Kiln Mechanics PDF

Page 1 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 L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 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
POLRO® 2-support rotary kiln

Kiln General

Rotary kiln assembly
1 Rotary kiln shell 7 Guard for rack and pinion drive

2 Kiln inlet with inlet seal with lubrication device
3 Tires with fastening 8 Kiln drive
system 9 Kiln outlet with outlet seal
4 Supporting roller stations 10 Kiln hood
5 Kiln longitudinal guide 11 Clinkering zone cooling (optional)
6 Rack and pinion drive
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

Design of rotary kilns
P
r
oc
es
s-
te
ch
n
ol
ogi
cal
dim
en
s
i
ons
K
i
l
n w
i
t
h c
a
lc
i
ner
K
i
l
n w
i
t
h p
r
eh
ea
t
er
1
0 1
2 1
415 1
7
L/
Dra
t
i
o
N
u
mb
e
ro
fs
t
at
i
ons
an
dL
/Dr
at
i
o
2
-S
ta
t
i
ons
3
-S
t3
-
a
t
i
oS
nt
a
st
i
ons
1
0 1
2 14 1
7
L
/
Dra
t
i
o

3 - support kiln versa 2 - support kiln
3-support kiln 2-support kiln
Statically undefined Statically defined
• possibility of • constant support loading

- extreme overload
- plastic deformation • elastic deformation only
• requirement for • no sensitivity to misalignment

- etxra safety margin
- regular adjustment long enough for process?

Kiln Inlet

“Low-dust” kiln inlet

Air cooled segmented inlet through

Kiln inlet seal
Seal principle

Kiln inlet
• Slot adjustment between support ring

and slide ring
Cardanical fastening

Kiln inlet
Air pressure system

Kiln Outlet

Kiln outlet sealing

Principle of kiln outlet sealing
Cooling jacket
Wear ring
Slide ring
Wear ring
Cord
Pneumatic
Support ring
cylinder

Kiln outlet
Principle kiln outlet Kiln outlet with dust chute

Kiln outlet
Outlet of kiln Outlet cooling

Kiln outlet
Air pressure system

Kiln Shell

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.

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

Splined Tires

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 %

Splined tires
Distribution of forces First splined tire in 1950

Splined tires
Principle splined tire Splined fixing

Splined tires
The Floating Shim Plates

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

Splined tires
Kiln shell ovality [%]
Floating tire
Splined tire
Kiln Dia. [m]
Kiln shell ovality Wedge pre-tensioning device

Splined tire

Floating Tires

Floating (loose) tires
Distribution of forces Principle of floating tires

Floating tires
Steps for radial play reduction

Floating tires

Comparison of kiln shell ovalities
Splined kiln tire Floating kiln tire

Supporting Roller Station

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

Roller station
1 Base frame
2 Bearing housing
assembly
3 Roller and shaft

assembly
5 Guide block
12 Oil level indicator

Self aligning roller station for Polro kiln

Kiln Drives

Girth gear drive system
1 Bridge support
2 Bridge plate
3,4 Plate bolts
5 Girth gear
6 Heat shield

Self-aligning pinion
Permitted tilting: ± 10 mm

Electro-hydraulic drive system

Electro-hydraulic drive system

Electro - mechanical drive

Kiln Hood

Kiln hood
1 Lower part of hood

2 Upper part of hood
3 Suspension door
4 Trolley arrangement
5 Burner seal
6 Inspection port
7 Access door
8 Sub plate
9 Collar segment
10 Seal to cooler
11 Opening for measuring
socket

Maintenance

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

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

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

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

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

Maintenance floating tires
Damages at base plates by defficient lubrication

Maintenance / lubrication points
1 Girth gear
2 Compressor plant
3 Oil atomizer

4 Self-aligning pinion and stock bin
5 Splash lubrication girth gear pinion
6 Pinion bearing
7 Rotary kiln drive

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

21 Supporting roller
bearing station I
bearing station II
bearing staton III
bearing station IV
25 Graphite lubrication
equipment

26 Thrust roller
27 Safety thrust roller
28 Slide pin
29 Hydraulic kilns
longitudinal guide
30 Graphite lubrication
equipment

Kiln Mechanics PDF

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Kiln Mechanics PDF

Transféré par

Droits d'auteur :

Formats disponibles

Page 1 L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.

ppt 140 TEI, 140 CD

Krupp Polysius Corp.

• Kiln Inlet Including Seal

• Kiln Outlet Including Seal

• Splined Kiln Tire

• Floating Kiln Tire

• Supporting Roller Station

POLRO® 2-support rotary kiln

Krupp Polysius Corp.

Krupp Polysius Corp.

Rotary kiln assembly

1 Rotary kiln shell 7 Guard for rack and pinion drive

The POLRO 2 - support kiln

• splined tires (cold gap 0.4%)

Krupp Polysius Corp.

Design of rotary kilns

Krupp Polysius Corp.

3 - support kiln versa 2 - support kiln

3-support kiln 2-support kiln

Statically undefined Statically defined

• possibility of • constant support loading

• requirement for • no sensitivity to misalignment

Krupp Polysius Corp.

Krupp Polysius Corp.

“Low-dust” kiln inlet

Krupp Polysius Corp.

Air cooled segmented inlet through

Krupp Polysius Corp.

Kiln inlet seal

Krupp Polysius Corp.

• Slot adjustment between support ring

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Kiln outlet sealing

Krupp Polysius Corp.

Principle of kiln outlet sealing

Krupp Polysius Corp.

Principle kiln outlet Kiln outlet with dust chute

Krupp Polysius Corp.

Outlet of kiln Outlet cooling

Krupp Polysius Corp.

Air pressure system

Krupp Polysius Corp.

Krupp Polysius Corp.

Description of the kiln shell calculation basics

The design criteria for a kiln shell is the Bending Stress.

Different kiln areas have different Loads.

Krupp Polysius Corp.

Functions of the kiln shell

• Guides gas from cooler to kiln

• Creates a constant moving material bed

• Holds the brick lining

Krupp Polysius Corp.

Krupp Polysius Corp.

Description and function of the kiln tire

The tire is a steel ring on the outside of kiln shell. It works as an

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

Krupp Polysius Corp.