Rotary Kiln Maintenance Seminar

Kiln Shell

Kiln Shell

Shell Details
Kiln Crank Measuring Kiln Crank Heat Correction of Kiln Crank Shell Repair Shell Welding Submerged Arc Welding
Kiln Shell 2

Shell Details

Kiln Shell

Shell Details

Inlet Cone

Tire No. 3

Tire No. 2

Tire No. 1

Outlet Shroud

30 mm

40 mm (gear)

30 mm

30 mm

50 mm 75 mm (under tire)

40 mm 75 mm (under tire)

40 mm

80 mm (under tire)

40 mm

Typical shell plate thicknesses.

Kiln Shell

Kiln Crank

Kiln Shell

Kiln Crank

Kiln crank occurs when a kiln shell is not perfectly straight. As the shell turns, cyclical loads and stresses occur in the shell and the kiln supports.
Kiln Shell 6

Kiln Crank

Kiln crank can cause severe cyclical loads, leading to shell cracks and fatigue cracks in the roller shafts.

Kiln Shell

Kiln Crank

Kiln crank will result in gear misalignment which can destroy gear teeth.

Kiln Shell

Kiln Crank

Kiln crank can be temporary, as in the case of a rain warped shell, or permanent, as in the case of a shell damaged by heat blisters.
Kiln Shell 9

Kiln Crank

When a hot kiln is stopped during a heavy rainstorm, one side of the shell cools off and contracts, causing a concave up curvature.

Kiln Shell

10

Kiln Crank

When a hot kiln is stopped too long without rotation, heat will rise and the top of the shell will expand, causing a convex-up curvature.

Kiln Shell

11

Kiln Crank

Irregular coating formation or refractory wear can cause one side of the shell to heat up more than the other. The result is a temporary crank in the shell.
Kiln Shell 12

Kiln Crank

Damaged refractory will cause a hot spot in the shell.

Kiln Shell 13

Kiln Crank

A hot spot left unattended will wrinkle the shell and create a crank. Refractory bricks will no longer stay in place and the shell section will have to be replaced at great expense.
Kiln Shell 14

Heat Damaged Kiln Shell

A heat-wrinkled kiln shell will also shorten the kiln, causing tires to run off-center.
Kiln Shell 15

Kiln Crank

Kiln crank can be caused by poor alignment of kiln sections during assembly or repair.

Kiln Shell

16

Kiln Crank

Kiln crank can be caused by weld shrinkage at a temporary shell patch.

Kiln Shell 17

Measuring Kiln Crank

Kiln Shell

18

Measuring Kiln Crank

Kiln crank can be identified by measuring roller deflection. The load on the roller will change as the kiln turns and this results in bending of the roller shaft.
Kiln Shell 19

Measuring Kiln Crank

A roller that deflects cyclically with kiln rotation by over 0.3 mm typically indicates a crank in the shell that should be repaired.
Kiln Shell 20

Measuring Kiln Crank

Kiln crank can be measured by measuring shell runout. A polar diagram is generated on which the deviation from the true kiln center can be seen.
Kiln Shell 21

Measuring Kiln Crank

A series of polar diagrams gives a picture of the shell crank.

Kiln Shell 22

Heat Correction of Kiln Crank

Kiln Shell

23

Heat Correction of Kiln Crank

A kiln shell can sometimes be straightened by heat correction. Insulation is wrapped around the shell, allowing the shell steel to overheat. Shell stresses then diminish as the kiln sags into place on the rollers.
Kiln Shell 24

Heat Correction of Kiln Crank

Temperature sensors are installed to carefully monitor shell temperatures beneath the insulation during the correction process.
Kiln Shell 25

Heat Correction of Kiln Crank

Kiln Shell

26

Shell Repair

Kiln Shell

27

Shell Repair

Major shell defects are normally repaired by replacing the damaged section. The bandaid approach is at best a temporary solution.
Kiln Shell 28

Field Joint Hardware

New shell sections are joined with adjustable erection lugs.

Kiln Shell 29

Shell Alignment

By adjusting the erection lugs the shell sections are straightened until a perfect centerline is achieved.

Kiln Shell

30

Tire Handling

Kiln Shell

31

Shell Rigging

Kiln Shell

32

Shell Rigging

Kiln Shell

33

Shell Handling

Kiln Shell

34

Spider Bracing

Kiln Shell

35

Spider Bracing

Kiln Shell

36

Spider Bracing

Kiln Shell

37

Shell Stiffening Rings

Many older kilns had shell stiffening rings. These rings would eventually cause shell cracks due to heat expansion. Field-cutting expansion slots may help this problem.
Kiln Shell 38

Shell Welding

Kiln Shell

39

Joint Preparation

Prior to welding the shell plate ends are carefully prepared.

Kiln Shell

40

Weld Shrinkage

The 60 double V weld results in less shrinkage and less weld metal being required. Weld distortion is minimized, avoiding the gull-wing effect.
Kiln Shell 41

Weld Shrinkage

Kiln Shell

42

Shell Welding

Kiln Shell

43

Shell Welding

After completing the outside weld, the root pass is removed using carbon arc gouging.
Kiln Shell 44

Shell Welding

After gouging, the joint is carefully cleaned and inspected to ensure that no defects from the root pass remain.
Kiln Shell 45

Shell Welding

When welding is finished, the joint is inspected radiography or ultrasound. Defects are marked and then repaired.
Kiln Shell 46

Submerged Arc Welding

Kiln Shell

47

Submerged Arc Welding

Kiln Shell

48

Submerged Arc Welding

Kiln Shell

49

Submerged Arc Welding

Kiln Shell

50

Submerged Arc Welding

Kiln Shell

51

Submerged Arc Welding

The depth of penetration increases with increased current.

The depth of penetration is also dependant of the welding speed.

Kiln Shell

52

Submerged Arc Welding

The depth of penetration is high with the welding rod as PLUS POLE and law with the welding rod as MINUS POLE.

Kiln Shell

53

Submerged Arc Welding

Kiln Shell

54

Submerged Arc Welding

Kiln Shell

55

Submerged Arc Welding

Kiln Shell

56

Submerged Arc Welding

Kiln Shell

57

Submerged Arc Welding

Kiln Shell

58

Submerged Arc Welding

Kiln Shell

59

Submerged Arc Welding

Kiln Shell

60

Submerged Arc Welding

Kiln Shell

61

Submerged Arc Welding

Kiln Shell

62

Submerged Arc Welding

Kiln Shell

63

Submerged Arc Welding

Kiln Shell

64