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Rotary Kiln Maintenance

Seminar

Kiln Miscellaneous

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.

The Good Old Days

The Good Old Days

The Good Old Days

Rivets

Dont Be Mean to Your Kiln