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Rotary Kiln Mechanical Training
Page 1
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 Page 2
POLRO® 2-support rotary kiln
Page 3
Kiln General
Page 4
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 5
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 6
Design of rotary kilns Process - technological dimensions
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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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
Page 9
“Low-dust” kiln inlet
Page 10
Air cooled segmented inlet through
Page 11
Kiln inlet seal
Seal principle
Page 12
Kiln inlet
• Slot adjustment between support ring and slide ring
Cardanical fastening Page 13
Air pressure system
Kiln inlet
Page 14
Kiln Outlet
Page 15
Kiln outlet sealing
Page 16
Principle of kiln outlet sealing
Wear ring
Cooling jacket Slide ring
Wear ring Pneumatic cylinder
Cord Support ring
Page 17
Kiln outlet
Principle kiln outlet
Kiln outlet with dust chute
Page 18
Kiln outlet
Outlet of kiln
Outlet cooling
Page 19
Kiln outlet
Air pressure system
Page 20
Kiln Shell
Page 21
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 22
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
Page 23
Splined Tires
Page 24
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 25
Splined tires
Distribution of forces
First splined tire in 1950
Page 26
Splined tires
Principle splined tire
Splined fixing
Page 27
Splined tires
The Floating Shim Plates Form the Connection Between the Tire Teeth and the X-Shaped Retaining Blocks
Page 28
Splined tires
Kiln shell ovality [%]
Floating tire
Splined tire
Kiln Dia. [m]
Kiln shell ovality
Wedge pre-tensioning device
Page 29
Splined tire
Page 30
Floating Tires
Page 31
Floating (loose) tires
Distribution of forces
Principle of floating tires
Page 32
Floating tires
Steps for radial play reduction
Page 33
Floating tires
Page 34
Comparison of kiln shell ovalities Splined kiln tire
Floating kiln tire
Page 35
Supporting Roller Station
Page 36
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 37
Roller station
1
Base frame
2
Bearing housing assembly
3
Roller and shaft assembly
5
Guide block
12
Oil level indicator
Page 38
Self aligning roller station for Polro kiln
Page 39
Kiln Drives
Page 40
Girth gear drive system
1
Bridge support
2
Bridge plate
3,4
Plate bolts
5
Girth gear
6
Heat shield
Page 41
Self-aligning pinion
Permitted tilting: ± 10 mm
Page 42
Electro-hydraulic drive system
Page 43
Electro-hydraulic drive system
Page 44
Electro - mechanical drive
Page 45
Kiln Hood
Page 46
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 47
Maintenance
Page 48
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
Page 49
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 50
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
Page 51
Maintenance splined tires
Check of splined tire fastening: • Check of wedge pre-tension • Visual check of tire area • Check of welds
Page 52
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
