Kiln Mechanics 222222

Page 1
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt
Rotary Kiln
Mechanical Training
Krupp Polysius Corp.
140 TEI, 140 CD
Page 2
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
140 TEI, 140 CD
Page 3
POLRO 2-support rotary kiln
140 TEI, 140 CD
Page 4
Kiln General
140 TEI, 140 CD
Page 5
140 TEI, 140 CD
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 6
140 TEI, 140 CD
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 7
140 TEI, 140 CD
Design of rotary kilns

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Page 8
140 TEI, 140 CD
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 9
Kiln Inlet
140 TEI, 140 CD
Page 10
140 TEI, 140 CD
Low-dust kiln inlet
Page 11
Air cooled segmented inlet through
140 TEI, 140 CD
Page 12
Kiln inlet seal
Seal principle
140 TEI, 140 CD
Page 13
140 TEI, 140 CD
Kiln inlet
Slot adjustment between support ring

and slide ring
Cardanical fastening
Page 14
Kiln inlet
Air pressure system
140 TEI, 140 CD
Page 15
Kiln Outlet
140 TEI, 140 CD
Page 16
Kiln outlet sealing
140 TEI, 140 CD
Page 17
140 TEI, 140 CD
Principle of kiln outlet sealing
Wear ring
Cooling jacket
Slide ring
Wear ring
Pneumatic
cylinder
Cord
Support ring
Page 18
140 TEI, 140 CD
Kiln outlet
Principle kiln outlet
Kiln outlet with dust chute
Page 19
Kiln outlet
Outlet of kiln
Outlet cooling
140 TEI, 140 CD
Page 20
140 TEI, 140 CD
Kiln outlet
Air pressure system
Page 21
Kiln Shell
140 TEI, 140 CD
Page 22
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.
Page 23
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
140 TEI, 140 CD
Page 24
Splined Tires
140 TEI, 140 CD
Page 25
140 TEI, 140 CD
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 26
140 TEI, 140 CD
Splined tires
Distribution of forces
First splined tire in 1950
Page 27
Splined tires
Principle splined tire
Splined fixing
140 TEI, 140 CD
Page 28
Splined tires
The Floating Shim Plates

Form the Connection
Between the Tire Teeth
and the X-Shaped
Retaining Blocks
140 TEI, 140 CD
Page 29
140 TEI, 140 CD
Splined tires
Kiln shell ovality [%]
Floating tire
Splined tire
Kiln Dia. [m]
Kiln shell ovality
Wedge pre-tensioning device
Page 30
Splined tire
140 TEI, 140 CD
Page 31
Floating Tires
140 TEI, 140 CD
Page 32
140 TEI, 140 CD
Floating (loose) tires
Distribution of forces
Principle of floating tires
Page 33
Floating tires
Steps for radial play reduction
140 TEI, 140 CD
Page 34
Floating tires
140 TEI, 140 CD
Page 35
140 TEI, 140 CD
Comparison of kiln shell ovalities

Splined kiln tire
Floating kiln tire
Page 36
Supporting Roller Station
140 TEI, 140 CD
Page 37
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
Design criteria:
Hertz Pressure
Bearing Pressure
Page 38
140 TEI, 140 CD
Roller station
Base frame
Bearing housing
assembly
Roller and shaft

assembly
Guide block
12
Oil level indicator
Page 39
140 TEI, 140 CD
Self aligning roller station for Polro kiln
Page 40
Kiln Drives
140 TEI, 140 CD
Page 41
140 TEI, 140 CD
Girth gear drive system
Bridge support
Bridge plate
3,4
Plate bolts
Girth gear
Heat shield
Page 42
140 TEI, 140 CD
Self-aligning pinion
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 - mechanical drive
140 TEI, 140 CD
Page 46
Kiln Hood
140 TEI, 140 CD
Page 47
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
Page 48
Maintenance
140 TEI, 140 CD
Page 49
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
140 TEI, 140 CD
Page 50
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
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
140 TEI, 140 CD
Page 52
Maintenance splined tires
Check of splined tire fastening:

Check of wedge pre-tension
Visual check of tire area
Check of welds
140 TEI, 140 CD
Page 53
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
140 TEI, 140 CD
Page 54
140 TEI, 140 CD
Maintenance floating tires
Damages at base plates by defficient lubrication
Page 55
140 TEI, 140 CD
Maintenance / lubrication points
Girth gear
Compressor plant
Oil atomizer
Page 56
140 TEI, 140 CD
Self-aligning pinion and stock bin
Splash lubrication girth gear pinion
Pinion bearing
Rotary kiln drive
Page 57
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
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
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 222222

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Page 1

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

Krupp Polysius Corp.

140 TEI, 140 CD

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

Kiln Outlet Including Seal

Krupp Polysius Corp.

140 TEI, 140 CD

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

POLRO 2-support rotary kiln

Krupp Polysius Corp.

140 TEI, 140 CD

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

Krupp Polysius Corp.

140 TEI, 140 CD

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

140 TEI, 140 CD

Rotary kiln assembly

Rotary kiln shell

Krupp Polysius Corp.

Guard for rack and pinion drive

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

140 TEI, 140 CD

The POLRO 2 - support kiln

splined tires (cold gap 0.4%)

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

constant support loading

Krupp Polysius Corp.

elastic deformation only

long enough for process?

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

Krupp Polysius Corp.

140 TEI, 140 CD

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

Air cooled segmented inlet through

Krupp Polysius Corp.

140 TEI, 140 CD

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

Kiln inlet seal

Krupp Polysius Corp.

140 TEI, 140 CD

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

140 TEI, 140 CD

Slot adjustment between support ring

Krupp Polysius Corp.

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

Krupp Polysius Corp.

140 TEI, 140 CD

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

Krupp Polysius Corp.

140 TEI, 140 CD

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

Kiln outlet sealing