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Kiln Mechanical behavior for Patrollers

Content

1 Thermal Expansion 2 Thermal Expansion effects on the shell 3 Thermal Expansion effects

4 Mechanical crankshaft

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Kiln temperature profile


> 110C > 145C > 180C > 215C > 250C > 285C > 320C > 355C > 390C > 425 C

500 Temp: C 450 400 350 300 250 200 150 100

Max Avg Min

Average 250C m
0 10 20 30 40 50 60 70 80 100701 Kiln Mec Behav patroller.ppt 3

How to evaluate Expansion?

Expansionmm

C C TFinal TInitial 1.2 ( ) Lengthinitial ( m ) 100

At 250C, a 70 m kiln is 190 mm longer than at 25C

Temperature must always be taken into account on kilns


On repair/replacement operations On adjustments when done in cold conditions

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1 Thermal Expansion 2 Thermal Expansion effects on the shell


Shrinkage of the tyre on shell Thermal bending

Thermal Expansion effects Mechanical crankshaft

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Shrinkage of the shell into the tyre

Under tyre shell temperature is greater than tyre average temp.


In normal operation .. and more in start-up phase

High risk to shrink the shell at start-up


too quick preheating too small cold clearance value

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

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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

Why this variation (max/min) of temperature in a section?

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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

Expansion at 300 C = 1.2 x (300-20)/ 100 x 12 = 40 mm Differential = 11 mm

Length = 12 m

Expansion at 220 C = 1.2 x (220-20)/ 100 x 12 = 29 mm


Avg. 220 C
100701 Kiln Mec Behav patroller.ppt
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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!
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Thermal bending causes

A defect in coating can lead


To different temperatures on the same section Then to differential expansion Then to kiln thermal bending

When the kiln is not properly rotated

During start-up

During kiln stoppage

When the kiln is not rotated after one incident

Importance of barring drive!

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Thermal bending corrective actions

Modify process parameters

to get proper equal coating

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)

Kiln bent forever (tyre/roller clearance 25mm)


Need for cut or shell replacement
Cost > 100.000 USD Stoppage time needed > 10 days

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1 Thermal Expansion 2 Thermal Expansion effects on the shell 3 Thermal Expansion effects
Girth gear Kiln bearing liner

Mechanical crankshaft

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Girth-gear root clearance increase


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

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Kiln roller bearing


Kilns are generally rotating on roller shaft with liners Few roller bearings because

very high loads and low rotating speed


expensive to design and use

Are there any limits?


Yes, there is a limit of pressure on a liner Special mode of friction, low speed, negative influence

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Kiln roller bearing liner Temperature

Depends on friction -> related to rotation

Most of the torque used to lift the material inside the kiln / Very little converted to heat through the shaft/liner contact

Torque liner about Torque motor x (0.03 to 0.05)

Depends on the load -> related to


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)

In case of severe liner overheating, this torque can suddenly increase

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Expansion effect on Kiln bearing liner


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
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Kiln bearing liner overheating cycle


Viscosity decreases

Overheating

Shaft diam. increases

More wear

Less clearance

Less oil

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Kiln bearing liner -> Emergency procedures

Best method = Oil re-circulation with cooling and cleaning

Small units available on the market with installation on request

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

Cool by air roller flank to limit kiln heat transmission to shaft

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
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Kiln bearing liner -> Musnt

Fan cooling: dangerous on bearing


Housing open = Dust contamination = Be careful! Are you sure you are cooling the shaft or the housing? (think of expansion)

Cool the roller flank with water Water on roller is dangerous

Permanent application or heat shock leads to spalling

Use grease or molycot is forbidden


very dangerous can block the oil pocket, preventing any oil from entering to lubricate liner and shaft

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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

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Content

1 Thermal Expansion 2 Thermal Expansion effects on the shell 3 Thermal Expansion effects

4 Mechanical crankshaft
Misalignment Brick Failure

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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

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Wrong Kiln Alignment

Wrong alignment of shell at erection due to


Subcontractors lack of know-how Deformed new or old shells Not properly chosen shells to be replaced

SHELL ECCENTRICITY OR "CRANKSHAFT" KILN SHELL AXIS UNDER TYRE

POOR ALIGNMENT OF SHELLS

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Wrong Kiln Alignment effects

On a poorly aligned 3-station kiln, tire 2 too high by about 10 mm


Overload = 8 t/mm x 10 mm = 80 t (TC calculation) Permanent load supported by this tire = 80 t higher than normal

Possible problems (depending on design safety coefficient) on


Bearing liners overheating Tyre (wear, holes, crack, )

Rollers (wear, holes, crack, )


Shaft crack Brick failures
Too high load => too high ovality => problem of bricks

Frame cracks
Shell cracks

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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

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Brick Failure effect

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Brick Failure effect

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Brick Failure effect

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Mechanical crankshaft without visual indications


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

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How to check there is a crankshaft?

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

IMPORTANT : To detect a potential problem you must wait for 5 or 6 rotations!!!

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