02/12/22

Hot Kiln Alignment

DG Khan Kiln no. 1

The information contained or referenced in this presentation is proprietary to FLSmidth and is protected by copyright law
Kiln characteristics

Kiln Characteristics
Kiln manufacturer UBE
Kiln size (dia. x length) 4.7 x 78 m
Number of supports 3
Position of girth gear Outlet side of support III

Thrust devices
Hydraulic at outlet side of support III, and mechanical at
outlet side of support II
Inclination 4%
Cooler type Grate
Kiln started up first time 1984
Production (present) 3000 tpd
Kiln speed (present) 2.3 rpm
Direction of rotation *) Clockwise

*) The direction of rotation is determined as seen from the kiln outlet towards the inlet, i.e. against the material flow direction.

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Terminology

Right hand side

Left hand side

Numbering of bearings

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The four root causes

1. Kiln axis

2. Kiln shell ovality

3. Kiln crank

4. Axial balance

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The four root causes
- Symptoms and root causes

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 1. Kiln axis

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Kiln axis
 Kiln axis geometry decides on distribution of the weight load among supports and
longitudinal distribution of bending stresses in the kiln shell .

Measurement method

T
T
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 I II III
Kiln axis
- Measurement result

0 +7 0

0 -1 0

Kiln inclination [%]: 4.01

Figure 1 Kiln axis measured.

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Shell bending stress for current axis position

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Kiln axis – Recommended corrections

I II III

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Shell bending stress after recommended corrections

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 2. Kiln shell ovality

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Kiln shell ovality

Kiln shell ovality decides on

distribution of circumferential
bending stress in the kiln shell
and mechanical load on the lining,
i.e. lifetime of the lining

The consequences of excess ovality:

-Lining damage
-Kiln shell damage

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Kiln shell ovality
- Consequence of excess ovality
 Lining damage

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Kiln shell ovality
- Consequence of excess ovality
 Longitudinal kiln shell cracks

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Kiln shell ovality
- Measurement results
  Tyre migration - Ovality  
Support Tyre migration

a
At measured tyre migration At optimal tyre migration [10mm/rev]
no. measurements
0 % M P
0.3 0
Tangential bending Tangential bending

3
  Year 2018 Present Relative ovality,
stress
Relative ovality,
stress

  [mm/rev] [%] MPa [%] MPa

I 37 45 0.36 40 0.26 23
II 0 1 0.17 12 0.24 23
III 11 22 0.30 35 0.20 21

The migration is too high on support I, which is causing

excessive shell ovality.
The migration is too low on support II, which is posing
the risk of shell constriction.
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 3. Kiln Crank

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Kiln crank
If the kiln cross-section centerline doesn't coincide with
its axis of rotation, the kiln is said to have a crank,
which means that if the support loads varies cyclically
during the rotation of the kiln the kiln is said to have a
crank.

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Kiln crank
Two kinds of kiln crank:
 Thermal crank
Thermal crank originates from uneven temperature
distribution in the kiln shell. I.e. in practice, therefore,
thermal crank will always be present in an operating kiln.
Reasons:
Uneven coating thickness/loss of coating
Uneven lining wear/loss of lining

 Mechanical crank
Mechanical crank originates from permanent deformations, e.g.:
• Faulty kiln stoppage procedure
• Thermal overload of kiln shell – hot spot
• Faulty procedure at repair welding
• Bad alignment during welding of kiln shell

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Kiln crank
- Identification
Supporting roller shaft deflection
Support No. Left-hand roller [±mm] Right-hand roller [±mm]

I 0.01 0.01
II 0.03 0.01
III 0.01 0.01

Recorder

FLS Tolerance
max. ± 0.15 mm

Transducer

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Kiln crank
- Thermal crank evaluation

Kiln Shell Temperatures

Tyre no. Inlet side [°C] Outlet side [°C]
Min Max Difference Min Max Difference
I 242 257 15 168 212 44
II 188 290 102 110 150 40
III 207 218 11 216 226 10

Safe temperature difference >100°C.

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Kiln crank
- Kiln shell throw and deformations
Throw of Kiln shell
Magnitude (e) Magnitude (e)
Position (d) [mm] Phase (φ) [°] Position (d) [mm] Phase (φ) [°]
[mm] [mm]
0 Outlet 38000 3.3 325

2000 8.7 63 42000 7.5 295

5300 7.2 57 46000 8.9 291

7000 1.2 50 51000 8.6 279

8000 Tyre I 55000 5.1 271

9000 0.6 110 60000 4.7 267

11000 3.5 245 61000 Gear

15000 3.2 200 62000 3.7 258

20000 6.0 176 65000 1.6 239

24000 6.6 153 66000 Tyre III

28000 7.8 146 67000 1.2 148

32000 2.7 111 69000 3.3 130

34000 1.1 122 72000 8.3 117

35000 Tyre II 75000 10.6 116

36000 0.8 354 78000 Inlet

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Kiln crank
- Kiln shell throw and deformations on
rt i
e d i st o
h a p
l a r s mm
u 8
Circ >

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 Kiln Crank
- Tyre Throw
i mi t
iln l
w k
NTyre Throw.0 mm
e
±1
Support No. [±mm]

I 2.5

II 1.1

III 0.4

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Drive station

Girth Gear Throw

Axial throw [±mm] 1.2
Radial throw [±mm] 2.5

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 Drive station

Pitting marks visible on the edges of pinion teeth and on the working surface
of the girth gear teeth.

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 Drive station

Tooth flanks bear marks of the past bottoming. Slightly burred contact edge
of the girth gear.

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Drive station
Overall condition of girth gear is
good.

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Pinion alignment
Te mpe rature pro file o f le ft pinio n (ºC)
outle t s ide 51.2 52.3 52.7 53 52.1 Inle t s ide

54

53

52

51

50
1 2 3 4 5

Maximum difference below 2°C indicates proper pinon alignment.

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 4. Axial balance

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Axial balance
SFaxial=0

FE

= FE·tan() = -FE·tan()
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Axial balance
- What is affecting the axial balance
 Skewing of supporting rollers
 Inclination of tyre and supporting rollers
 Cylindricity of the rolling surfaces on tyre and supporting rollers

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 Axial balance
- Evaluation of thrust

Evaluation of axial thrust

5 ° C
<
Thrust device
Support No. Direction of thrust Temperature difference

∆T
pressure
      between thrust face and journal in [°C] – (Tf –  
      T1)  

  Left roller Right roller Left roller Right roller [bar]

I Downhill Uphill 3 1
II Uphill Uphill 1 2 80-100
III Downhill Downhill 4.5 1

The overall axial balance of the kiln appears is acceptable.

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 Consequences of excessive thrust

Wear rings – Wear

Support Type Wear ring width [mm] Clearance [mm]
No. a b c d

I C 60 56 18 0
II C 70 70 0 3
III C 58 60 0 12

Axial gap is excessive on support I.

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Axial balance
- Supporting roller inclination
Inclination of tyres and supporting rollers
Tyre Left-hand roller [%] Right-hand roller [%]
Supp. no. Upper
[%] Lower limit Measured Upper limit Lower limit Measured
limit
I 4.02 4.02 3.91 4.04 4.00 3.96 4.02
II 4.01 4.01 4.02 4.03 3.99 4.03 4.01
III 3.97 3.97 3.97 3.99 3.95 3.97 3.97

Inclination of rollers on the outlet support deviates from

the ideal value.

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 Axial balance
- Condition of rolling surfaces

Tyre and supporting roller Surfaces

Supp.
Tyre Rollers
no.
Left 2 mm “S” shaped
I 1 mm convex
Right 1 mm “S” shaped
Left 1 mm concave
II 1 mm convex
Right 1 mm concave
Left
b le1 mm concave

ta
III 1 mm “S” shaped

c ep Right 1 mm concave

A c
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 5. Supplementary observations and measurements

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Tyre diameters

Tyre - Temperature and Diameter

Tyre no. Measurements taken during the inspection Original value
  Temperature measured Diameter at measured Diameter at 20 °C
Diameter at 20 °C [mm]
  [°C] temperature [mm] [mm]

I 140 5661 5653 5650

II 125 5811 5804 5800
III 121 5809 5802 5800

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Supporting roller diameters

Supporting rollers - Temperature and diameter

Supporting Roller Side Measurements taken during the inspection Original value
    Temperature Diameter at measured Diameter at 20°C Diameter at 20°C
    measured [°C] temperature [mm] [mm] [mm]

Left 75 2001 2000 2000

I
Right 77 2000 1999 2000
Left 62 2250 2248 2250
II
Right 65 2250 2248 2250
Left 71 2002 2000 2000
III
Right 73 2001 2000 2000

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 Position of tyres on supporting rollers

Position of tyre I is incorrect on the supporting

rollers.

Position of tyres on supporting rollers

Width of supporting Width of Tyre
Support no. Position of tyres [mm]
roller (WR) (WT)
  S1 S2 S3 S4 [mm] [mm]
I 100 -50 -50 100 850 800
II 0 50 50 0 1050 1000
III 5 45 45 5 850 800

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 Thrust roller

HTD working surface and tyre I face MTD working surface and tyre II
are worn into convex/concave shape face are worn into
by 2 mm. convex/concave shape by 3 mm.

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 Recommendations

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Recommendations
Actions to be taken as soon as possible:
 Improve kiln axis by adjustment as recommended in Section 5.3.
 Order a new set of thinner supporting blocks for tyre II in order to increase the tyre creep.
Actions to be taken during the next kiln shutdown:
 Consider replacement of tyre supporting system on support I for the FLS loosen welded
supporting blocks. This will allow to reduce the excessive migration on tyre I now and adjust it
by shimming in the future.
 Reposition the tyre I to eliminate the offset with the supporting rollers. This action should be
combined with the supporting blocks replacement mentioned above.

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Kiln Inspection

44 Friday, December 2, 202 Comprehensive Hot Kiln Allignment Reporting The information contained or referenced in this presentation is proprietary to FLSmidth and is protected by copyright law
2
Thank you

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