Kiln Mechanics

Page
L\DATA\Dept150\Polysius Presentations
and Training\Polysius Training\Pyrop
rocessing\Kiln\kiln_mechanics.ppt
140 TEI, 140 CD
Rotary Kiln
Mechanical Training
Krupp Polysius Corp.
Page
2
Content:
and
Training\Polysius Training\Pyrop
Kiln General
140 TEI, 140 CD
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
3
POLRO 2-support rotary kiln
140 TEI, 140 CD
Page
4
140 TEI, 140 CD
Kiln General
Page
5
1
2
3
4
5
6
Rotary kiln assembly
and
Training\Polysius Training\Pyrop
140 TEI, 140 CD
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)
140 TEI, 140 CD
Page
6
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
L\DATA\Dept150\Polysius
Presentations
Design of rotary kilns
Process - technological dimensions
140 TEI, 140 CD
Page
7
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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8
3-support kiln
2-support kiln
140 TEI, 140 CD
3 - support kiln versa 2 - support kiln
Statically undefined
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
9
140 TEI, 140 CD
Kiln Inlet
Page
10
Low-dust kiln inlet
140 TEI, 140 CD
Page
11
Air cooled
segmented inletTraining\Pyrop
through
and Training\Polysius
140 TEI, 140 CD
Page
12
Kiln inlet seal Training\Pyrop
140 TEI, 140 CD
Seal principle
Page
13
Kiln inlet
Training\Pyrop
140 TEI, 140 CD
Slot adjustment between support ring

and slide ring
Cardanical fastening
Training\Pyrop
Kiln inlet
Air pressure system rocessing\Kiln\kiln_mechanics.ppt
140 TEI, 140 CD
Page
14
Page
15
140 TEI, 140 CD
Kiln Outlet
Page
16
and
Training\Polysius
Kiln
outlet sealing Training\Pyrop
140 TEI, 140 CD
Page
17
Principle
of kiln outlet sealing
Training\Pyrop
140 TEI, 140 CD
Wear ring
Cooling jacket
Slide ring
Wear ring
Pneumatic
cylinder
Cord
Support ring
Page
18
Kiln outlet Training\Pyrop
140 TEI, 140 CD
Principle kiln outlet
Kiln outlet with dust chute
Page
19
140 TEI, 140 CD
Outlet of kiln
Outlet cooling
Page
20
140 TEI, 140 CD
Air pressure system
Page
21
140 TEI, 140 CD
Kiln Shell
Page
the kiln shell calculation basics
andofTraining\Polysius
Training\Pyrop
22 Description
140 TEI, 140 CD
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
23
Functions
of the kiln shell
Training\Pyrop
140 TEI, 140 CD
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
24
140 TEI, 140 CD
Splined Tires
Page
Description
and function of the
kiln tire
Training\Pyrop
25
140 TEI, 140 CD
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
26
Splined tires Training\Pyrop
140 TEI, 140 CD
Distribution of forces
First splined tire in 1950
Page
27
140 TEI, 140 CD
Principle splined tire
Splined fixing
Page
28
Presentations
Splined tires
140 TEI, 140 CD
The Floating Shim

Plates Form the
Connection Between
the Tire Teeth and the
X-Shaped Retaining
Blocks
140 TEI, 140 CD
Page
29
Kiln shell ovality [%]
Floating tire
Splined tire
Kiln Dia. [m]
Kiln shell ovality
Wedge pre-tensioning device
Page
30
Presentations
Splined tire
140 TEI, 140 CD
Page
31
140 TEI, 140 CD
Floating Tires
Page
32
(loose) tires
andFloating
Training\Polysius
Training\Pyrop
140 TEI, 140 CD
Distribution of forces
Principle of floating tires
Page
33
Floating tires
140 TEI, 140 CD
Steps for radial play reduction
Page
34
Floating tires Training\Pyrop
140 TEI, 140 CD
Page
35
Comparison of kiln shell ovalities
Splined kiln tire
Floating kiln tire
140 TEI, 140 CD
Page
36
140 TEI, 140 CD
Supporting Roller Station
Page
Description
and function of aTraining\Pyrop
kiln roller
37
140
TEI,which
140isCD
A kiln roller is a steel
wheel
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
38
Roller station Training\Pyrop
140 TEI, 140 CD
Base frame
Bearing housing
assembly
Roller and shaft

assembly
Guide block
12
Oil level indicator
Page
roller station for Polro kiln
Training\Pyrop
39 Self aligning
140 TEI, 140 CD
Page
40
140 TEI, 140 CD
Kiln Drives
Page
41
Girth gear drive system
140 TEI, 140 CD
Bridge support
Bridge plate
3,4
Plate bolts
Girth gear
Heat shield
Page
42
Self-aligning
pinionTraining\Pyrop
and
Training\Polysius
140 TEI, 140 CD
Permitted tilting: 10 mm
Page
43
Electro-hydraulic drive system
140 TEI, 140 CD
Page
44
Electro-hydraulic drive system
140 TEI, 140 CD
Page
45
Electro
- mechanicalTraining\Pyrop
drive
and
Training\Polysius
140 TEI, 140 CD
Page
46
140 TEI, 140 CD
Kiln Hood
Page
47
Kiln hood Training\Pyrop
140 TEI, 140 CD
1
Lower part of hood
2
3
4
5
6
7
8
9
10
11
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
48
140 TEI, 140 CD
Maintenance
Maintenance
kiln inletTraining\Pyrop
Check points of kiln inlet seal:140 TEI, 140 CD
Page
49
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
50
Air pressure net:
Maintenance
kiln inlet
and
Training\Polysius
Training\Pyrop
140 TEI, 140 CD
Air pressure for pneumatic-cylinder

Check of water separator
Check of lubricator of pressurized air
Check for leakages
Air pressure system
Page
51
Maintenance
kiln outlet
Training\Pyrop
Check of outlet
140 seal:
TEI, 140 CD
(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
Maintenance
splined tires
Training\Pyrop
140 TEI, 140 CD
Check of splined tire fastening:
Check of wedge pre-tension
Visual check of tire area
Check of welds
Maintenance
floatingTraining\Pyrop
tires
Check of floating tire fastening:
140 TEI, 140 CD
Page
53
Control of relative movement

Play measurements during stop times
Control of axial retainers
Lubrication of slide surfaces
Check of welds
Page
54
Maintenance
floatingTraining\Pyrop
tires
140 TEI, 140 CD
Damages at base plates by defficient lubrication
Page
55
Maintenance
/ lubrication points
Training\Pyrop
140 TEI, 140 CD
Girth gear
Compressor plant
Oil atomizer
Page
56
Maintenance
Training\Pyrop
140 TEI, 140 CD
Self-aligning pinion and stock bin
Splash lubrication girth gear pinion
Pinion bearing
Rotary kiln drive
Page
57
Maintenance
Training\Pyrop
140 TEI, 140 CD
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
58
Maintenance
Training\Pyrop
140 TEI, 140 CD
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
59
Maintenance
Training\Pyrop
140 TEI, 140 CD
26
Thrust roller
27
Safety thrust roller
28
Slide pin
29
Hydraulic kilns
longitudinal guide
30
Graphite lubrication
equipment

Kiln Mechanics

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Page

Krupp Polysius Corp.

Kiln Outlet Including Seal

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Rotary kiln shell

Krupp Polysius Corp.

Guard for rack and pinion drive

The POLRO 2 - support kiln

splined tires (cold gap 0.4%)

Krupp Polysius Corp.

Kiln with calciner

Number of stations and L / D ratio

Krupp Polysius Corp.

constant support loading

Krupp Polysius Corp.

elastic deformation only

long enough for process?

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Slot adjustment between support ring

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Principle kiln outlet

Krupp Polysius Corp.

Kiln outlet with dust chute

Krupp Polysius Corp.

Air pressure system

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Transfer load from shell to the rollers

Tire bending stress

Krupp Polysius Corp.

Krupp Polysius Corp.

First splined tire in 1950

Principle splined tire

Krupp Polysius Corp.

The Floating Shim

Krupp Polysius Corp.

Kiln Dia. [m]

Kiln shell ovality

Krupp Polysius Corp.

Wedge pre-tensioning device

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Principle of floating tires

Steps for radial play reduction

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Supporting Roller Station

Krupp Polysius Corp.

Transfer load from tires to base plate