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Identifying & Resolving Common Rotary Kiln Processing Challenges
Identifying & Resolving Common Rotary Kiln Processing Challenges
Home ► Rotary Kilns ► Identifying & Resolving Common Rotary Kiln Processing Challenges
Rotary kilns are incredibly diverse in their processing capabilities, a characteristic that has pushed
them into a growing number of applications. And while rotary kilns are reliable machines, they can
experience issues, especially when not properly designed, monitored, or maintained.
Knowing why such issues occur, as well as how to recognize and resolve them, is critical to
maximizing the longevity of a rotary kiln. And although issues are often specific to the unique
parameters of the operation at hand, many rotary kiln operators find themselves facing similar
challenges. The following covers some of the most common issues, along with their causes, how to
spot them, and potential avenues to resolution.
The formation of a material ring in the kiln has several implications, including affecting residence
time and causing product quality issues, creating problems with material buildup in the feed-end
seal, reducing throughput, and promoting material backup in the kiln. It can also significantly
reduce throughput. Further, if the ring (or a portion of the ring) breaks free, it has the potential to
completely block the kiln outlet, resulting in more severe problems.
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Ring formation often necessitates frequent shutdowns to clear out material, as well as wasted
product and a higher need for reprocessing. In short, it reduces overall process efficiency.
The slagging temperature is the point at which the material will fuse together, allowing it to solidify. If
a change in feed composition that reduces the slagging temperature is allowed to occur, ring
formation will result.
Similarly, if the kiln temperature is not properly measured and controlled, the temperature may be
allowed to exceed the point at which slagging will occur, resulting in ring formation.
To prevent additional slagging in the future, operators should check the combustion chamber
thermocouples and monitoring systems to ensure they are functioning properly for adequate
temperature monitoring. They should also compare feed material specifications to original process
parameters to ensure a change in feedstock is not to blame.
In some cases, operators may be able to prevent slag formation by increasing the kiln’s rotational
speed, which moves the material through the kiln more quickly.
Material sticking creates an additional challenge in indirect rotary kilns; when material sticks to the
kiln interior, it creates an additional barrier through which heat must pass, further reducing heat
transfer efficiency.
WHAT CAUSES ROTARY KILN STICKING?
Unfortunately, sticking can be caused by almost innumerable issues, making it difficult for operators
to pinpoint the source of the problem. In a broad sense, une
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issue with
how the material’s unique chemical composition and physical characteristics interact with heat.
Material may also become more sticky as it moves through the chemical or physical changes
induced by the kiln.
For these reasons, rotary kiln testing is a critical part of process development; testing helps to identify
such problems prior to commercial-scale production, allowing the kiln to be engineered to work
around the material characteristics.
SIGNS OF STICKING
As with ring formation, a sticking problem is typically indicated by a reduction in material exiting the
kiln.
Batch rotary kiln used for testing in the FEECO Innovation Center
Refractory protects the kiln shell from the high temperatures passing through the unit. When
refractory is allowed to fail, the kiln shell can become damaged, even requiring total replacement in
extreme cases. Further, frequent failures significantly increase downtime, adversely affecting
processing capacity; at a minimum, refractory repair takes three-to-five days to correct a minor
problem. In most applications, plant managers should plan on replacing up to 5% of the refractory
system as a result of normal wear and tear on an annual basis.
While refractory is less commonly employed in indirect kilns (calciners), when it is used in these
applications, a failure has the potential to reduce the thickness of the kiln shell, resulting in
deflection, ovality, or even cracking.
Another issue presented by refractory wear is product contamination; through degradation, small
amounts of refractory may deposit into the product via corrosion or abrasion.
Cycling
The most common cause of refractory wear is the amount of cycling that a kiln undergoes. Cycling is
the shutdown and startup of the kiln. This heating up and cooling down puts stress on the refractory,
and if carried out frequently, substantially increases wear and decreases the life of the refractory.
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Temperature, retention time, and the potential for corrosion and abrasion paired with high
temperatures must be considered.
A reduction or stoppage of material exiting the kiln could also indicate a refractory problem, as
loose refractory may be plugging up the discharge.
Less noticeable are hot spots on the kiln shell. Operators should routinely measure the drum shell
exterior with a temperature gun to check for abnormalities in temperature across the shell.
The rotary kiln’s interior should also be inspected when possible to evaluate refractory health.
Spalling or mechanical degradation of the refractory typically indicates an incompatibility of
materials.
Additionally, misalignment has the potential to impact the effectiveness of the seals. Because rotary
kilns are a carefully controlled processing atmosphere, a reduction in seal effectiveness can change
process conditions, causing process upset or under-processed material.
Several factors can expedite the path to misalignment. This might include sinking foundations or
changes in the structural integrity of the system, fugitive material allowed to build up on
components, and even humidity, among other things.
While misalignment is easily resolved, it’s essential to recognize that if the root cause of misalignment
is not addressed, the kiln will immediately begin to fall out of alignment again. A full rotary kiln
inspection should be conducted to determine the cause of the issue and assess any resulting
damage.
Resolution may involve repairing foundations, skewing or shimming trunnions, or resurfacing (and
sometimes replacing) worn tires, trunnions, or thrust rollers.
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Laser alignment software helps the Customer Service Engineer determine where the rotary kiln needs
adjustment during the alignment process
In addition to raising the burden on downstream equipment, carryover also increases the amount of
product lost as waste, or requiring reprocessing, reducing overall system efficiency.
A drop in pressure also frequently signals excess carryover; material accumulates in the kiln outlet
duct, air pollution control system, and induced draft fan, causing a drop in system pressure.
Other potential indications include a reduction in removal efficiency of the air pollution control
equipment and increased emissions from the system’s discharge stack.
Depending on the provider, inspections typically evaluate the overall mechanical condition of the
unit, identifying components that need attention, as well as providing valuable benchmark data.
Those experiencing process issues or inefficiencies may also benefit from a rotary kiln process audit,
which looks at the system as a whole, along with process parameters, to identify any issues or
opportunities for improvement.
CONCLUSION
Rotary kilns provide an efficient and reliable approach to a wide range of thermal processing
applications. Recognizing where potential for issues exists, as well as how to identify and correct
these issues, is essential to maximizing the life of the unit. Process and equipment audits, along with
annual inspections, are powerful tools in a preventative maintenance program and can also help to
improve kiln process efficiency.
FEECO Customer Service Engineers are highly skilled in the mechanical and operational aspects of
rotary kilns and in addition to identifying issues, can also help to carry out repairs such as
realignment, tire and trunnion grinding, retrofitting solutions, and so much more. For more information
on our extensive rotary kiln parts and service support, contact us today!
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