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Kiln Shell Ovality Measurement Guide

Ovality refers to changes in the curvature of a kiln shell, mainly near the tyre areas. It is caused by large gaps between hot shells and cold tyres, worn filler bars, shell deformations from overheating, tyre wobbling, and misaligned rollers. This leads to stresses on refractory lining and spalling of bricks near tyres. Ovality is calculated and should not exceed 10% of the kiln's diameter. Measures to address ovality include frequent monitoring, replacing worn tyre shoes, using shims, and flexible refractory bricks. The Holderbank device records ovality and slip must be kept below 1/200 of the diameter through reducing tyre clearance with sh

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525 views17 pages

Kiln Shell Ovality Measurement Guide

Ovality refers to changes in the curvature of a kiln shell, mainly near the tyre areas. It is caused by large gaps between hot shells and cold tyres, worn filler bars, shell deformations from overheating, tyre wobbling, and misaligned rollers. This leads to stresses on refractory lining and spalling of bricks near tyres. Ovality is calculated and should not exceed 10% of the kiln's diameter. Measures to address ovality include frequent monitoring, replacing worn tyre shoes, using shims, and flexible refractory bricks. The Holderbank device records ovality and slip must be kept below 1/200 of the diameter through reducing tyre clearance with sh

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Kiln shell ovality and measurement

Vietnam Seminar, November 21-22, 2011


REFRATECHNIK Asia Ltd. Hong Kong
Matthias Franke
Ovality terms and aspects

Ovality: - change of curvature of the kiln shell Æ main occurrence in


vicinity of tyre areas

Cause: - large gap between cold tyre and hot kiln shell leading to slip,
- increased tyre clearance due to worn out filler bars,
- shell deformations after overheating / shrinkage,
- tyre wobbling,
- misalignment / pressure of the rollers

Result: Deterioration of refractory lining


Ovality reasons

1. rotation,
2. kiln shell / lining weight,
3. shell deformations and
4. roller pressure
Stresses on refractory lining
Movements inside of the brick arch
Mechanical stress leads to shearing of the brick heads

releasing squeezing
Consequences of ovality

spalling of bricks
near the tyre area

deep spalling of single bricks in-between an intact lining


Spalling of brick heads due to mechanical stress
Calculation of ovality

ϖ = 4/3 x D2 x σ x 100 (%)

(ϖ < 1/10 D)

ϖ = Ovality

D = Diameter of Kiln

σ = Greatest deflection value from Shelltest

Ovality should not exceed 1/10 = 10% of the kilns internal diameter!
Ovality counter measures:

– Frequent monitoring of ovality and slip,


– Replacement of worn out tyre shoes,
– Shimming of fillerbars,
– Full mortar lining,
– Installing highly flexible refractory brick grades such as:

¾ TOPMAG A1
¾ ALMAG 85
Holderbank Ovality Device

introduction 1973/74
Mounting with magnets
Polar graph
Heavy weight item
Indicator

Recording Disc Pencil


Flattening

Labeled paper disk

Roller impression
Imperative necessity
compensation difference of thermal expansion between shell and tyre

Tyre

Filler bars
clearance too large -> increased slip

Shell
Reducing the gap between tyre & shellÆ tyre clearance should be within a range of 4 – 8mm!

GAP REDUCED
Tyre
TO NORMAL
Filler Bar + Shim
Shell
Execution of slip measurement

• marking of measuring points at tyre and shell


• measuring of the emerging distance
• calculation of the slip and clearance
• determination thickness of shims to reduce clearance

maximum slip ΔU < 1/200 x D

(D= 4,2 m -> ΔU= 21 mm per revolution)

ΔU = slip = ΔX / N

ΔX = slip after N rotations


N = number of rotations
Chalk marking of shell and tyre Measurement of slip

ΔX
Determination of clearances
Clearancetheoretical = STH = DT – DS (cold status)

DT = diameter of tyre
DS = diameter of shell

Clearance operational = Sop = ΔU / π (hot status)

thickness of shim to insert tS = (SOP – 3) / 2


(1 mm thickness of the shim reduces slip by 10 mm, fixed by spot welding)

Calculating ovality based on the operational clearance

ϖ = 0.0396 SOP + 0.0865

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