Calculate the shim thickness for kiln tires? (Engr.

Tarique)
Cold gap calculation:
If historical temperature information is available, long term averages of shell to tire temperature
differences are a good way to calculate the cold gap/filler bar thicknesses. If so, the filler bar
thicknesses determined by creep reduction can be verified.
Kiln Shell Diameter x Temperature Difference between Tire and Shell x Expansion Coefficient =
Reduction of the Filler Bar to Tire ID Gap (Expansion)
Extra gap (safety factor) = Ave. recorded creep/?
Total gap = Expansion + Extra gap
Average shim thickness = [(Tire I.D. - Shell O.D.) - Total gap]/2
Typically for any tires and shell chairs that are in good condition the tire creep will be in the range
of 6 to 12mm (Migration of tires (Creep) is specific for each tire and is specified in the OEM
documents).
(Ahmad Nilforoushan)
OEMs design the a diameter difference of 3 mm between the live ring dia and the kiln shell OD
which corresponds to relative movement of 3x?. Relative movement determined during the kiln
operation in relation to the kiln rotation does not provide shim plate thickness which needs to be
inserted to check the creep especially if it is on higher side. It has been seen that insertion of shim
based on relative moment calculations may lead to a seizure or very restricted relative movement.
Much accurate method of calculating the shim thickness to be inserted is based on calculation of
tyre expansion and air gaps. Tyre expansion at the inner tyre surface pertains to tyre inner surface
temperature which cannot be measured. This can be back calculated from the tyre outer surface
temperature. The air gap in cold condition is determined by correcting for the tyre expansion and
kiln shell expansion.
(Ashim Bhattacharya)
the simplest way to calculate shim thickness that you have recorded the migration for last three
months and if the migration exceed the limit then you can simply calculate the thickness by the
following formula.
T=Thickness of shim required
V=Average of migration recorded during last three months
10=Amount by which we are going to reduce the migration
so T=V-10/6.28
For e.g
if migration recorded is 35
so T=3.98mm
so we have to insert 2mm shim under all chair plates.
?Aftab Ahmad?
You can determine correcting of old shims according to creep (Hot kiln) in this way, i tell you in an
example:
Your information:
Ave. recorded creep = 40mm/rev, Recommended Creep base on OEM document = 6mm
Needed reduction of creep = (40 - 6) = 34mm/rev
Needed reduction of Tire clearance (Hot kiln) = (34 / ?) = 10.8mm
Needed increased thickness for each shim = (10.8 / 2) = 5.4mm
Then, indicate each one of old shims and its position on shell, and then:
each composition of each old & new shims in specified position will be: (thickness of old shim +
5.4mm), then install composition of each old & calculated new shim with together on specified
position.
(Ahmad Nilforoushan)
It is important that the creep is neither too low (<5 mm) nor too high (>25 mm). Ideally the creep

or migration for any roller stations or pier

of the kiln should be around 8-10 mm suggesting presence of ideal hot air gap (creep/PI=3 mm).
If the creep is not within the range of 5-25 mm (just as a guide only) it will lead to either shell
constraction or excessive flexing of the shell depending on creep value. This in turn leads to premature failure of refractories and in extreme conditions it can even cause shell cracks.
The following steps must be taken to ensure that the creep falls between the above mentioned
limits:
1. The hot air-gap is not less or in excess of 3 mm. If less, reduce the chair pad thickness
appropriately. If high, carry out chair pad shimming or replacement.
2. Ensure the shell and tyre temperatures are close to those considered during chair pad designing.
Daily check the average shell temperatures on either side of tyre as well as tyre temperature. If
necessary,adjust process parameters.
3. Use of proper lubrication for tyre bore (ID) with Lube Bars (wax based graphite bars) only. Use
of grease or other liquid based lubricant attracts dust aggravating chair pad wear causing high
creep.
4. Ensure that the kiln is in well aligned condition. Mis-aligned kiln may exhibit false creep values.
5. Ensure that shell is not allowed to bend and distort due to occurrence of red spot, etc. Bent shell
will not allow the tyre to rest properly on the rollers causing false creep.
?Carlito Tolentino?