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The kiln is the heart of the plant – what reliability and minimum operating costs
an entire cement plant is dimensioned help our customers stay competitive
around, and where most of the final as well.
chemical reactions take place. So it’s not
surprising that a producer requires an Since 1897, FLSmidth has been supplying
ideal kiln solution. cement plants around the world with
the best in rotary kilns. Today our
FLSmidth’s ROTAX-2® and 3-base kilns ROTAX-2 and 3-base kilns reflect our
deliver the best in rotary kiln designs. commitment to constantly pushing the
With the ideal temperature profile and limits of pyro-technology. Proven
material retention time, these rotary performers, they bring reliability and
kilns play a key role in ensuring optimal cost-effectiveness to the ambitious
quality clinker. Their maximum operating cement plant.
The components
of success
ensures reliable transmission of drive are the preferred choice for both the
power under any operating conditions. ROTAX-2 and 3-base kiln; however
All parts are also visible with tangential inlet pneumatic seals and lamella seals
suspension, simplifying both inspection are also available.
and maintenance.
Automatic thrust device
The ROTAX-2 kiln uses only tangential = stability
suspension to accommodate its higher Both types of kilns are kept in position
flexibility. While the 3-base kiln is by an automatic hydraulic thrust device
provided with floating suspension as (HTD) that controls the axial motion of
standard, it can also be fit with the kiln. It counteracts the slope of the
tangential suspension. kiln and ensures uniform use of the Hydraulic thrust device
contact surfaces between tyres and
In the 3-base kiln, when using floating supporting rollers, as well as the girth
suspension of the kiln tyre, loose-fitting gear and pinion. The hydraulic thrust
blocks are held in place by bushings device is designed to take up the full
secured to the kiln shell. This allows axial load of the kiln, so skewing of
easy restorative shimming to take the support rollers is not needed.
place, lessening maintenance costs.
3-base kiln: the traditional choice
Different designs kiln. Due to the ROTAX-2 kiln’s partic- ratio compared to the ROTAX-2 kiln.
= same quality ular length to diameter ratio, it has It has a balanced design that ensures
The ROTAX-2 kiln is the choice of the small space requirements and lower optimal combination of stiffness and
modern cement plant. The 2-base rotary surface heat loss. flexibility to minimise kiln crank and
kiln is a statically determined beam misalignment.
system, where the support load is The ROTAX-2 kiln is directly driven via
always known. It is a shorter and wider the inlet-end roller station, a design The ROTAX-2 kiln uses tangential sus-
kiln, with a reduced slope to maintain that takes the place of the traditional pension support of kiln tyres, whereas
the material retention time, similar to a girth gear and pinion drive used in the 3-base kiln normally uses floating
3-base kiln. The larger diameter reduces 3-base kilns. suspension. Both kilns also share a
the gas velocity and the dust recircula- number of design details. For more
tion, and secures a lower burning zone The 3-base kiln is a high-quality, tradi- information on the differences – and
thermal load (Gcal/h/m2) at the same tional rotary kiln system. It is character- similarities – please turn the page.
production as a corresponding 3-base ised by a higher length to diameter
Guidelines for standard cement kiln dimensions
(where Di=free diameter inside refractory)
Nominal output of kilns with In-Line Calciner and Cross-Bar® cooler
NOMINAL OUTPUT
(ton clinker/day)
13,000
6.30 x 98
12,000
6.60 x 80
11,000
6.00 x 95
6.30 x 76 10,000
5.75 x 91
9,000
6.00 x 72
5.50 x 86
8,000
5.75 x 69
7,000 5.25 x 82
5.50 x 66
6,000 5.00 x 78
5.25 x 62
4.75 x 74
5.00 x 60
5,000
4.55 x 71
4.75 x 56 4,000
4.35 x 67
4.55 x 54
3,500
4.15 x 64
4.35 x 51
3,000
3.95 x 61
4.15 x 49
2,500 3.75 x 58
3.95 x 46
3.60 x 55
3.75 x 44 2,000
3.45 x 53
3.60 x 42
3.30 x 50
3.45 x 40 1,500
3.30 x 38 3.15 x 47
3.15 x 36 1,000
500
ROTAX- kilns 3-base kilns
Size LxD in meters Size LxD in meters
L/Di ~ 13 L/Di ~ 17
Inclination = 3.5% Inclination = 4%
Kiln length is variable within a range and can be designed for special cases. The nominal output is based C 11-14 400-14-ENG V2
on normal clinker quality and kiln volumetric loading of 5.0 ton/day/m3 for 3-base kilns and 5.3 ton/day/m3
for ROTAX-2 kiln. The potential output of a kiln also depends on the burnability of the raw materials.
The kiln rotational speed is designed for 5.0 rpm (revolutions per minute) with a nominal speed of 3.6.
Copyright © 2014 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth®, ROTAX-2® and Cross-Bar® are registered trademarks of FLSmidth A/S. This brochure makes
no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may
change at any time. www.flsmidth.com