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    Ovality

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    quỳnh lê
    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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    Ovality

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    55 views17 pages
    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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    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

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    55 views17 pages

    Ovality

    Uploaded by

    quỳnh lê
    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

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 17

    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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