A study on the failure of steel chains in rotary cement kilns

The failure of steel chains which are used in rotary cement kilns costs cement companies a significant price. This study investigated the causes of chains failure at the Kufa cement plant and proposes new materials that can serve for a prolonged period of time. Two grades of steel chains were investigated including DIN 1.4742 (AISI 10F) and St37. Ten samples of chains from different locations from the kiln flame have been taken after 30 days and after 180 days of continuous work inside the rotary cement kiln. To study the effect of the distance from the kiln flame on the DIN 1.4742 (AISI 10F), another two samples have been replaced the St37 grade at a distance of 28.2 m. Chemical analysis for each sample under study has been carried out in order to highlight the differences between the used chain and the original chain in terms of alloying elements weight. An optical images of the unused and used chains of DIN 1.4742 (AISI 10F) steel grade have been taken to understand that the change occurs in the grain size. SEM-EDS technique was also applied to understand the possible segregation of elements. The results showed that the decrease of alloying elements pct, especially Cr, in the microstructure was the main reason of chain failure by corrosion/erosion mechanism. Preventing Cr from segregation can prolong the life of kiln chains during service. The study suggests new steel grades to replace DIN 1.4742 (AISI 10F) and St37 steel grades.