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    73 views19 pages

    Holcim Doc Ovality

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    Depoutot David

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    © All Rights Reserved
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    4. INTRODUCTION ‘All over the world, efforts are being made by the cement industry to increase the availabilty of plants and, particulary, the utlisation of kiins, In order to establish how the utilisation of kilns can be increased, the causes of shut-downs must first be analysed. In Table 1.1 @ typical analysis of shut-downs of a characteristic kiln faciity for a period of one year is illustrated. Table 1.1: Analysis of shut-downs Brick fining failures Mechanical failures Electrical failures Although the refractory lining needs not always be the cause of a shut-down, however, the length of the shut-down and, hence, the utilisation factor are significantly a:fecied by the brick lining repairs and rehabilitation, respectively. It is therefore of vital interest for every plant to obtain the iongest possible brick lining service life. ‘The durability of the refractory lining depends on various factors which can be summarised in three main groups (mechanical stability of the brick lining; (2 _ process and general running condition; type of refractory lining and its installation quality, itis well known that the mechanical forces in the radial direction, created by the elastic shell deformation, are of particular significance with respect to the durability of the refractory lin- i ing. Since the radial deformations are proportional to the radial forces itis essential to know the deformation behaviour of a rotary kiln. Consequently, kiin sheil deformation measure- ments have to be frequently carried out. From this point of view, the “Holderbank" kiln shell deformation measuring gauge, called “Shelltest" is a useful tool in kiln preventive maintenance. In the mid-fifties, "Holderbank" started using shell deformation measuring equipment devel- oped by Skanska in Sweden. As the use of deformation measurements gained recognition worldwide, "Holderbank" improved the equipment in the early sixties. The gauges were- equipped with magnetic feet for easy attachment on the rotary kiin and the deformations were logged on a recorder disk, which reproduced the deformation as a clear polar graph for easy and quick assessment. j igs the “Holderbank" Process Technology Division hat Since the beginning of the sev sold over 150 of these "Shelltest" devices both inside and outside the "Holderbank” Group. grated In the protective yoke of the device and, at the same time, the complicated paralieio- gram stylus guide was repiaced by a rack-and-pinion drive, This enabled the scale to be increased from 1:10 to 1:15 (1 mm on the kiln shell = 15 mm on the diagram). Other advan- tages were the significant reduction of the overall height and the weight of only 7 kg. Fi nally, since 1993 modified magnets have been used, the adhesion forces of which have been increased by a factor of 10. : | In 1979, the recorder disk which, until then, had been attached to the outside, was inte- “Shelltest" measurements are an indispensable aid as they allow increased mechanical stresses on the refractory lining of a kiin to be detected at an early stage and damage to the brick lining to be prevented which, as is well known, would lead to a prolonged shut down of the kiln. “Shelltest" records in the form of polar diagrams, taken close to the supporting planes fe- fiect the mechanical condition of the kiln tube. Since the elastic deformations are propor- tional to the bending moments to which the kiln shell is subjected during one rotation, the peak-to-peak stresses also can be estimated from the "Shelitest” diagrams. This option is of particular interest if cracks in the kiln shell are found ang the cause of them has to be ana- lysed. The radial deformation behaviour reflects quite well the mechanical “health” of a ro- tary kiln. Therefore *Shelltest" measurements shouid be taken as a reference data source on newly installed kiins, at least twice a year or before and after kiln shell repair and over- haul work and whenever refractory lining problems occur, ‘The "Shelitest" diagram in a polar graphic form offer the great advantage that interpretation in a quantitative sense is immediately possible, as the diagram curve represents a geomet- fical similar representation of the deformed cross-section, Conclusions can be drawn from the diagrams with respect to; (mechanical effects to the refractory lining in the case of brick failures and/or inade- quate reliability due to mechanical wear and tear, alternating radial shell stress behaviour in case of crack formation in the kiin shell, a assessment of the supporting roller position in relation to the kiln center, (verification of plastically deformed kiln axis due to buckling and hot spots. ‘The evaluation of the diagrams and the preparation of graphical illustrations for proper re- porting is indeed a time-consuming job. Furthermore, in the course of time 2 large number of diagrams and graphical illustrations of measurements are produced and have to be prop erly and systematically stored for quick and easy call-up on demand. This routine works can easily be done by a newly developed PC software "Shellsoft’, by which the diagrams can be stored on the harddisk and diskettes. The software is based on a new type of diagram disk with radial co-ordinates. The mechanically plotted curve can be broken into fifty measurement points, providing digitalised measurement data. The deforma- tion curve can be transferred either manually (via the keyboard) or with the CAD program (ie. AUTOCAD). ‘The calculations and verious graphical illustrations of the results are performed by the PC very quickly However, the beauty of this software is its quick call-up of individual diagrams and graphs, no time-consuming searches through measuring sheets and files, on-line ac- cess to all the measurements taken in the past. No space in the office is necessary to store all the records and diagrams. The manual consists of three main parts: Fundamental knowledge regarding kiln mechanics. (Measuring principle, measuring gauge and evaluation of the records. (Experience and useful hints. ‘This manual can be used as instructions to handle the "Shelltest" gauge and to evaluate the diagrams by “Shellsoft” software as Well as a guide-line whenever refractory lining and me- chanical problems occur, and as a useful means of educating and training the maintenance staff with respect to kiln mechanics. 23 Fig. 2.6 itis clearly shown that an excessive temperature spot of 430°C exists at 36 m, may be 2 coating ring is falien down causing a brick fare. Such so-called hot spots can Cause plastic deformations on the kiln shel, called buckling with subsequent bending of the kiin tube, referring to chapter 2.4. During heating up the kiln tube expands axially and becomes somewhat ionger AL and the shall diameter increases radially AD in accordance with the following basic law Axial increase AL=LoxarxAT [mm] (2.2) Radial increase AD = Do xarx AT [mm] (2.3) where q, = thermal expansion coefficient [mmc] = 12.2 10° AT = temperature rise rc} D, diameter in the cold state [mm) L, = length in the cold state [mm] Some fundamental operating problems have to be connected with the thermal expansion both in radial and axial direction, as discussed in the following, Elastic deformation Beside the axiel defiection of the kiin axis caused by static loading, the kiln cross-section iS subjected to radial elastic deformations when in operation. In Fig. 2.7 the axial deflection and radial deformation are illustrated so that both terms can be clearly distinguished (The radial deformation reaches maximum values in the supporting planes Basoa. and Ininitnum in the middle section between the tyres. However, the radial deformation be- haviour of a rotary kin is an essential factor in kiln operation and depends mamly from the tyre/shell attachment behaviour (clearance) and the radial stiffness of the iyres ‘The radial deformations of the kiln shell are proportional to the radial bending mo- ments to which the kiin shell is subjected during one turn of the kiln (Fig. 2.7, righ) D_inthe tyre section the axial deflection is zero whereas in the mid-section (between two tyres) maximum. values can be noticed Svernca. (Fig: 2.7, left). The deflection DenAy” igur depends on the cistances from the supporting planes and the thickness of the shell A certain degree of flexibility should be achieved by suitable design and dimen” Sioning in order to absorb misalignment of the kiln axis (referring to Tables 2.4 and 2.2) The elastic deformation can be represented by @ s0 called “Shelltest" diagram, shown if Fig, 2.7, bottom, measurements performed with a special type of measuring dex'c® called “Shetiest” gauge. This device allows the racial deformations to be detected under normal running conditions, The measuring principle is very simple, the radial deformation of the Kiln Shall e transferred by a mechanism (feeler pin, recorder) to a diagram chart, during one fm ition the deflection 's recorded and a polar graph is created, ilustrating a geometrically similar representation of the kiln shell, more details under chapter 3. 34 RADIAL DEFORMATION, EFFECTS AND INFLUENCING FACTORS Effects of radial deformations During one rotation of the kiln the shell will take up different curvature radii as shown in Fig. 3.1. This elastic deformation of the kiln shell can be classified as; 2 figing ring deformation in the area of the supporting rollers, caused by the reaction forces Q,, depending of the radial stiffness of the tyre. In case of adequate dimension- ing these deformations can hardly be recognised; 1D _ kiln shell deformations and/or flattening in the apex point due to clearance between shell and tyre. From the above it is seen that the Kiln deformation which occurs during each revolution is highest either in the apex point or in the supporting roller area. As already mentioned (Fig. 2.7) inthe ‘axial direction the deformation is rraximm in the tyre area and minimum in the middle section between two tyres. ‘These deformations of the cross-section of the kiln tube are transferred to the brick lining which, however, is subjected to altemating pressure, affecting its service life significantly as well as the stabiliy of the coating. Due to the continuous change of the curvature radius of the kiin shell, 2 so-called fulling (milling) process is generated. The refractory lining Is ex: posed to a greater surface pressure at its edges which can lead to @ high rate of wear and/or to bricks dropping out. The brick lining in large kilns is particularly sensitive to racial deformation. In targe kilns the coating is usuaily less evenly distributed than in kilns of smaller diameter. in the compara tive table below the normal ranges of cross-sectional mass and heat loading are shown . Table 3.1 Comparison of kiln characteristics =| 700-1200 2700-4 400 ee ca, 10 me ca. 24m ey 2.9-5.0 47-76 Fihemial load: 36Gb i 47-45.0 74-738 lanivalsonsumnionofbecks | Morse] 200i; 50 It is seen thethese specific data are about 45 - 65% higher in the larger kilns. Conse- quently, the’ sensitivity to kiln deformation and general iregularity of operation increases Zasing kiln diameter. The radial deformation is an important factor in kiln operation. (arly monitoring the deformation behaviour of the kiln tube an unforeseen break: of the refractory lining can be avoided. i | | 12 3.2 Determining factors of the radial deformation 3.2.1 Badial stiffness The vertical load Q,, and its associated reaction forces Qq to which the lyre is subjected, Causes radial deformations, whereas in an ideal case the shape of the deformed tyre is as- sumed to be an ellipse. Consequently, the deformation pattem shows maximum values in 42-, 3, 6 and S-o'clock positions, as illustrated in Fig. 3.2, above: According to mathematical analysis the values of the horizontal deflection, expressed by an non-dimensional constants, are tabulated in the Table 3.2. ty Mies 2 pbser end Kamen ‘Table 3.2: Non-dimensional constants of deflection [acc cote NET O.020S ° % OAGZS 0.0212 + © ©2037 9.0205 0-45) GOALS ES el 0.9394 7,024 O, 010892 ‘The deformation 6, of tyres with a solid rectangular cross-section is caleuleted as fellows: Deformation 81 = Crx os se [mm] (3.1) where: C, — non-dimensional constant according to Table 3.2 Q, = total vertical station load NI R= mean radius of tyre [mm] E modulus of elasticity IMPa] J, = moment of inertia = BxH/12 {mmn'] B face width of tyre [mm] H_— = section height of tyre [rnm} . ‘The degree of deformation of 2 tyre js called NiES ovality (/3/, /4/) and is calculated as fotiows: Tyre ovality ora =4%* Stmax QrxR? Exdx = 0.085 x {mm} (3.2) wS Usually the ovality of tyres is expressed in % of the mean diameter (2R): Tyre ovality @rr ord x 100 [%] (3.3) It's illustrated by the above equations that for a given tyre diameter the decisive factor for the radial stiffness is the section height H, because the moment of inertia J, increases with the third power of H. The stiffness requirement is met ifthe calculated ovality @;, < 0.18% “The riding ring stiffness can also be expressed by a simplified term called the stiffness fac- tor ST, which should not exceed approx. 630 MPa corresponding to an ovality Of Or = 0.18%, Between the ovality o,, and the stifiness factor ST, an empirical relationship exists Tyre ovality o7R= é Soon) -0.102 = (4.5 x 10 x STz) - 0.102 [%] (3.4) = stiffness factor [MPa] = section modulus [mm] in Fig. 3.2, bottom, a graph is represented showing the results of a statistical investigation of a large number of tyres from kilns in the "Holderbank" group. It is seen that many tyres do not meet the stiffness criterion, as their section moduli and moment of inertia, respec- tively, are too low. In conclusion, in case of a new kiln project or if a damaged kiln tyre has to be replaced, the dimensioning regarding the radial stfiness should be evaluated by calcutation of the radial stiffness and ovality. If necessary, the section height must be properly adapted to meet the criterion mentioned above. 3.2.2 Clearance between tyre and shell In case of loose riding rings, the riding ring’s inner diameter must always be greater than the outside diameter of the kiln shell in order to compensate the different thermal expansion rates, the kiin shell expands much faster than the tyre. In an optimum case the clearance in normal operation is nearly zero; however, in general there is @ certain clearance of 3 to 10 mmm or mpre, The consequence of a riding ring clearance is looseness of the radial support- ing action and consequently the shell is fiatiening in the apex point. One can say: The greater the operating clearance the greater the radial deformation. In general there is @ tinear relationship between the clearance end the deformation and ovallty, respectively of the cross-section. Because of the great importance of the tyre clear- ance this item will be discussed in more detail in chapter 4 44 3.23 |nfluence of brick lining and coating condition Beside the riding ring clearance and the stiffness of the tyre a third influencing factor on the kiln shell deformation is the refractory lining and the coating condition of a kiln section. The brick lining and the coating itsetf exhibits an inherent stability which significantly increases the radial stiffness of the kiln shell. ‘A rough idea regarding the stiffening effect is flustrated by the following computer analysis (Fig, 3.3). The results are represented by polar graphs, the stiffening effect of the brick lin- ing is taken into account by variation of the modulus of elasticity E. Figures A and C illustrate the radial deformation 5, (mn, left) and the bending stress o, (MPa, right) calculated in the mid-section, figures B and D illustrate radial deformation 85 (rm, left) and the bending moment M, (Nm, right) in the tyre section. Figures A and B represent the deformation behaviour when no brick lining was taken into account, whereas the stiffening effect by the brick lining is considered in figures C and D. “The foliowing can be seen. in the support piane of the Kiln: there is no significant stiffening effect on the deformation and moment pattems by the brick fining. However, in the middle ‘section between two supports that effect is clearty illustrated by the shapes of the radial de- formation. When the stiffening effect of the brick fining is taken into account the deformation is nearly zero (shaped like 2 circle) and the bending stress of the kiln shell is approx. 10 times iower. 3.3. Conclusion From the above it is seen that radial deformation and consequently the stability of the re- fractory lining is mainly influenced by; the radial stitiness of the riding rings as a matter of dimensionin the operating clearance between the riding ring and kiln shell; Q the condition and stability of the brick lining and the coating, ig. 3.4 the shell ovality, expressed in % of the kiln diameter, is shown as a function of the riding ring clearance and the riding ring stiffness for a kiln section with a stable coating and a kiln section where the stiffening effect by the brick lining and coating is poor. This ap- proximation is based on the fact that between the clearance and the ovaiity 2 linear relation: ship exists (see chapter 10.2). However, the radial stiffness of the tyres is a question of design arid dimensioning and itis. important to known it and to check it previously by calculations, whereas the deformation behaviour of the shell is mainly influenced by operating conditions and consequently the op- erating personnel is responsible. 44 45 E OF THE RIDING RING C! LEARANCE “There are two different concepts of riding ring attachment to the Kiln shell (Fig. 4.1): D__Loose riding rings are not fitted direct to the shell but by filler bars (riding ring shoes) which may be arranged loose, fitted by radial and axial retainer blocks, of they are Wolded or bolted to the shell (old design philosophy). The forces are radially Vans: Tenred to the fyre and are concentrated in a small area, One of the difficulties of this system lies in the clearance between shell end tyre under operating conditions, as an excessive clearance allows too much ovality in the kiln shell 1) The toothed fiting system (offered by POLYSIUS and FLS) is designed to overcome the probiems experienced with foose tyres. Itwill be noticed that the Klin shell "hangs" concentrically in the riding ring wih reaction forces being transmitted tangentially and hot radially 2s in sre case of loose tyres. The shellis free to expand in the radial direc- tion, the diametrical clearance has no influence on the shell ovality (For both types of riding rings the same design eriteria are taken into consideration, namely; > the NIES ovality should be kept < 0.18% in order to avoid deformations in the area of the supporting roller and consequently to keep the shell ovality as low as possible; = the Hertzian contact stress should be within acceptable limits, i.e. the operating Contact siress should be clearly below the limiting endurance strength of the material, > the radial bending stress should not exceed the admissible limiting stress 25 2 function of the material strength. In Fig. 4.2 the condition of riding ring shoes after 20 years in operation is illustrated. That kin was operated at a circumferential speed of 30 mvmin, that is 1.7 revolutions Per minute 157-800 000 kin revolutions per year of operation, With an average creep of 18 mm, ie. the kiln tube tums 48 mm faster than the tyre per revolution, that is about 12 km of ereeP per year. For this reason the running surface must regularly be lubricated by a special type of LBM cor idan application range from -20°C to +600°C, Even with lubrication it cannot be corided that in the course of time the shim plates become thinner. According to experene® Gained in the past after about 4-5 years 2 mm wear of the riding ring shoe outer diamefer must be compensated with 1 mm thicker shims. However, some problems were aiso were found on toothed tyres as shown In Fig. 4.3. Dud to excessive tangential forces of a Kiln with planetary coolers, pitting was noticed on the teeth of the tyre after about 15 years in operation. In the meantime the design of toothed fit- fing has been modified to overcome this problem. Basically two different types of cross-section of riding rings are known, namely, LD __ the hollow or sectional type (A'section); (1 the solid rectangular section type. Fe ene 42 16 Older kilns of smaller size are mostly equipped with the hollow type. The advantage of this design is the favourable mass ratio between the iy" ‘and the shell which is of particular sig- oesegnce regarding the thermal expansion behaviour in the heating period of the kiln. Based a he same principal dimensions the radial stiffness of the hollow type is slightly lower than that of the solid section type ‘The following discussion is related to loose riding rings having 2 solid cross-section. In general a clearance always represents a difference in diameter and does not include any a ction of the cross-section. In order to avoid any confusion the following terms must be strictly distinguished (Fig. 4.4): : © Design or cold clearance S.,, difference of the diameters tyre/shell in the undeformed cross-section. Operating or hot clearance Son: the clearance between tyre and shel! at operating seadition causing relative movement between tyre and shell. 1D Cold or hot gap Ge, G,. the gap in 12-0'clock position between tyre and shell In the following the above terms are discussed in more details Design clearance Design or cold clearance is understood to mean the difference between the inner diameter of the riding ring and the outer diameter of the kiln shell (over the riding ring shoes), the kiln cross-section being undeformed (Fig. 4.4 A): Diameter difference AD=Dr- Ds=Sm [mm] (4.1) where: D, = inner diameter of tyre [mm] Dy = outer diameter of shell [mrn} Sy, = design clearance [mm} ‘The design’ clearance must be properly adapted to the thermal expansion rate of the shell and riding ring during heating up 2s well as the temperate variation at steady state. Due Tithe different masses of the shell and riding ring the shell ‘expands much faster than the fiding ring when both are subjected to temperature rise For loosely fitted riding rings the cold clearance S,,, must be selected such that under oper- ating conditions the clearance is minimum (0 < Sx < 3 mm). There is a linear relationship betwoon the temperature difference AT (between tyre and shell) and the diameter differ- ence (between tyre and shell) according to the basic equation 2.3 Diameter difference AD=Doxar~ AT {mm] (4.2) \n Fig, 4.5 the above relationship is graphically ilustrated for Kilns of different sizes (@ 3.5 m2 5 mand @ 6.5 m diameter). For instance, the thermal expansion for a temperature difference of 180°C of akiin of @ 5 mis 9.8 mm. 64 62 22 KILN OVALITY MEAS! \G GAUGE "SHELLTEST" Definition of the term ovality Under ovality of the kiln tube is understood the magnitude or degree of the radial deforma- ton of the cfoss-section under normal operation condition. In a theorefical model, where «the droular kiln shel is deformed to an ellipse, the ovality can be defined as twice the diffe ‘ence of both half axes. From Fig, 6.1 the following terms can be derived: Us = (a+b)xn @ UcsDxn a+baD Circumference ellipse Ue = Circumference circle Uc Based on the above term ovaiity is defined by the following relationship Ovality o=2a-2b=2x(a-b) [mm (6.1) where: a= mayorhalf-axis [mm] b= mayor half-axis [mm] ‘The ovality is a measure of deformation and is used to assess the degree of deformation to which a kiln tube is subjected. The ovality is expressed elther in mm (absolute ovality) or in % of the kiln diameter (relative ovality) However, to determine both axes (a and b) of a deformed cross section of a kin in opera- tion is hardly possible, The determination of the ovality can be performed by a special type of measuring gauge called "Shelltest" “Shelitest” measuring principle “The radial kiln shel! deformation of a rotary kiln under actual operating concitions can be re- corded by means of mechanically based measuring gauge, called *Shelitest’ especially de- Veloped for this purpose, The measuring principle of this instrument can be described as follows, referring to Fig. 6.2. ‘Ayoke (A), provided with two magnet devices (B) at both ends, is fastened to the rotary tile vertically to the center axis, The yoke spans a circular sector with the basic length |= 1 m and a comesponding sector height h. A recorder (C) is provided in the middle of the yoke whose feeier pin (D) is in contact with the Kin shell during the measurement, in the course of one rotation, the kiln shel! is subject to different curvature radii, These cur” yature changes are noticeable by changing of the sector height h, these movements are transferred by the feeler pin via a pencil (E) to a diagram disk (F), scale 1:45. Simones 23 ‘The diagram disk is fastened to the fecorder shaft and kept in place by the effect of gravity of a weight (H) of the pendulum disk (G). As a result, a relative movement takes piace be- tween the pencil and the diagram disk, After one Klin rotation a closed line graph has been produced which represents a geometrically similar representation of the deformed kiln shell. This polar graph is called "Shelitest" diagram or “Shelitest” record. The alteration in the sector height (Ah) during one rotation can be regarded as a measure of the radial deformation and is equal to the greatest difference (6) between the two haif- axes of the diagram curve, magnified 15-fold. “Shelltest" diagrams can above ali be used for qualitative evaluations in a simple manner, because any deviation from the circular form points to the magnitude of the radial deforma- tion. From the location of the curve with respect to the polar co-ordinate system, deforma- tions can be easily located. The vertical axis of the Kiln corresponds to the vertical axis of the diagram, which is marked by means of 2 small hole above the co-ordinate center. Due to the polar representation, the assessment of the deformation behaviour of a shell section is quite simple, because the curve represents 8 geometrically similar representation of the ceformed kiln's cross-section. For instance, it is easy to see if a significant deformation is present in the vicinity of the supporting rollers (this is the case if the riding ring is not rigid enough); or if deformation of the kiln shell is present in the apex point, which points in the direction of too large a riding ring clearance. ‘An actual measurement in the sense of obtaining absolute values does not take place. Only the change in the polar sector height is recorded, whereby only the maximum deflec- tion, i.e. the greatest difference between both diagram ellipse half-axes, is of interest. For the evaluation of the diagrams, the following terms are important: OC) Degree of deformation called ovality « is defined as the 2-fold difference of both half- axes of the elliptically deformed kiln cross-section in accordance with the equation 61. Extent of deformation 6,, the greatest difference between both diagram haif-axes. The mathematical relationship between the ovality a, and the extent of deformation 5, is provided by the following equation: Ovality (abs) a= $x D4 x8s {mm] (6.2) Ovality (rel) @sr=Osax eo (%] (6.3) = extemal diamieter where the gauge is attached Imm} nominal diameter [mm] radial deformation, difference between the greatest and the sammest semi-axis of the diagram curve [mm] 63 24 itis seen from the above equation that the ovality increases with the second power of the kiln diameter, Therefore the ovaiity of 2 Kiln tube is mainly expressed in % of the nominal kin diameter in order lo compare ovality values of different kiln sizes. We distingu ish be- tween the absolute ovality Og {mm and the relative ovatity © [%] There is a linear relationship between the relative ovality @g, the kiln diameter D, and the deformation value &,. In Fig. 6.3 the relationship between the diameter difference (@-») and the absolute ovaity, on the one hand and on the other hand between the deformation bs wes the "Sheltest” ovalty 2s a function of various kiln diameters (2 3.6 m, @ Sm and @ 6.5 m). It is clearly seen that there are linear relationships. For instance, a diameter difference of (e-b) = 15 mm corresponds to an ovality of a, = 30 mam and a deformation of 5, = 1.8 mm (2 3.5 m), 8, = 0.9 mm (@ 5 m) and 6, = 0.5 mm ( © 65 m). in the other direction a deformation of 8,= 0.9 mm corresponds to an absolute ovality vaiue of 14,7 mm (2 3.5 m), 30 mm (2 § m) and 60.7 mm (2 6.5 m). The example has shown that the ovaiity value is significantly influenced by the kiln diameter: “Therefore it makes more sense to express the ovaity in % of the Kiln diameter, Based on the above exemple the following values were found Table 6.1: Deformation and ovality values ‘The above calculation of the relative ovality is based on the following simplified rormula Ovality (rel) osa=3xODnx8ds [%] (6.4) where: 5, = deformation [mm} D,,= nominal kiln diameter [m] Ovality limiting values The increase in the rate of fining wear, the dropping out of lining bricks can be avoided if the shell ovality does not exceed certain limits. The determination of ovalty limits, which can be exceeded only at the perl of damiage, is difficult and depends among other factors ‘on the size of the kiln and the actual coating condition. For medium sized klins, the maximum deformation d of the shell below a riding cing, meaS- vred over 1m of basic fength ("Sheltest’ gauge) should never be more than 0.7 mm, this, however, is considerably smaller tolerance than generally expected. These findings are ex pressed in a graph in Fig. 6.4, above, The figures illustrate the deformation of 0.8 mm % 64 65 25 which is regarded as the limit for a kiln of @ 3 m and 0.65 mm fora kiln of @ 7 m, to avoid any effects on the brick lining. In Fig. 6.4, bottom the above relationship is converted into relative ovality values. It is seen, that for a kiln of 3 m the above limit is approx. 0,3%, and fora kiln of @ 7 m, ap- prox. 0.7%. The upper limit may be applied for a stable coating or 4 new brick lining. Kiln ovality measuring gauge “Shelltest” The “Shelitest" instrument comprises three main parts: The yoke, two magnet supports and the recorder (Fig. 6.5). Parts of the recorder are the feeler pin and the adjusting screw. The supply schedule includes a useful set of accessories. The normal supply schedule in- cludes, among other things two pencils and two knurled nuts. Based on experience these ‘two parts can be damaged when the gauge falls down, The recorder is located in the middle of the yoke, inside the quadrangular tube, Fig. 6.6. Its main parts are the feeler pin, the recorder shaft and the pencil. The movements of the feeler pin are transferred to the pencil via a rack-and-pinion arrangement. The pencil re- cords the deflections on the diagram to scale 1:15. The pencil can be inserted into the hull from the rear and engages in two positions, first in the "off" position (no contact) ang, after a light pressure forward, in the “record” position, the pencil is in contact with the diagram disk, The pendulum disk with the diagram chart is fastened to the recorder shaft by means of a knurled nut. A pin in the shoulder of the recorder shaft serves to secure the diagram against independent rotation in such 2 manner that it penetrates the small hole in the dia~ ‘gram and the slit of the pendulum disk so that the diagram and the disk are fastened and rotate together. The magnet supports are screwed to the two ends of the yoke. if the star handles are loos- ened, the magnet supports can be readjusted by elevating them for roughly adapting the instrument to different kiln sizes. There is a scale to find easily the position of the two mag- nets depending on the kiin diameter, however, the feeler pin must be set in @ middle posi- tion. A micrometer screw is provided to move the feeler pin up and down and allows fine adjustments of the "Shelltest" gauge corresponding to the kiln diameter and the pencil to be brought into a suitable and desirable position on the diagram. The instrument is easily adaptable to kiins with diameters between 2.2 m and 7.5 m. Maintenance and spare parts The instrument hardly requires any maintenance. Only stainless and rust-protected metals were used. However, the only parts which require any attention are the magnets. It is a new type of magnet, the technical data are shown in Fig. 6.7, above. The magnet system exists of two steel plates, whereas in between four cylinder-shaped magnets are focated, each attached by bolts. Each magnet support offers a magnetic ad- hesion of 800 N. A very strong attachment of the "Shelitest” gauge is provided even for un favourable surface condition of the kiln shell, Dismantling of the magnetplates defect in the "Shelltest" gauge. Due to a cleara! t of the yoke itself took place whenever the ga! in. The evaluation of such diagrams make s shown in Fig. 6.7. sent; The above curves illustrate & magnet supports a radial movemen'! 4 the 10-o'clock and the 2-o'clock positio _ Check and tighten the socket-head screws 4 wple 2 ba Ses ltl ee e illustrates the thermal expansion of the gauge due toh feeler pin transfers the expansion to the diagram chart, ¢ t closed and cannot be properly evaluated imment: The above Cur! ition of the kiln shell. The It the diagram curve is no 1600 1200 800 Refractory 400 =~ Shell =~ Tyre AT (Refractory) = ca. 900 °C AT (Shell) = ca. 900 °C AT (Tyre) = ca. 900 °C \TURE PATTERN Fig. 2.4 RIDING RING OVALITY CALCULATIONS ___ Angle of | Coefficient rotation @{'] Gt | 0 0.02 8205 goz7o | +0.0212 180 0.0194 Deformation arx RE Br = OX Fick Stiffness factor sT;=38 {MPa} era Ovality @7a=4x 8tmax = 9 0848 x= (mm) ora=$8x100 [%] TYRE OVALITY VERSUS STIFFNESS FACTOR Er T aT at OVALITY (2 L ft wo 2 x STIFFNESS aN ve “Bis : = $3903 SHI LV GALVBLNSONOO SAOUOS BOHO4 NOLLOVAE =O galnalussia ATIWNDA S308O4 t AVOINOLLWIS 7D q SNldv SUNLVAUND FHL AO NOLLVIEVA SNiOWs ABALVAHNO WHLASN UAL BHL4O SSANS4ILS HOH BUAL SO SSAN4AUS MOT “VBS ONY BAL “TAHS ONY ANAL N3AMLBa FONVAVSTO NBaMI38 SONVEVSIOON =O NOILOSS-SSOND AAWHOASANVAY NOILOaS-SSOND aawuosaann/wadl NOLLVINHOSAG IWIGWH JO SLO3443 eee KILN WEIGHT IS RADIAL SUPPORTED BY A SMALL AREA COLD: CLEARANCE t TOOTHED TYRE ATTACHMENT | —

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