Kiln Mechanics

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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

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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

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POLRO® 2-support rotary kiln


140 TEI, 140 CD

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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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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

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?

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Kiln Inlet


140 TEI, 140 CD

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“Low-dust” kiln inlet


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Air cooled segmented inlet through


140 TEI, 140 CD

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Kiln inlet seal

Seal principle


140 TEI, 140 CD

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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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Kiln outlet sealing


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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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Kiln Shell


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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


140 TEI, 140 CD

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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

Design criteria:

 Tire bending stress  Ovality in %


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Splined tires

Distribution of forces


First splined tire in 1950

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Splined tires

Principle splined tire


Splined fixing

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Splined tires

The Floating Shim Plates Form the Connection Between the Tire Teeth and the X-Shaped Retaining Blocks


140 TEI, 140 CD


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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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Splined tire


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Floating Tires


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Floating (loose) tires

Distribution of forces


Principle of floating tires

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Floating tires

Steps for radial play reduction


140 TEI, 140 CD

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Floating tires


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Comparison of kiln shell ovalities Splined kiln tire


Floating kiln tire

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Supporting Roller Station


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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


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Roller station


1

Base frame

2

Bearing housing assembly

3

Roller and shaft assembly

5

Guide block

12

Oil level indicator

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Self aligning roller station for Polro kiln


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Kiln Drives


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Page 41


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Girth gear drive system


1

Bridge support

2

Bridge plate

3,4

Plate bolts

5

Girth gear

6

Heat shield

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Self-aligning pinion

Permitted tilting: ± 10 mm


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Electro-hydraulic drive system


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Electro-hydraulic drive system


140 TEI, 140 CD

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Electro - mechanical drive


140 TEI, 140 CD

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Kiln Hood


140 TEI, 140 CD

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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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Maintenance


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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

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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


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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

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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

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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

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140 TEI, 140 CD

Maintenance floating tires

Damages at base plates by defficient lubrication


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Maintenance / lubrication points


1

Girth gear

2

Compressor plant

3

Oil atomizer

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140 TEI, 140 CD


4

Self-aligning pinion and stock bin

5

Splash lubrication girth gear pinion

6

Pinion bearing

7

Rotary kiln drive


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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

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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

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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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