Rotary Kiln

Mechanical Training

Page 1

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

Page 3

Kiln General

Page 4

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)

Page 5

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

Page 6

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

Page 7

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?

Page 8

Kiln Inlet

Page 9

Low-dust kiln inlet

Page 10

Air cooled segmented inlet through

Page 11

Kiln inlet seal

Seal principle

Page 12

Kiln inlet

Slot adjustment between support ring

and slide ring

Cardanical fastening
Page 13

Air pressure system

Kiln inlet

Page 14

Kiln Outlet

Page 15

Kiln outlet sealing

Page 16

Principle of kiln outlet sealing

Wear ring

Cooling jacket
Slide ring

Wear ring
Pneumatic
cylinder

Cord
Support ring

Page 17

Kiln outlet

Principle kiln outlet

Kiln outlet with dust chute

Page 18

Kiln outlet

Outlet of kiln

Outlet cooling

Page 19

Kiln outlet

Air pressure system

Page 20

Kiln Shell

Page 21

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.

Page 22

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

Page 23

Splined Tires

Page 24

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 %

Page 25

Splined tires

Distribution of forces

First splined tire in 1950

Page 26

Splined tires

Principle splined tire

Splined fixing

Page 27

Splined tires

The Floating Shim

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

Page 28

Splined tires

Kiln shell ovality [%]

Floating tire

Splined tire

Kiln Dia. [m]

Kiln shell ovality

Wedge pre-tensioning device

Page 29

Splined tire

Page 30

Floating Tires

Page 31

Floating (loose) tires

Distribution of forces

Principle of floating tires

Page 32

Floating tires

Steps for radial play reduction

Page 33

Floating tires

Page 34

Comparison of kiln shell ovalities

Splined kiln tire

Floating kiln tire

Page 35

Supporting Roller Station

Page 36

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

Page 37

Roller station

Base frame

Bearing housing
assembly

Roller and shaft

assembly

Guide block

12

Oil level indicator

Page 38

Self aligning roller station for Polro kiln

Page 39

Kiln Drives

Page 40

Girth gear drive system

Bridge support

Bridge plate

3,4

Plate bolts

Girth gear

Heat shield

Page 41

Self-aligning pinion

Permitted tilting: 10 mm

Page 42

Electro-hydraulic drive system

Page 43

Electro-hydraulic drive system

Page 44

Electro - mechanical drive

Page 45

Kiln Hood

Page 46

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

Page 47

Maintenance

Page 48

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

Page 49

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

Page 50

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

Page 51

Maintenance splined tires

Check of splined tire fastening:

Check of wedge pre-tension
Visual check of tire area
Check of welds

Page 52

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

Page 53

Maintenance floating tires

Damages at base plates by defficient lubrication

Page 54

Maintenance / lubrication points

Girth gear

Compressor plant

Oil atomizer

Page 55

Maintenance / lubrication points

Self-aligning pinion and stock bin

Splash lubrication girth gear pinion

Pinion bearing

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

Page 57

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

Page 58

Maintenance / lubrication points

26

Thrust roller

27

Safety thrust roller

28

Slide pin

29

Hydraulic kilns
longitudinal guide

30

Graphite lubrication
equipment

Page 59