Thy Tyre – a Critical Section

Cement

ICTM • R.Krischanitz • Nov. 2010

 Introduction

3 41 Basic Brick Types

 Predominant wear mechanisms
in rotary kilns
Outlet/LTZ CBZ UTZ SZ CZ IZ

severe chemical load (infiltration of alkaline salts)

critical chemical load (alkali bursting of non basic lining depending on Alk./S ratio)
thermal load/overheating (clinker melt infiltration)
high thermal load (no coating)
thermal shocks (instable coating)
high mechanical load (lining thrust)
increased mechanical load in the tyre area, depending on ovality
strong abrasion
4 41 Wear Mechanisms
 Tyre Area
The tyre area, one of the most
critical kiln zones, due to the
combination of all three wear
thermal load mechanisms, which increases
the speed of wear dramatically.

chemical mechanical
load load

5 41
 Pre-mature Wear at Tyre Section

6 41 RHI AG
 Clearance
cold condition

hot condition

Clearance is important in order

to allow the kiln shell to expand
when heating up without getting
damaged by the tyre.

7 41 Kiln Shell Ovality

 Clearance
hot condition But once the filler bars are
worn down the clearance
between kiln shell and tyre
becomes too large
 Increased ovality and
mechanical stress

8 41 Kiln Shell Ovality after re-shimming

 Ovality and refractory lining

The lining life of the refractory lining is significantly

influenced by the mechanical condition of the kiln shell.
9 41 Kiln Shell Ovality
 Effects of Increased Mechanical
Load Due to High Ovality

10 41 Basic Brick Types

 Consequences for the lining

An increased ovality leads to

increased mechanical load on the
lining. The consequences are spalling
of hot face brick parts in the area
beneath the tyre (approx. +/- ½ D).
11 41 Kiln Shell Ovality
 Consequences for the lining
Besides of spalling often
also a movement of the
lining can be observed
which also can lead to
damages of the lining.
12 41 Kiln Shell Ovality
In combination of an
increased tyre clearance at
the outlet tyre often an
increased lining thrust in
observed. Leading to
failures at the retaining
ring.
 Consequences for the lining

The torsion effect and bending of the

kiln axis can lead to damages (crack
formation and twisting) of the lining
also outside the tyre area.

13 41 Kiln Shell Ovality

 Not only the refractory also
the equipment can be effected

14 41 Kiln Shell Ovality

 Signs of increased mechanical load

Formation of vertical cracks

(white and red arrows) and a
crumbly microstructure
(circles) at the cold face as
well as scratches (yellow
lines) at the cold face are
clear signs of increased
mechanical load.
15 41 Kiln Shell Ovality
 Recommended Limits

16 41 Basic Brick Types

 Recommended tyre creep and ovality
The ovality of the kiln shell depends on the tyre clearance, the
distance between kiln shell and tyre. The higher the clearance the
higher also the ovality. The acceptable clearance depends on the
diameter of the kiln.
Ideal situation under hot conditions (on the example of a 4,8m Ø kiln):
max. clearance = kiln Ø [mm] /1000
(4800mm Ø  4,8mm clearance)
rec. creep = tyre clearance x  (4,8 x PI = 15,1)
The ideal creep value for a 4,8m diameter kiln should be around
15mm/rev.

17 41 Wear Mechanisms
 Recommended Limits
A too low tyre clearance can
lead to a constriction of the kiln
shell within the tyre especially
during the heating up procedure Restricted thermal expansion of
(ΔTmax = 150 C). the kiln shell by the tyre

In order to reduce the risk of kiln

shell constriction due to a Deformation of the kiln shell
process related change of the
thermal profile (e.g. loss of
coating) of the kiln the tyre
creep should not be lower than
10mm/rev.

18 41 Wear Mechanisms
 Evaluation of Mechanical
Condition

19 41 Basic Brick Types

 Creep measurement
The creep can easily be
easy method to monitor the mechanical
measured by placing a chalk
mark between tyre and kiln
condition of the tyres
shell.
The displacement of the chalk
mark is the creep and is
measured after X revolutions.
This value divided by the
number of revolutions gives the
creep (U) in mm/rev.

The theoretical clearance

between tyre and kiln shell
is U / π.

20 41 Kiln Shell Ovality

 Measurement of creep and tyre clearance

21 41 Kiln Shell Ovality

 Results
Kiln 2 31/ENERO/2005
Tyre 3

h
U

U =creep = 16 mm/rev
h = tyre clearance = 8 mm

Time = 12:15
TEMP. LR = 217 °C
TEMP. DH = 316 °C
TEMP. UH = 329 °C
Δ T = 105.50°C
Revolution / min RPM = 2.16
feed TPH = 186
22 41 Kiln Shell Ovality
 Shelltest Measurement

23 41 Basic Brick Types

 Shelltest measurement
For more detailed information of the mechanical condition of the tyre a so
called Shelltest Measurement should be carried out regularly.
It gives useful information for possible maintenance measures:

 measured ovality in comparison to recommended range

 tyre clearance
 alignment of the support rollers
 load of the support rollers
 alignment of the kiln axis
 permanent kiln shell deformations
 cracks in the kiln shell

24 41 Kiln Shell Ovality

 Definition of ovality
Ovality is the twofold difference between
the smallest and biggest radius of the
kiln shell during one revolution
expressed in percent of the inner
diameter.

b
a

relative Ovality

absolute Ovality ω r = ω ÷ di x 100 (%)

ω = 2 (a - b) (mm)
di = inner Diameter (mm)
25 41 Kiln Shell Ovality
 180°

B C
Definition of ovality 120
°
270° 120 120 90°
° °

Mannloch

A
0°

A
A A
A

27 41 Kiln Shell Ovality

 Application of the measuring beam

For a representative result the measurement has to be carried out under normal
operation conditions (coating conditions, kiln rotation, capacity etc.).
28 41 Kiln Shell Ovality
 Measurement
For the shelltest measurement the device from
Philips kiln services of latest generation is used :
Philips Electronic Ovality Beam.

29 41 Kiln Shell Ovality

 Example of a shelltest
measurement

Mean value of temp. Of the

kiln shell between DH and UH
position minus the temp. of the
tyre. This value should not
exceed 150°C during the
heating up procedure.

30 41 Kiln Shell Ovality

 Summary Graph
Based on numerous investigation a
direct correlation has been
established between kiln shell ovality
and the lining life of the refractory
lining.

The Summary Graph shows if the

measured ovality values are within
the recommended range for the
specific kiln diameter. With this
diagram it is easy to see in which
area are influenced by an increased
ovality.

31 41 Kiln Shell Ovality

 Interpretation and evaluation
%
a b c Maximum.
0.55

0.50

0.45

0.40

0.35

0.30

0.25

0.20

0.15

0.10

Normal Condition: 0.05

The ovality values vary, but the0.00shape of the
curves is widely parallel (no overlapping).
DH UH DH UH DH UH

LR 1 LR 2 LR 3
32 41 Kiln Shell Ovality
 Interpretation and evaluation
%
a b c Maximum
0.55

0.50

0.45

0.40

0.35

0.30

0.25

0.20

0.15

0.10

Deformed Kiln Axis: 0.05

An overlapping of the curves indicates

0.00 a
DH UH DH UH DH UH
distortion or displacement of the kiln axis .

LR 1 LR 2 LR 3
33 41 Kiln Shell Ovality
 Interpretation and evaluation:
Ideal Curve

180°

lower
area

270° 90°

0
Rotation
upper
area
left right 0°
roller roller

0° 90° 180° 270°

Rotation

34 41 Kiln Shell Ovality

 Interpretation and evaluation:
Deviations

0
°

0
35 41 Kiln
° Shell Ovality 0 0
 Conclusions

 The results of the Shelltest measurement can give

useful advises for maintenance measures.
 Regular maintenance can prevent from increased or
premature wear of the refractory lining due to
increased mechanical load.

36 41 Kiln Shell Ovality

 Refractory Solution:
ANKRAL QF

37 41 Basic Brick Types

 New ANKRAL QF
Raw Materials: highest purity synthetic sintered magnesia
fused hercynite spinel + other flexibilizer

Properties:
• excellent corrosion resistance (low amount of CaO and SiO2)
• high resistance to clinker melt (high MgO content and low Al2O3 cont.)
• outstanding flexibility and TSR
due to use of fused hercynite in comb. with MA spinel
• lower thermal conductivity compared to conventional MA spinel bricks
• high refractoriness
• coating friendly due to use of hercynite
Application:
Highly stressed (chemical, thermal, mechanical) LTZ / CBZ / UTZ due to use of AF.
In particular in case of increased mechanical load.
38 41 RHI AG
 ANKRAL QF - References

39 41 RHI AG
 Highlights ANKRAL QF
 Südbayerisches PZW, Rohrdorf, Germany ( 5,2 x 87m SP, 2.500tpd)
Lining area: UTZ tyre, rm 31,6 - 35,6
Lifetime: from 4 months 12 months
 Holcim Rohoznik, Slovakia ( 5,0 x 78m PC (hot disc), 3.600 tpd)
Lining area: UTZ tyre, rm 30 – 35
Lifetime: from 6 months 20 months (still in operation)
 Lafarge Karsdorf, Germany ( 4,6 x 67m SP, 2.200 tpd)
Lining area: LTZ tyre, rm 5- 8
Lifetime: 12 months with res. thickness from 70mm 155mm
 Lafarge Retznei, Austria ( 4,5 x 78m SP, 2.000 tpd)

Lining area: UTZ, rm 31,6 and 24 – 26, 80 – 100% AF

Lifetime: 18 months, stoppage due to failure of competitor brick
ANKRAL QF still 155mm res. thickness
40 41 RHI AG
 Thank you for your attention!

www.rhi-ag.com

41 41 Basic Brick Types