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Content
1 Thermal Expansion 2 Thermal Expansion effects on the shell 3 Thermal Expansion effects
4 Mechanical crankshaft
500 Temp: C 450 400 350 300 250 200 150 100
Average 250C m
0 10 20 30 40 50 60 70 80 100701 Kiln Mec Behav patroller.ppt 3
Expansionmm
Consequences
Shell will be deformed permanently Will possibly lose some bricks Will probably have some problems of fixation Will lead to potential shell cracks in the future
Thermal bending
Variation of Temperature along kiln
400 350 300 250 200 150 100 50 0 0 8 16 24 31 39 is the 47 effect 55 of What this profile of temperature? 63 71
GG Pier Pier Pier door Max Average Min
Thermal bending
Variation of Temperature along kiln
400 350 300 250 200 150 100 50 0 0 8 16 24 31 39 47 55 63 71
Avg. 300 C
Length = 12 m
Thermal bending
Variation of Temperature along kiln
400 350 300 250 200 150 100 50 0 0 8 16 24 31 39 47 55 63 71
12m + 40mm
12m + 29mm
Due to the mass of the kiln, there is still a contact on each pier
.. but load is lighter at central pier and higher at the other one .. and opposite after half a rotation !
If the thermal bending is very high some tyres could even not touch the rollers!
100701 Kiln Mec Behav patroller.ppt
9
To different temperatures on the same section Then to differential expansion Then to kiln thermal bending
During start-up
Barring drive always to be ready to operate If too late, shell replacement: Figuil (Cameroon) Example
Production incident, no barring during 10 min. Tropical rain (which cools only top of shell)
1 Thermal Expansion 2 Thermal Expansion effects on the shell 3 Thermal Expansion effects
Girth gear Kiln bearing liner
Mechanical crankshaft
Girth-gear fixed on the shell Example of a 3-pier 4.6 m diameter kiln with pre-heater: Root clearance increases about 6 mm
Clearance
Kilns are generally rotating on roller shaft with liners Few roller bearings because
Yes, there is a limit of pressure on a liner Special mode of friction, low speed, negative influence
Most of the torque used to lift the material inside the kiln / Very little converted to heat through the shaft/liner contact
Design. (FLS, POLYSIUS, CLE, FCB using approx. same design limit) Quality of geometry and lubrication Alignment of kiln tires Shell axis deformation (permanent or thermal)
When the kiln starts, tyre will heat the roller, then the shaft After 48 hrs, the shaft diameter will be bigger but the liner support will remain cool (water cooling) The expansion of the shaft will reduce the oil film thickness and the contact will increase
SHAFT (HOT)
SHAFT (COLD)
Contact Surface
100701 Kiln Mec Behav patroller.ppt
16
Overheating
More wear
Less clearance
Less oil
In case of small problem, putting the kiln on barring can save you!
Time to decrease shaft temperature, get proper viscosity back, come out of the vicious cycle
Oil usage
The best oil cannot solve contact pattern problems Very thick oil or synthetic oil cannot solve too low clearance between shaft and liner
Check if this synthetic oil can be mixed with mineral Check if this synthetic oil does not chemically attack any bearing part
put the highest viscosity you can, assuming the real viscosity will drop very quickly because of temperature (oil viscosity diagram versus temperature must be known) 100701 Kiln Mec Behav patroller.ppt
18
Housing open = Dust contamination = Be careful! Are you sure you are cooling the shaft or the housing? (think of expansion)
very dangerous can block the oil pocket, preventing any oil from entering to lubricate liner and shaft
Expansion Conclusion
Heat is a very important parameter for kiln shell Attention should be always given to temperatures
Maximum temperature
But also differential
Mechanical staff must take extreme care in case of kiln thermal bending
Content
1 Thermal Expansion 2 Thermal Expansion effects on the shell 3 Thermal Expansion effects
4 Mechanical crankshaft
Misalignment Brick Failure
Kiln Misalignment
As an example on 3 piers, a mechanical bend is one tube which is deformed so the 2nd section is rotating when sections 1 and 3 are perfectly set-up in line
Subcontractors lack of know-how Deformed new or old shells Not properly chosen shells to be replaced
Overload = 8 t/mm x 10 mm = 80 t (TC calculation) Permanent load supported by this tire = 80 t higher than normal
Frame cracks
Shell cracks
Brick Failure
If not followed by stoppage (major cause) Too long run with missing bricks / Too high temperature on the shell with bricks Some indicators
If the circumference of hot-spot is > 90 of the total, it becomes dangerous for the kiln shape, otherwise it will create only local deformations (but still bad) Axial hot-spots are less dangerous than radial
Possible Since kilns are generally very flexible, you may have a crankshaft but as the kiln deforms during rotation, the deformation is not visible Sometimes kilns are affected by several crankshafts in opposite phases
By looking for
Periodical noise at the speed of kiln rotation Periodical motor amperage fluctuation Periodical deflection of roller shaft
If you see a significant radial run-out on kiln seals or on the shell between two piers