This document provides information on rotary kiln maintenance. It discusses various components of the kiln including inlet and outlet seals, thrust rollers, and checklists for daily, weekly, and annual maintenance. The inlet seal prevents cold air from entering and uses pneumatic cylinders or springs to maintain a tight seal. The outlet seal uses spring plates to seal the kiln discharge. Thrust rollers help control the position of the kiln and can use mechanical or hydraulic systems. Regular maintenance is important to monitor temperatures, lubrication, and alignment of components.
This document provides information on rotary kiln maintenance. It discusses various components of the kiln including inlet and outlet seals, thrust rollers, and checklists for daily, weekly, and annual maintenance. The inlet seal prevents cold air from entering and uses pneumatic cylinders or springs to maintain a tight seal. The outlet seal uses spring plates to seal the kiln discharge. Thrust rollers help control the position of the kiln and can use mechanical or hydraulic systems. Regular maintenance is important to monitor temperatures, lubrication, and alignment of components.
This document provides information on rotary kiln maintenance. It discusses various components of the kiln including inlet and outlet seals, thrust rollers, and checklists for daily, weekly, and annual maintenance. The inlet seal prevents cold air from entering and uses pneumatic cylinders or springs to maintain a tight seal. The outlet seal uses spring plates to seal the kiln discharge. Thrust rollers help control the position of the kiln and can use mechanical or hydraulic systems. Regular maintenance is important to monitor temperatures, lubrication, and alignment of components.
This document provides information on rotary kiln maintenance. It discusses various components of the kiln including inlet and outlet seals, thrust rollers, and checklists for daily, weekly, and annual maintenance. The inlet seal prevents cold air from entering and uses pneumatic cylinders or springs to maintain a tight seal. The outlet seal uses spring plates to seal the kiln discharge. Thrust rollers help control the position of the kiln and can use mechanical or hydraulic systems. Regular maintenance is important to monitor temperatures, lubrication, and alignment of components.
Kiln Miscellaneous Kiln Inlet Seal Kiln Outlet Seal Thrust Roller Hydraulic Thrust Roller Kiln Maintenance Checklist The Good Old Days
Kiln Inlet Seal
Kiln Inlet Seal
The kiln seal prevents cold air from entering the process and driving up fuel costs. The seal must remain tight while accommodating kiln run-out and longitudinal movement.
Kiln Pneumatic Inlet Seal
Pneumatic Cylinders
The pneumatic seal consists of two sliding
surfaces pushed together by pneumatic cylinders.
Kiln Inlet Seal
Pneumatic Cylinders Seal Detail
Spring Loaded Graphite Plug
Kiln Inlet Seal Detail
Sliding Contact Stationary Sealing Surface
Rotating Sealing Surface
Graphite Plugs Wire Rope Graphite Seal Cord
Stationary Kiln Inlet Hood
Rotating Kiln Shell
Kiln Inlet Seal
Carriage
Turnbuckle
The seal is suspended by a carriage which allows it to
move longitudinally as the kiln expands and contracts.
Pneumatic Inlet Seal
Stationary Seal Half
Rotating Seal Half
The pneumatic cylinders, when pressurized,
will press the two seal halves tightly together.
Filter, Regulator, Lubricator
Cylinder force is controlled by adjusting the air pressure.
A lubricator prevents cylinder corrosion and seize-up. The filter keeps condensation and dirt out of the cylinder.
Filter, Regulator, Lubricator
Kiln Inlet Seal
Spring Loaded Graphite Plug
Graphite Plugs in Seal Plate
The seals sliding surfaces are graphite lubricated.
Kiln Inlet Castings
Castings on the inlet hood and kiln inlet
cone keep the castable refractory in place. Inspect them at annual shutdown.
Spring Plate Inlet Seal
Spring Plate Inlet Seal
Spring Plate Inlet Seal
Spring Plate Inlet Seal
No, covering the spring plates with plastic wont help.
Outlet Seal
Kiln Outlet Seal
The spring plate outlet seal has become the
outlet seal of choice. The seal can withstand the harsh conditions at the kiln hood.
Kiln Outlet Seal
Spring Plate
Wire Rope
Kiln Outlet Seal
Counterweight
Spring plates are wrapped with a counterweighted wire
rope arrangement to keep them tight against the cowl.
Kiln Outlet Seal
Forced Air Cooling
A stainless steel cowl at the kiln outlet provides an
air channel for cooling of the kiln discharge castings and the spring plate contact surface.
Kiln Outlet Seal
Spring plates are bolted on and are easily replaced.
Kiln Outlet Seal
The Old Way
The Better Way
Dust from kiln hood puffing falls down the chutes to
the drag chain conveyor or into the clinker cooler.
Kiln Outlet Sector
The kiln nose rings sees severe service and must be
regularly inspected for refractory and casting failure.
Kiln Outlet Seal
This alternate spring plates design features
outwardly protruding spring plates.
Kiln Outlet Seal
Outwardly protruding spring plate design.
The Most Expensive Seal
A bad seal allows cold air into the kiln. The cost of extra fuel to heat this cold air can amount to tens of thousands of dollars per year.
Thrust Roller
Thrust Roller Assembly
Clearance Oil Seal Oil Level Pipe
Tire Tie Rod
Spherical Bearings
Shims
Keep the clearance to a minimum (6mm),
and adjust the shims to keep the kiln gear in proper longitudinal alignment.
Thrust Roller Assembly
Set Screws
The kiln position can be controlled by
adjusting set screws on this thrust roller base.
Thrust Roller Position
Stop Ring
Thrust Tire
The thrust roller is positioned to maintain proper hot
running alignment between kiln gear and pinion. Repositioning may be necessary as stop rings wear.
Thrust Roller Misalignment
Roller Tilted to Left
Roller Offset to Left
Roller Tilted to Right
Roller Offset to Right
A misaligned thrust roller will result in vertical forces
on the roller as shown above.
Thrust Roller Misalignment
An improperly aligned thrust roller can ride out of
its socket, causing damage to tire stop blocks.
Thrust Roller
Thrust rollers can become overloaded if the kilns
supporting rollers are improperly skewed. This thrust roller base became deformed from excessive force.
Fuller Thrust Roller
Fuller Thrust Roller
Hydraulic Thrust Roller
Hydraulic Thrust Roller
The hydraulic thrust roller maintains a constant,
controlled force on the thrust tire and keeps the kiln in an electronically determined position.
Hydraulic Thrust Roller
Position Sensor
Hydraulic Cylinder
Guide Bar
Hydraulic Thrust Roller
Breather
Oil Level Sight Glass
Guide Bar Grease Fittings
The spherical bearings are lubricated with ISO VG
1000 gear oil. Guide bars are grease lubricated.
Thrust Roller
The roller surface is graphite lubricated.
Hydraulic Thrust Roller
Hydraulic Cabinet
The hydraulic power unit is normally
placed beneath the kilns thrust pier.
Hydraulic Cabinet
Relief Valve
Tank
Accumulator Directional Valve Pump
Hydraulic Pump
The axial piston pump has manual
adjustments for pressure and flow rate.
Directional Valve
A directional valve directs fluid to the thrust
cylinder, or allows the cylinder to bleed down.
Hydro-pneumatic Accumulator
An accumulator stores hydraulic energy. It is used to
maintain a steady force on the thrust tire even though the tire wobbles slightly as the kiln turns.
Hydro-pneumatic Accumulator Gas Valve
Nitrogen Gas
Bladder
Anti-Extrusion Valve
Shell
Port
The accumulator contains a rubber bladder
which is charged with nitrogen gas.
Hydro-pneumatic Accumulator
1000 500
1500
2000
psig
System Pressure Less Than pprecharge
1000
1000
500
1500
500
1500
2000
2000
psig
System Pressure at pmax
psig
System Pressure at pmin
When hydraulic pressure increases and decreases
the gas is compressed and expanded.
Hydro-pneumatic Accumulator
Danger! Do not charge with air or oxygen!
The accumulator is pre-charged with nitrogen
to approximately half of the expected average operating hydraulic pressure.
Pressure Relief Valve
A pressure relief valve limits hydraulic pressure in
the system. This prevents excessive downhill kiln force from damaging the thrust roller.
Hydraulic Filter
An in-tank filter with a 10 micron element
keeps hydraulic fluid clean. The protruding red button indicates the element needs changing.
Thrust Cylinder LVDT
An LVDT (linear variable differential transformer)
mounted in the hydraulic cylinder measures the distance that the cylinder rod is extended.
Thrust System LVDT Cabinet
The LVDT signal goes to a cabinet where the kilns hot
running axial position is set and where alarms are programmed for excessive uphill and downhill kiln position.
Fuller Hydraulic Thrust Roller
Fuller Hydraulic Thrust Roller
Preventive Maintenance Checklist
Daily Thrust Roller
Kilns with one thrust roller (mech. or hyd.)
visual check of the thrust rollers including recording of the thrust pressure (ideal 500 psi, can vary from 200-800 psi). Maximum design pressure is 12001300 psi check the temperature of the thrust roller housing and face.
Kilns with two thrust rollers
Observe the kiln position relative to the uphill or downhill thrust rollers Check temperature of the housing and thrust roller face if there is constant contact.
Daily Seals
Visually check feed and discharge seals
Gear
Visually check the gear and pinion
Rollers and Live Rings
Visually check all roller and tire surfaces
Lubricate contact faces between tires and shell
mounted tire pads and stop blocks using a mixture of graphite powder and water.
Daily Temperatures
Record kiln shell temperatures and
include a night visual inspection for hot spots
Weekly
Check and record direction of thrust on all
rollers. Check lubrication on all support rollers. Check oil levels in support roller bearings and thrust roller bearings. Check and record the tire creep and clearance. Record related shell and tire temperatures. Check condition of tire stop blocks and wear rings.
Weekly
Check general condition of kiln
shell.
Check contact patterns between
gear and pinion by observing the oil smear on the contact face for at least one full kiln rotation.
Annually
Perform complete check of kiln alignment
utilizing the laser or mechanical alignment method. Kiln alignments should be completed after major repairs have been made to the kiln.
With this information recorded and compared,
a problem should be caught before a real dilemma occurs (i.e. an unplanned shutdown).
Prior to planned kiln shutdowns, an extensive
mechanical inspection should be completed to determine repairs required.
