Monitoring and Optimum Alignment of Kiln Axis

Yu Shi a,

Yougang Xiao b,

and

Xuejun Li a

a. College of Mechanical and Electrical Engineering, Hunan University of Science and Technology, Xiangtan, 411201, China;
b. College of traffic and Transportation Engineering, Central South University, Changsha, 410075, China
csuxyg@163.com

Abstract
The rotating center of kiln cross-section can be
measured exactly by displacement measurement along
zero-deformation direction of shell cross-section, whose
measuring principle is studied. In order to distribute kiln
loads evenly and minimize axis deflections, the fuzzy
optimization model of kiln axis alignment is set up. The
results show that fuzzy optimum alignment of kiln axis can
improve kiln performance greatly by making kiln axis as
straight as possible and distributing kiln loads equally.

1. Introduction
Rotary kiln is the key equipment in the industry of
metallurgy and cement. As misalignment of kiln axis can
cause severe economic distress to the owner due to the cost
of wear and premature failure of components, the rotary
kiln industry has responded with various techniques to
monitor and align kiln axis. Using laser targeting, Teskey[1]
developed an electronic theodolite system and applied it to
kiln alignment. Gebhart[2] derived the state of alignment by
direct and continuous non-contact measurement to the
rotating kiln shell. Though it is possible to keep the
average kiln axis error within 1.5mm for the horizontal
plane and within 2.5mm for the vertical plane by applying
these methods, there are difficult to carry on online
monitoring, the error caused by shell deformation alsocant
be eliminated. Support reactions have affected kiln
performance greatly, so it should be considered during kiln
alignment. By analyzing kiln shell deformation, Ross[3],
Andersen [4] drew the conclusion that the deflection of the
shell at the roller position is directly related to the reactions
applied on the support pier. As kiln performance is affected

by kiln axis deflections and support reactions deeply, they

should be considered synchronously during kiln alignment.
Whats more, there exist a lot of fuzzy factors during axis
alignment, so kiln axis alignment is a fuzzy optimization
problem.

2. Monitoring kiln axis

According to the radial deformations at various
angular position of shell cross-section at the supports[5],
maximal tensile deformations are observed along
horizontal diameter. At the bottom of the shell, maximal
compressive deformations are found. But at the angle 15,
the radial deformations of tyre and shell are 0. According
to this accomplishment, displacement measurement
method along zero-deformation direction is developed,
which can measure rotating center of rotary kiln exactly.
The measuring principle is shown as fig.1. In fig.1, o is
origin, which also is the ideal rotating center of shell
cross-section, A, B are the measuring points on shell
cross-section respectively. LA, LB are the distances between
origin and ends of left, right eddy current sensors
respectively. lA, lB are the displacements measured by left,
right sensors respectively. h, t are the vertical and
horizontal deflections of rotating center respectively.
y

o2

o1
h

LA

LB

lA

lB

30 0

sensor
1

sensor
2

key3

4
shell

Fig.1 Deflection measurement at zero-deformation

0-7695-2882-1/07 $25.00 2007 IEEE

Ra = K aY K b Z + C a

Through geometry calculation, t, h can be obtained:

t = 1 . 932 ( L B L A + l A l B )
h =

z zA
( y B2 y A2 ) + ( z B2 z A2 )
t
B
yB yA
2( y B y A )

(1)

where, y A , z A are the vertical and horizontal coordinate

of point A, y A = (LA l A ) cos15o , z A = (LA l A ) sin15o ,

y B , z B signify the vertical and horizontal coordinate of

point B, y B = ( LB l B ) cos15o , z B = ( LB l B ) sin15o .
As the error caused by shell deformation can be

removed due to the measurement along zero-deformation

direction, thus the measure error mainly results from
temperature drift of sensors and the vibration of sensor
brackets. By error analysis, the rotating center of shell can
be measured with an accuracy of 1.5mm horizontally
and vertically, and it is convenient to carry out online
monitoring, so we developed the monitoring systems of
kiln axis based on this method.

Rb = K aY + K b Z + C b

(2)

where
1301.0
14.83 30.39 16.86 1.36 0.06
1383.5
30.39 76.01 61.34 17.68 1.96 ,

K a = 16.86 61.34 79.65 47.78 12.61 Ca = 1329.9

994.7
1.36 17.68 47.78 52.23 20.77
488.5
0.06 1.96 12.61 20.77 10.05

0.11
25.68 52.63 29.20 2.36
1259.7
52.63 131.65 106.24 30.62 3.39
1335.1
,

Kb = 29.20 106.24 137.96 82.75 21.84 Cb = 1276.7

2.36 30.62 82.75 90.47 35.97

937.2
0.11 3.39 21.84 35.97 17.41
467.8
Ra1
R b1
y1
R
R
y
,
,
a
2
b
2

2,

Ra = Ra 3 Rb = R b 3 Y = y 3

y4
Ra 4
Rb 4

R
R
y5
a5
b5

z1
z
2
Z = z3

z4
z
5

3. Roller forces of rotary kiln

Ra, Rb signify the left and the right roller forces (unit: kN),

Kiln shell with

Y
multiple
two-rollers
supports is loose-fitted
in kiln tyre, Each kin
Z
shell
support is made up of
tyre
two rollers and one roller
3030
roller
tyre, the setting angle
of rollers are 30,
which is shown in
Fig.2 Structure of kiln support
fig.2.
The length is 100m, diameter is 4m for No.2 kiln in
Henan Aluminum Ltd. No.2 kiln can be distinguished into
six zones: dry zone, preheating zone, calcination zone,
transition zone, sintering zone, and cooling zone. Along the
zones, the thickness and temperature of the shells are
different. The kiln loads are basically body loads, including
shell, refractory lining, chains, material weight, crust,

Ka, Kb the affected coefficients of roller forces by vertical

toothed ring. According to the structure and temperature

distribution of the shells, considering all kiln loads, the
finite element model was established. Applying the finite
element method of calculating kiln reaction forces[6], we
obtained the fitting formula between the roller forces and
axis deflection of No.2 kiln.

and horizontal axis deflections, Ca, Cb the left and right

roller forces when axis deflections is 0 and Y, Z the vertical
and the horizontal axis deflections respectively (unit: mm).

4. Fuzzy optimization model of axis alignment

4.1.

Design variables
Postulating the alignment values of the vertical and

horizontal deflections are

y i , z i ( i = 1,2,...,5 ).

y i , z i are chosen as design variables.

X = [ y 1 ,..., y 5 , z 1 ,..., z 5 ] T

4.2.

(3)

Objective function
Great axis deflections will affect the lining life

heavily and produce great dynamic load because of great

kiln weight, so the kiln axis should be aligned as straight as
possible. The first and second objective functions are as
follows:
y0i + yi y0 j y j

f1[ X ] = max

l
ij

z0s + zs z0t zt

f2[ X ] = max
lst

i, j = 1,2,...,5, i j
s, t = 1,2,...,5, s t

(4)

where, y 0 i , y 0 j , y i , y j are the initial vertical axis

deflections and their alignment values at i , j supports,
z 0 s , z 0 t , z s , z t are the initial horizontal axis
deflections and their alignment values at s , t supports,
l ij , l st are the distances of i , j and s , t supports
respectively.

5. Solving the optimization model

5.1.

According to fuzzy optimization theory, the fuzzy

constraints of axis alignment can be written as follows:

~
g j (X ) hj

(5)

In order to distribute kiln loads evenly, roller forces

g j is confirmed in amplifying coefficient method,

p j (1 < p j < 2) is its amplifying coefficient and a j its
tolerance. The linear membership function of g j is as
follows:

1,
gj (X) hj

ug j (X) = [(hj + aj ) gj (X)]/ aj hj < gj (X) < hj + aj

0,
gj (X) hj + aj

should be adjusted as equal as possible. For this the

elements in Ra , Rb are integrated into matrix R , whose
largest element is

Rmax , least element is Rmin .

Rmax Rmin is taken as the third objective function.

R = [Ra Rb ]T
f 3[ X ] = Rmax Rmin
T

4.3.
(1)

Constraint

conditions

Alignment values

When the alignment values of axis deflections are too

large, the elastic or plastic deformation of kiln shell will be
great, so the alignment values of axis deflections should be
controlled. Their upper bounds are [Y U ] , [Z U ] , lower
bounds are [Y L ] , [Z L ] . Wave-lines show fuzzy
information.

~
~
[Y L ] Y [Y U ]
~
~
[Z L ] Z [Z U ]

(7)

support cant surpass the permitted value [d i ] .

~
d i = ( y 0i + y i ) 2 + ( z 0i + z i ) 2 [d i ]

(8)

Thus the fuzzy optimization model of axis alignment

of No.2 kiln is as follows:
Find

X = [ y1 ,..., y 5 , z1 ,..., z 5 ] T

min

f [ X ] = [ f 1 ( X ),
~
[Y L ] Y
~
[Z L ] Z
~
d i [d i ]

s.t.

f 2 ( X ), f 3 ( X )]
~
[Y U ]
~
[Z U ]
(i = 1, 2,..., 5)

5.2.

Membership function of objective function

The steps to set up the membership function of

objective function are as follows:
(1) Obtaining the minimums of every individual
objective under loose constraints, namely
i = 1, 2 ,3

min

fi (X )

s.t.

g j (X ) bj + a j

can be obtained.
(2) Confirming the minimum mi and the maximum

M i of every child objective

m i = min f i( X l* ) = f i( X i* )
M

(13)

= max f i( X l* )
1 l 3

(3) Constructing the membership function of every

individual objective
1,
f i ( X ) mi

qi

(
)
M
f
X

i
u Gi ( X ) = i
mi < f i ( X ) < M i
M i mi
0 ,
fi (X ) M i

(14)

(4) Constructing integrated membership function of

multi-objective

F (X ) =
(9)

(12)

Applying complex method, the optimization solution

*
i

1 l 3

(2) Resultant axis deflections

If kin axis deflects from its ideal axis greatly, the
contact status of kiln components will worsen quickly,
therefore the resultant axis deflections d i at every

(11)

where a j = ( p j 1)h j .

(6)

(10)

The bound of fuzzy transition region of constraint

The rollers forces are as follows after kiln axis

deflections are aligned X :
R a = K a (Y 0 + Y ) K b ( Z 0 + Z ) + C
R b = K a (Y 0 + Y ) + K b ( Z 0 + Z ) + C

Membership function of constraint condition

i =1

Gi

(15)

where i = 1, i > 0 .
~
The fuzzy judgment sets D should be the
intersection of fuzzy integrated objective and fuzzy

~
~
constraints. Namely D = F I g~ , so the optimization
problem expressed by Eq. (9) can be changed as follows
u D ( x) =
max
s.t

ug j (X )

(16)

uF ( X )
0 1

The optimization solution X can be obtained by

complex method.

kiln loads equally, so fuzzy optimization alignment can

improve the performances of rotary kiln remarkably, which
will bring great economic benefits to the kiln owner.
For the alignment parameters can be supplied by kiln axis
alignment model, the alignment labor can be reduced
efficiently. whats more, the malfunction caused by
mistaken alignment can be avoided.

8. References
6. Fuzzy optimization results analysis

[1] Teskey, W.F.; Bayly, D.A.; Martell, H.E. Use of laser

At one typical running condition of No.2 kiln, the

vertical and horizontal axis deflections are Y 0 , Z 0 , the
initial left and right roller forces are R a0 , Rb0 . After axis
alignment, the vertical and horizontal axis deflections are
Y , Z , the left and right roller forces are R a , R b . Their
values are shown in table 1.
Table 1

Items

Results comparison before and after fuzzy

optimization of axis alignment

Pier 1

Pier 2

Pier3

Pier 4

Pier 5

/mm

10.9

3.2

-6.5

-3.8

0.5

Z /mm

7.6

4.2

4.7

0.9

10.8

Y /mm
Z /mm
Ra0 /kN
Rb0 /kN
Ra /kN
Rb /kN

2.90
-0.10
1150.6

1.36
-0.34
982.8

1.50
1.09
0.29
1.44
419.6 1723.5

-2.10
3.33
240.0

1330.1

2220.8

1537.4 495.4

709.1

1305.8

1305.8

1305.8 1067.3

447.5

1305.8

1305.8

1305.8 962.4

454.2

According to the table 1, the maximal axis deflection is

at support pier 1, its value is 10.9mm, the linearity of kiln
axis is very bad. The maximal roller forces is at the right
roller at support pier 2, its value reaches up to 2220.8kN,
far above the average loads, and kiln loads distribution is
very uneven. After axis alignment, the maximal axis
deflection is only 2.9mm, and kiln axis have been aligned
as straight as possible. The roller forces at support pier
1,2,3 are equal, their values are 1305.8kN, so kiln
alignment is ideal to distribute kiln loads evenly.
7.

Conclusions

Kiln alignment using fuzzy optimization theory can

make kiln axis as straight as possible and can distribute

targeting in precise machinery surveys. Journal of Surveying

Engineering. 1993,119(2):59-70.
[2] Gebhart, W. Kiln alignment analysis: an overview of the
direct method. Global Cement and Lime Magazine, 2001,53
(11):21-24.
[3] Ross, J. Shell deformation. World Cement. 1994,25(12):20-26

[4] Andersen, N.K. The choice of optimal methodology

and procedure for the correct alignment of rotary kilns and
parameters influencing such choice. ZKG International,
1992,45(1):7-10.
[5] Li Xuejun. Research on theory and technology of health
maintenance for rotary kiln with multi-support. Central South University,
Chang-sha: 2003.
[6] Y.G. Xiao, Y.L. Liu, X.L. Li, X.M. Lei. Finite element
method of calculating reaction forces of large kiln shell with
multi-supports.

J. Cent. South Univ.

37(2)(2006)300-305