Kiln Mechanics

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L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt
140 TEI, 140 CD
Rotary Kiln
Mechanical Training
Krupp Polysius Corp.
Page 2
140 TEI, 140 CD
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
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140 TEI, 140 CD
POLRO 2-support rotary kiln
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140 TEI, 140 CD
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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140 TEI, 140 CD
Design of rotary kilns

P r o c e s s t e c h n o l o g i c a l d i m e n s i o n s
K i l n w i t h c a l c i n e r K i l n w i t h p r e h e a t e r 1 0 1 2 1 41 5 L / D r a t i o 1 7
N u m b e r o f s t a t i o n s a n d L / D r a t i o
2 S t a t i o n s 3 S t a t i o n s 3 S t a t i o n s 1 0 1 2 1 4 L / D r a t i o 1 7
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140 TEI, 140 CD
3 - support kiln versa 2 - support kiln

3-support kiln 2-support kiln
Statically undefined possibility of - extreme overload - plastic deformation requirement for - etxra safety margin - regular adjustment
Statically defined
constant support loading elastic deformation only no sensitivity to misalignment long enough for process?
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Kiln Inlet
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140 TEI, 140 CD
Low-dust kiln inlet
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140 TEI, 140 CD
Air cooled segmented inlet through
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140 TEI, 140 CD
Kiln inlet seal
Seal principle
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140 TEI, 140 CD
Kiln inlet
Slot adjustment between support ring and slide ring
Cardanical fastening
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Kiln inlet
Air pressure system
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Kiln Outlet
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140 TEI, 140 CD
Kiln outlet sealing
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140 TEI, 140 CD
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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140 TEI, 140 CD
Kiln Shell
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140 TEI, 140 CD
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 Tire bending stress Ovality in %
Design criteria:
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140 TEI, 140 CD
Splined tires
Distribution of forces
First splined tire in 1950
Page 27
140 TEI, 140 CD
Splined tires
Principle splined tire
Splined fixing
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140 TEI, 140 CD
Splined tires
The Floating Shim Plates Form the Connection Between the Tire Teeth and the X-Shaped Retaining Blocks
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140 TEI, 140 CD
Splined tires
Kiln shell ovality [%]
Floating tire
Splined tire
Kiln Dia. [m]
Kiln shell ovality
Wedge pre-tensioning device
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140 TEI, 140 CD
Splined tire
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140 TEI, 140 CD
Floating Tires
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140 TEI, 140 CD
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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140 TEI, 140 CD
Comparison of kiln shell ovalities

Splined kiln tire Floating kiln tire
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Supporting Roller Station
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140 TEI, 140 CD
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 Hertz Pressure Bearing Pressure
Design criteria:
Page 38
140 TEI, 140 CD
Roller station
1 2
Base frame Bearing housing assembly Roller and shaft assembly Guide block Oil level indicator
5 12
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Self aligning roller station for Polro kiln
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140 TEI, 140 CD
Kiln Drives
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140 TEI, 140 CD
Girth gear drive system
1
2 3,4 5 6
Bridge support
Bridge plate Plate bolts Girth gear Heat shield
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140 TEI, 140 CD
Self-aligning pinion
Permitted tilting: 10 mm
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Electro-hydraulic drive system
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140 TEI, 140 CD
Electro-hydraulic drive system
Page 45
140 TEI, 140 CD
Electro - mechanical drive
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140 TEI, 140 CD
Kiln Hood
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140 TEI, 140 CD
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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140 TEI, 140 CD
Maintenance
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140 TEI, 140 CD
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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140 TEI, 140 CD
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 51
140 TEI, 140 CD
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 52
140 TEI, 140 CD
Maintenance splined tires
Check of splined tire fastening: Check of wedge pre-tension Visual check of tire area
Check of welds
Page 53
140 TEI, 140 CD
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 54
140 TEI, 140 CD
Maintenance floating tires
Damages at base plates by defficient lubrication
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140 TEI, 140 CD
Maintenance / lubrication points
1 2
Girth gear Compressor plant
Oil atomizer
Page 56
140 TEI, 140 CD
4 5 6 7
Self-aligning pinion and stock bin Splash lubrication girth gear pinion Pinion bearing Rotary kiln drive
Page 57
140 TEI, 140 CD
15 16 17 18 19 20
Kiln tire Inlet seal Oil atomizer for inlet seal Oil atomizer for outlet seal Cooling air fan Fan for clinkering zone cooling system
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140 TEI, 140 CD
21
Supporting roller bearing station I Supporting roller bearing station II Supporting roller bearing staton III Supporting roller bearing station IV
22
23
24
25
Graphite lubrication equipment
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140 TEI, 140 CD
26 27 28
Thrust roller Safety thrust roller Slide pin
29
Hydraulic kilns longitudinal guide

Graphite lubrication equipment
30

Kiln Mechanics

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Page 1

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Kiln Outlet Including Seal

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

POLRO 2-support rotary kiln

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Rotary kiln assembly

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

The POLRO 2 - support kiln

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Design of rotary kilns

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

3 - support kiln versa 2 - support kiln

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Low-dust kiln inlet

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Air cooled segmented inlet through

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Kiln inlet seal

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Slot adjustment between support ring and slide ring

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Kiln outlet sealing

Krupp Polysius Corp.

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Principle of kiln outlet sealing

Cooling jacket Slide ring