEMI, Nova School of Science and Technology, Department of Mechanical and Industrial Engineering, Campus de Caparica, 2829-516 Monte de Caparica, Portugal c Cimpor – Cimentos de Portugal, S.A., Praceta Teófilo Braga, Araújo Rato, 2600-540 Alhandra, Portugal ICSI 2021 The 4th International Conference on Structural Integrity Failure Analysis of a Double-Cyclone located in a Cement Production Line Alexandre Fragoso a , Rui F. Martins b,* , António César Soares c a Nova School of Science and Technology, Department of Mechanical and Industrial Engineering, Campus de Caparica, 2829-516 Monte de Caparica, Portugal b UNIDEMI, Nova School of Science and Technology, Department of Mechanical and Industrial Engineering, Campus de Caparica, 2829-516 Monte de Caparica, Portugal c Cimpor – Cimentos de Portugal, S.A., Praceta Teófilo Braga, Araújo Rato, 2600-540 Alhandra, Portugal Peer-review under responsibility of Pedro Miguel Guimaraes Pires Moreira Keywords: Failure Analysis ; Cement Industry ; Preheating tower ; Double-cyclone 1. Introduction Cement production begins in the quarry where limestone and other raw materials are extracted through explosion and drilling operation; then, the material is reduced to a dimension of less than 40 mm using hammer crushers. * Corresponding author. Tel.: +351 212 948 567 E-mail address: rfspm@fct.unl.pt

2452-3216 © 2022 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of Pedro Miguel Guimaraes Pires Moreira 2452-3216 © 2022 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of Pedro Miguel Guimaraes Pires Moreira

2452-3216 © 2022 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of Pedro Miguel Guimaraes Pires Moreira 10.1016/j.prostr.2022.01.119