Kiln Training

Rotary Kiln Mechanical Training

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Content: • Kiln General • Kiln Inlet Including Seal • Kiln Outlet Including Seal • Kiln Shell • Splined Kiln Tire • Floating Kiln Tire • Supporting Roller Station • Kiln Drives • Kiln Hood • Maintenance, Lubrication Page 2

POLRO® 2-support rotary kiln

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Kiln General

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Rotary kiln assembly

1 2 3 4 5 6

Rotary kiln shell Kiln inlet with inlet seal Tires with fastening system Supporting roller stations Kiln longitudinal guide Rack and pinion drive

7 8 9 10 11

Guard for rack and pinion drive with lubrication device Kiln drive Kiln outlet with outlet seal Kiln hood Clinkering zone cooling (optional)

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The POLRO 2 - support kiln

• • • • •

splined tires (cold gap 0.4%) self-aligning rollers direct drive via supporting rollers pneumatically applied inlet and outlet seals air cooled kiln inlet tray

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Design of rotary kilns Process - technological dimensions

Kiln with calciner Kiln with preheater 10

12 L/D ratio

14

15

17

Number of stations and L / D ratio 2 - Stations 3 - Stations 3 - Stations 10

12

14 L/D ratio

17

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3 - support kiln versa 2 - support kiln 3-support kiln

Statically undefined

2-support kiln

Statically defined

• possibility of - extreme overload - plastic deformation

• constant support loading

• requirement for - etxra safety margin - regular adjustment

• no sensitivity to misalignment

• elastic deformation only

long enough for process?

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Kiln Inlet

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“Low-dust” kiln inlet

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Air cooled segmented inlet through

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Kiln inlet seal

Seal principle

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Kiln inlet

• Slot adjustment between support ring and slide ring

Cardanical fastening Page 13

Air pressure system

Kiln inlet

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Kiln Outlet

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Kiln outlet sealing

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Principle of kiln outlet sealing

Wear ring

Cooling jacket Slide ring

Wear ring Pneumatic cylinder

Cord Support ring

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Kiln outlet

Principle kiln outlet

Kiln outlet with dust chute

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Kiln outlet

Outlet of kiln

Outlet cooling

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Kiln outlet

Air pressure system

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Kiln Shell

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Description of the kiln shell calculation basics

The shell is a rotating drum made from rolled steel plates. These shell sections have the same inside diameter but different plate thickness. All sections are welded together. The shell thickness is a result of some calculations, the so-called Kiln Static. Basic for the kiln static are some mechanical rules and some limiting factors for the shell material, the so-called Design Criteria. The design criteria for a kiln shell is the Bending Stress. Different kiln areas have different Loads.

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Functions of the kiln shell

• Conveys material • Guides gas from cooler to kiln • Creates a constant moving material bed allows heat exchange between gas and material • Holds the brick lining

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Splined Tires

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Description and function of the kiln tire The tire is a steel ring on the outside of kiln shell. It works as an stiffener for the kiln shell. The kiln tires have to carry the kiln weight. Functions:

 Transfer load from shell to the rollers  Keeps the shell in a round shape  May transfer torque from roller to tire

Design criteria:

 Tire bending stress  Ovality in %

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Splined tires

Distribution of forces

First splined tire in 1950

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Splined tires

Principle splined tire

Splined fixing

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Splined tires

The Floating Shim Plates Form the Connection Between the Tire Teeth and the X-Shaped Retaining Blocks

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Splined tires

Kiln shell ovality [%]

Floating tire

Splined tire

Kiln Dia. [m]

Kiln shell ovality

Wedge pre-tensioning device

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Splined tire

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Floating Tires

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Floating (loose) tires

Distribution of forces

Principle of floating tires

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Floating tires

Steps for radial play reduction

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Floating tires

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Comparison of kiln shell ovalities Splined kiln tire

Floating kiln tire

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Supporting Roller Station

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Description and function of a kiln roller A kiln roller is a steel wheel which is supported on each side. Each tire is supported by two rollers. Functions:

 Transfer load from tires to base plate  Supports tires and keeps them in position  Can transfer torque from rollers to tire  Allows rotation

Design criteria:

 Hertz Pressure  Bearing Pressure

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Roller station

1

Base frame

2

Bearing housing assembly

3

Roller and shaft assembly

5

Guide block

12

Oil level indicator

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Self aligning roller station for Polro kiln

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Kiln Drives

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Girth gear drive system

1

Bridge support

2

Bridge plate

3,4

Plate bolts

5

Girth gear

6

Heat shield

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Self-aligning pinion

Permitted tilting: ± 10 mm

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Electro-hydraulic drive system

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Electro-hydraulic drive system

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Electro - mechanical drive

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Kiln Hood

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Kiln hood 1 2 3 4 5 6 7 8 9 10 11

Lower part of hood Upper part of hood Suspension door Trolley arrangement Burner seal Inspection port Access door Sub plate Collar segment Seal to cooler Opening for measuring socket

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Maintenance

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Maintenance kiln inlet Check points of kiln inlet seal: • Slot between support ring and slide ring • Thickness of the wear ring • Visual check of sealing surfaces • Check for material leakage • Pre-tensioning of sealing robe

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Maintenance kiln inlet

Air pressure net: • Air pressure for pneumatic-cylinder • Check of water separator • Check of lubricator of pressurized air • Check for leakages

Air pressure system

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Maintenance kiln outlet Check of outlet seal: (similar to inlet seal), with additional points: • Graphite lubrication of slide rings • Function of pendling hatch • Clearance of dust chute • Functioning operation of expansion joints

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Maintenance splined tires

Check of splined tire fastening: • Check of wedge pre-tension • Visual check of tire area • Check of welds

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Maintenance floating tires Check of floating tire fastening: • Control of relative movement • Play measurements during stop times • Control of axial retainers • Lubrication of slide surfaces • Check of welds

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Maintenance floating tires

Damages at base plates by defficient lubrication

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Maintenance / lubrication points

1

Girth gear

2

Compressor plant

3

Oil atomizer

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Maintenance / lubrication points

4

Self-aligning pinion and stock bin

5

Splash lubrication girth gear pinion

6

Pinion bearing

7

Rotary kiln drive Page 56

Maintenance / lubrication points

15

Kiln tire

16

Inlet seal

17

Oil atomizer for inlet seal

18

Oil atomizer for outlet seal

19

Cooling air fan

20

Fan for clinkering zone cooling system

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Maintenance / lubrication points

21

Supporting roller bearing station I

22

Supporting roller bearing station II

23

Supporting roller bearing staton III

24

Supporting roller bearing station IV

25

Graphite lubrication equipment

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Maintenance / lubrication points

26

Thrust roller

27

Safety thrust roller

28

Slide pin

29

Hydraulic kilns longitudinal guide

30

Graphite lubrication equipment

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