Qualitative and Quantitative Coating Tests: A Comparison in Magnesia-Spinel Refractory Bricks

In cement processing, which involves the production of clinker in rotary kilns, the main refractories used in the transition and burning zones are magnesia-spinel bricks. These bricks present suitable chemical and thermomechanical properties, not to mention that they can be easily landfilled. Among the main wear mechanisms of these bricks in the kiln, the infiltration of alkaline salts is noteworthy and occurs through the open pores of the refractory. In this way, the coating-a clinker layer adhered to the brick surface-appears as a protection mechanism of the lining against infiltration. Thus, the objective of this investigation is to run a qualitative coating test based on the contact method, and quantitative coating test based on the sandwich method to check the suitability of the methodologies and to evaluate the coating adherence on two different magnesia-spinel bricks. It was possible to distinguish the superior adherence ability of brick B in both coatings due to the higher porosity and the presence of nonreacted ZrO2. Despite the similarity between the test results, the quantitative sandwich-coating test is preferable because it does not depend on subjective analysis.