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Case study for Kiln Migration and Effect on Bricks lining

Production Team

1. Ovality and Brick Lining

The Lining life of kiln is significantly influenced by mechanical conditions of kiln. The
difference in diameter between kiln shell and tyre leads to a gap between tyre and kiln shell
which decreases under hot conditions. The relative movement of the tyre and kiln shell is known
as creep or slippage.
The higher the gap the higher will be the ovality and also the creep. The relation is as under
TyreGap [ mm ] =creep [

mm
]
sec

Due to direct relation between creep, tyre gap and ovality the tyre creep can be used for
assessment of the gap between kiln shell and tyre and consequently also the kiln shell ovality

2. Tyre Migration and Gap

Clearance is important in order to allow the kiln shell to expand when heating up without getting
damaged by the tyre. The higher gap under cold conditions is reduced during heating up to
operation temperature, in order to guarantee:

Operation without damages of the brick work from overdue mechanical stresses.
Avoid risk of constriction of kiln shell and damages of the refractory lining during
heating up or due to process instabilities such as flame change or coating falling

3. Tyre Migration and Gap (2)

But once the cheat plates worn down the clearance between the kiln shell and tyre becomes too
large. This leads to

Increased ovality and mechanical stresses.

4. Recommended Creep
Rule of thumb: (under hot conditions)
Kiln Diameter (mm)
=Recommended clearence [mm]
1000
Clearence [ mm ] =Recommended Creep[ mm]

BCL Chakwal Kiln Diameter = 4.8 meter

Recommended Gap (hot conditions) = 4.8 mm
Recommended Creep = 15 mm
The clearance should never become < 3mm! (~ 10 mm/sec tyre creep)
This rule should be followed in particular strictly when firing alternative fuels. A brick structure
per-damaged by infiltrated alkali salts, looses flexibility and is therefore much more sensitive to
higher mechanical stresses.
5. Consequences for high Ovality
I.
II.
III.

Consequences for the lining

Signs of increased mechanical stress
Not only can be damaged

Conclusion
Regular maintenance can prevent from increased or pre-mature wear of refractory lining due to
increased mechanical load.
6. Case study of PC operation on average temperature to reduce fuel consumption
7. New cord rope and its holding pins for kiln inlet seal