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Análise e prevenção de falhas num forno rotativo de satélites localizado na linha de produção de uma empresa cimenteira
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A presente dissertação foi realizada de modo a obter o grau de Mestre em Engenharia
Mecânica. O principal objetivo desta é a análise das falhas existentes num equipamento loca-
lizado numa linha de produção de uma empresa cimenteira, denominada CIMPOR. O equi-
pamento em causa é um forno rotativo com arrefecedor de satélites.
Este equipamento sofre diversas variações térmicas e, consequentemente, esforços ter-
momecânicos, também devidos às suas dimensões, massa e velocidade angular de rotação.
Como tal, pretende-se desenvolver propostas de solução de engenharia para eliminar ou mi-
tigar as falhas detetadas e, assim, aumentar a durabilidade deste equipamento.
Nesta dissertação apenas são analisados os últimos 32 m do forno rotativo com arrefe-
cedor de satélites, ou seja, a zona responsável pelo arrefecimento abrupto do clínquer, através
do conjunto de cachimbos e satélites.
As principais falhas verificadas no equipamento foram: fissuração ao longo do cordão
de soldadura da boquilha à virola do forno; fissuração da virola do forno na zona dos furos
que permitem a saída do clínquer para os cachimbos. A solução proposta para a mitigação
destas falhas foi a implementação de golas de reforço ao redor das boquilhas, de forma a que
haja uma maior distribuição de tensões. Através das simulações numéricas efetuadas verifi-
cou-se que o valor médio de tensão de von-Mises com a implementação das golas era 99,65
MPa. Na simulação sem golas esse valor era 117,25 MPa.
The present dissertation was carried out in order to obtain the Master's degree in Me- chanical Engineering. The main objective is the analysis of the existing failures in an equip- ment located in a production line of a cement company, named CIMPOR. The equipment in question is a rotary satellite kiln. This device undergoes several thermal variations and, consequently, thermal mechani- cal stresses, also due to its dimensions, mass and angular speed of rotation. As such, it is in- tended to develop engineering solution proposals to eliminate or mitigate the detected failures and, thus, to increase equipment durability. In this dissertation, only the last 32 m of the rotary satellite kiln were analyzed, that is, the area responsible for the abrupt cooling of the clinker, throughout satellite coolers. The main failures observed in the equipment were the cracking along the weld bead from the outside nozzle to the kiln ferrule and also cracking of the kiln ferrule in the area of the openings that allow the clinker to exit into the satellite coolers. The solution proposed to mitigate these failures was the implementation of reinforcement pads around the outside noz- zle, so that there is a greater distribution of tensions. Through the numerical simulations car- ried out, it was verified that the average value of von-Mises stress with the implementation of the collars was 99.65 MPa. In the simulation without collars, this value was 117.25 MPa.
The present dissertation was carried out in order to obtain the Master's degree in Me- chanical Engineering. The main objective is the analysis of the existing failures in an equip- ment located in a production line of a cement company, named CIMPOR. The equipment in question is a rotary satellite kiln. This device undergoes several thermal variations and, consequently, thermal mechani- cal stresses, also due to its dimensions, mass and angular speed of rotation. As such, it is in- tended to develop engineering solution proposals to eliminate or mitigate the detected failures and, thus, to increase equipment durability. In this dissertation, only the last 32 m of the rotary satellite kiln were analyzed, that is, the area responsible for the abrupt cooling of the clinker, throughout satellite coolers. The main failures observed in the equipment were the cracking along the weld bead from the outside nozzle to the kiln ferrule and also cracking of the kiln ferrule in the area of the openings that allow the clinker to exit into the satellite coolers. The solution proposed to mitigate these failures was the implementation of reinforcement pads around the outside noz- zle, so that there is a greater distribution of tensions. Through the numerical simulations car- ried out, it was verified that the average value of von-Mises stress with the implementation of the collars was 99.65 MPa. In the simulation without collars, this value was 117.25 MPa.
Descrição
Palavras-chave
Forno rotativo com arrefecedor de satélites Linha de produção de cimento Análise de falhas Integridade estrutural