回转窑筒体的椭圆度

OvalityofKilnshellOvalityofKilnshell回转窑筒体的椭圆度Content目录1.DefinitionofOvality椭圆度的定义2.Whywepaysomuchattentiontotheovalityofkilnshell为什么我们要如此关注窑筒体椭圆度3MeasuringOvalitywiththeOvalityTester3.MeasuringOvalitywiththeOvalityTester使用椭圆度测量仪测量椭圆度4.TyreMigrationandGap轮带滑移及轮带间隙轮带滑移及轮带间隙5.Howmuchtyregapissuitableforourkiln?我们回转窑的轮带间隙是多少才合适?6.Somethingneedtomention需要说明的一些事情7.Casestudy282y案例研究1.DefinitionofOvality椭圆度的定义DefinitionofOvality椭圆度的定义Twicethedifferencebetweenmaximumandminimumkilnshellradiusduringonerevolution回转窑转动一周期间，窑筒体昀大半径和昀小半径之差乘以2bbaω=2(ab)(mm)Absoluteovality绝对椭圆度Relativeovality相对椭圆度ωr=100ω/di(%)283ω=2(a-b)(mm)ri()di=innerdiameterofkilnshell(mm)di=窑筒体内径(mm)2.Whywepaysomuchattentiontotheovalityofkilnshell为什么我们要如此关注窑筒体椭圆度0.8Upperlimit上限(Overduetyregapandconsequentialwearofrefractory)Refractorylifetimeissignificantlyinfluencedbythemechanicalconditionofkilnshell,i.e.bycontinuousdeformationduringoperation.0.6度(%)0.45(轮带间隙过大,随即耐火砖衬损坏)ygp窑筒体的机械状态对耐火砖衬的寿命影响很大,即窑筒体在运转过程中不断的变形会影响耐火砖衬的使用寿命。Lowerlimit下限0.4Ovality椭圆0.35Basedonempiricalderivedguidelinestheacceptablelimitofovalityinpercentshouldf(riskofconstrictionofkilnshellanddamageofrefractorylining)(有窑筒体被抱死和损坏耐火砖衬的风险)0.20.0notexceedthetenthpartofthekilndiameterinmeters(e.g.diam:5,0m0,50%).基于经验得来的指南，容许的椭圆度限值不应超过以米计的窑直径的kilndiameterinmeters窑直径(m)234567acceptablerange可接受的范围4550容许的椭圆度限值不应超过以米计的窑直径的十分之一百分比(如直径5.0m0,50%).2842.1.Otherwise–theresultofneglecting(1)不然的话-疏忽产生的结果(1)Titdhdfbikki2ndtftthTwistandcrushedofbrickworksin2ndtyreareaafteronemonth新砖衬砌一个月后，2＃轮带区域因椭圆度过大造成的火砖扭曲和碎裂2852.2.Otherwise–theresultofneglecting(2)不然的话-疏忽产生的结果(2)Exaggeratedgapundertyre夸张的轮带下间隙Evencandamageoutletcastable,canyousaythecastablehasqualityproblem?1stHowlargeareatheovalitycaninfluenced.286夸张的轮带下间隙Tyrelocatedin6mfromoutlet甚至会损坏窑口浇筑料，这里能讲浇筑料有质量问题吗？1挡轮带位于距窑口6m处椭圆度过大影响的范围可真不小3.MeasuringOvalitywiththeOvalityTester(1)使用椭圆度测量仪测量椭圆度(1)()(1)Markthemeasuringpointsonkilnshellonbothsideoftyre(1)在轮带两侧窑筒体上标出测量点(2).Thetemperatureofkilnshellandtyrecreepoftyre287装配好的椭圆度测量仪Onecircledividedby120º圆弧120º等分andtyre,creepoftyre.(2).测量相应的窑筒体和轮带温度，轮带滑移量3.1.MeasuringOvalitywiththeOvalityTester(2)使用椭圆度测量仪测量椭圆度(2)()Duringmeasuring,theovalitytesterrotatingtogetherwithshell(redcircle)测量期间,测量仪附着在窑筒体上，随窑转动(见红圈内)。2883.2.OneexampleofmeasuringresultfromtheOvalityTester椭圆度测量仪的测量结果示例The“hotheart”alwaysindicatetheoverduemechanicalstressandshortliningservicelife289yg“火热的心”总是指示着过度的机械应力和很短的砖衬寿命。4.TyreMigrationandGap(1)轮带滑移及轮带间隙Mustbecarriedouttogetherwithovalityanalysis在进行椭圆度测量的同时，要测量滑移量Suitablerange滑移量的适宜范围：g滑移的适范围Upperlimit上限:20mm/revolution每转Lowerlimit下限:10mm/revolution每转Lowerthanlowerlimit,riskofconstrictionofkilnshellanddamageofrefractoryliningcausedbyprocessfluctuationandcoatingfalling.滑移量低于下限因窑内工况波动以及窑皮垮落有窑冷态间隙滑移量低于下限，因窑内工况波动以及窑皮垮落，有窑筒体被抱死和损坏耐火砖衬的风险Higherthanupperlimit,riskofhighershelldeformationandbrickdamagefromoverduedeformationandbrickdamagefromoverduemechanicalstress.高于上限，窑筒体变形大，火砖会因过大的机械应力损坏。热态间隙2810Ifusealternativefuel,pleasekeepitwithin:如果采用了替代燃料，请保持在如下范围：ØD(直径)x(3.14)±3mm4.1.TyreMigrationandGap(2)轮带滑移及轮带间隙磨损前间隙磨损后间隙磨损前间隙磨损后间隙2811磨损的轮带下垫板4.2.Thefixingsystemoffloatingtyreneedmaintaenceregularly浮动轮带的固定系统需要定期维护Differentfloatingtyrefixingsystem不同的浮动轮带固定系统KHDdesignKHD的设计SINOMATDIdesign天津院的设计SINOMANDIdesign南京院的设计28124.3.Anotherwaytomonitorovalityofshell-measuretyrecreep监控窑筒体椭圆度的另一种方法-测量轮带滑移量回转窑运转时，在轮带侧面使用石笔贴着垫板挡块划出一条线（见左图中的白线）图中的白线），而后待窑转动5圈后，测量轮带和挡块端面错开的尺寸，例如100mm，除以5，则轮带与筒体相100mm，除以5，则轮带与筒体相对滑移量为20mm,测量圈数越多，昀终读数误差越小。Remember牢记:Remember牢记:Upperlimit上限:20mm/revolution每转Lowerlimit下限:10mm/revolution每转28134.4.Thecreepmarkonthesidefaceoftyre轮带侧面的轮带滑动痕迹Tyregapduringrunning运转时的轮带间隙Tyrecreep轮带滑移量e.g.aØ4,800mmkilnshouldhaveaclearanceofapprox.4,80mmunderstableoperationconditions.Multiplyingthisvaluebytheidealtyremigration(creep)canbecalculated.AccordinglytheidealcreepvalueforaØ4,80mdiameterkilnshouldbearound15mm/rev(4,80x3.14=15).一把来讲，在热态状态下，在轮带和窑筒体垫板之间的容许间隙应为每米窑径1mm；例如，一台Ø4,800mm2814的回转窑在稳定的运转情况下，应有约4.80mm的(热态间隙)。此数据乘以即可计算出理想的轮带滑移量。相应地直径Ø4.80m的回转窑的理想滑移量应约15mm/每转(4,80x3.14=15)。4.5.Tomonitorcreepoftyre(ovalityofshell)inroutinejob日常工作中监控轮带的滑移量(窑筒体椭圆度)Operatorsshouldcancomeintocircleareatocheckcreep圆圈区域人员应可进入测量轮带滑移量滑移量Thetyrebottomareashouldcouldbeaccessforcreepcheckingandcreepshouldberoutineinspectedp应可接近轮带下部来测量轮带滑移量且应日常检查Andshouldbedonebypersonwhoisresponsibleforrefractory！Tyrecreepshouldbecheckedduringeachkilnheatingupandroutineinspectionandrecord2815responsibleforrefractory！要由耐火材料负责人检查！heatingupandroutineinspectionandrecord轮带滑移量应每次点火烘窑时测量且进行日常测量记录4.6.Onefunctionoftyre-confinethedegreeoffreedomofshell轮带的功用之一-限制窑筒体的自由度28165.Howmuchtyregapissuitableforourkiln?(1)我们回转窑的轮带间隙是多少才合适?(1)()∆t=dØBxfØBxf∆t=Temperaturedifferencebetweentyreandshell轮带和筒体温差轮带和筒体温差d=Theorygapundertyre理论轮带下间隙f=Expansionfactorofsteel钢材热膨胀系数,0.000012ØBOtditfhidtØB=Outerdiameterofshimsundertyre轮带下垫板外直径e=Deformationofshellfromgravity,normallyaround1/1000Dia.窑筒体因自重产生的变形,一般约1/1000窑直径ShelltemperatureisnotthereasonofConstrictionofkilnshell，t