OVALITY

ANALYSIS
for Kilns &
Other Refractory-Lined
Rotary Units
 KILN SHELL
OVALITY
Definition:
The change of curvature of the shell plate
caused by normal rotation.
The Principle of Distortion
Measurement
O.D. O.D. a

H

b

H
1M
ete

Distorted Cross Section

r
m an
D D

H = a - b
PO

2
4 x OD
Ovality = x H
Data Logger 3
 Ovality
Measurement

tells us

The Mechanical
Stability
of
Refractory
 Manual
Cable & Cable & PODDMAN SOFTWARE

Shipping Case

Heat Shield

PKO-BEAM
 It is the kiln tire
that determines
Thickness the OVALITY of
the kiln shell
Determines
Bending
Strength Face Width
Determines Hertz Pressure

Ovality determines refractory stability

 The tire dictates
the basic shell
OVALITY
but

Where the shell is not supported by the tire

Ovality increases by the size of the gap
The "Normal" Ovality Curve
Curvature more severe
Top of shell

Shell deflection
(+)
(+)
Normal
diamet Right roller
(-)
er
Left roller
(-)

Curvature flat
of normal 0 90 180 270
diameter Top of shell
180 Rotation

270 90
Rotation

Left roller. Right roller

Bottom dead center
0
 Interpretation Of Ovality Curves
Common Characteristics
Rotation
Rotation Rotation

Large
Large
Spread
Spread

1) Heavily loaded or 2) Excessive tire/shell gap 3) Bowed shell

undersized tire (requires at least two curves)

*
Small Spread Right

* * Peaks
Higher
Abrupt
Change of
than Left Curvature
Peaks
4) Underloaded pier or 5) Misalignment: Pier holding shell 6) Cracked shell plate
oversized tire left in relation to adjacent
piers
 Typical Shell Characteristics
Data taken from actual readings
0.80

Abrupt change of
0.60
curvature indicates a
Ovality meter readings in MM

SHELL CRACK
0.40

0.20

0.00

-0.20

Excessive Shell Gap

-0.40

-0.60

-0.80
5 10 15 20 25 30 35 40 45 50 55 60 65 70

Readings for one revolution

 Indication: Differential Shell Slope
0.60

Downhill Curves
0.40
Ovality meter readings in MM

0.20

0.00

-0.20

Kiln shell top center

-0.40 Uphill Curves

-0.60
5 10 15 20 25 30 35 40 45 50 55 60 65 70

Readings for one Revolution

 Some Extreme Shell Characteristics
0.40
Instrument Slipped
Ovality meter readings in MM

0.30

Typical
0.20 Misalignment
Signatures
0.10

0.00

-0.10

-0.20

-0.30
Heat expansion of the beam. PODDman automatically
-0.40 corrects this.
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120

Readings for Two revolutions

 Ovality Measurements
0.6
Ovality meter readings in MM

0.4

0.2

0.0

-0.2 Damaged shell plate

causing erratic and
-0.4 unpredictable curves!

-0.6
3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60 63 66 69 72

Readings for One Revolution

Case Study #1

Kiln Specifications:
Kiln Size:
11'-0" Dia. x 10'-0" Dia. x 270' long
- (3) Pier Design Mfg. By: Allis Chalmers
Ring Size:
157-1/2" O.D., 139" I.D., 22" Face
Roller Size:
42" O.D. x 24" Face
Design Slope:
0.313" /ft.

Kiln Problems: Recommendations:

Mechanical Instability Ovality Analysis
Unsatisfactory Refractory Life Alignment
Replace Ring Support Pads (Filler
Bars)
Recondition Rings and Adjust
Rollers
Case Study # 1
OVALITY CURVE AND FINDINGS
FROM HOT ALIGNMENT - Before Repairs
Ovality meter readings in MM

0.80

0.60

0.40 1.25 MM
Shell Deflection
0.20

0.00
Over 1 Meter Span
-0.20

-0.40

-0.60
Support #1 - DOWNHILL
0 10 20 30 40 50 60 70 80
Case Study # 1
Alignment BEFORE Roller
Adjustments

.320" .030"
LEFT RIGHT .320"
PLAN VIEW LEFT
.010"
LOW

.140"
HIGH .140"
ELEVATION VIEW HIGH
Case Study #1
ACCEPTABLE OVALITY RANGE

0.8
.61% Before .95" Creep
Ovality %

0.6

0.4

0.2

0.0
3.353 Meters 3 4 5 6 7
11' Diameter Kiln Diameter (Meters)
The Cross Section of the Rotary Kiln
 Shell Flattens - Bricks Loosen

2
Shell Pinches Shell Pinches
Bricks Compress Bricks Compress

3 1

Compression and Relaxation

1, 2, 3 Cycles per turn
 Shell Flattens - Bricks Loosen

Shell Pinches
Bricks Compress

3 Cycles per turn x 3 turns per minute x 60 minutes per hour x 24 hours per day

= 12,960 Cycles per Day

Zoom in on Refractory - Before Repairs

GAP IS TOO
Tire
LARGE

Shell
Zoom in on Refractory - After Repairs

Tire
GAP REDUCED
TO NORMAL
Filler Bar + Shim
Shell
Case Study #1
Raw Data Curve - After Repairs
Ovality meter readings in MM

0.80
0.70 Support #1 - DOWNHILL
0.60
0.50
0.40
0.30
0.20
0.10
0.00
-0.10
-0.20
-0.30
0.68 MM Shell
-0.40
Deflection over 1
-0.50
-0.60 Meter Span

0 10 20 30 40 50 60 70 80
Case Study #1
Before and After Raw Data Curves
0.80
Ovality meter readings in MM 0.70
Support #1 - DOWNHILL
0.60
0.50
0.40

Before
0.30
0.20
0.10
0.00
-0.10
-0.20
Repairs
-0.30
-0.40
-0.50
-0.60

0 10 20 30 40 50 60 70 80

Note: Improvement on roller alignment after adjustments.

Support #1 - DOWNHILL
Ovality meter readings in MM

0.50
0.40
0.30
0.20
0.10
0.00 After
Repairs
-0.10
-0.20
-0.30
-0.40
-0.50

0 10 20 30 40 50 60 70 80
Case Study #1
ACCEPTABLE OVALITY RANGE

0.8
.61% Before .81" Creep
Ovality %

0.6

0.4
.43% After .57" Creep
0.2

0.0
3.353 Meters 3 4 5 6 7
11' Diameter Kiln Diameter
(Meters)
 PODDMan
Windows-based data transfer from
instrument to computer

Select Icon on Toolbar to View & Print :

Ovality Summary Table

Ovality Summary Graph (Omega Chart)

Individual or Grouped Data Curves

Choice of Polar Plot or Linear Plot Format

Writes ASCII Data Files for use

by other applications
Data Summary Table

Discharge End

Thickness (mm)
Diametro(mm)

Ovalidad
(%) A
Point
Point B
Point C

Average

Shell Temp 230 246 289 302 245 250

Tire Temp 140 152 146
Tire Creep 16 20 4
Acceptability Range

D U D U D U

1 2 3

% Ovality
A
0.7
B
0.6
C
0.5
0.4
0.3
0.2
0.1
0.0
Linear Graphs

C
Polar Diagrams
Routine Ovality
Measurements
Understand shell behavior
Maximize refractory life

Document:
Ovality measurement
Shell & Tire temperatures
Creep