1 Hornos Rotatorios

Rotary Kiln
Maintenance Seminar
Introduction
Institute ™
Introduction
 Kiln Seminar Agenda

 Types of Kilns Systems
 The Clinker Production Process
 Terminology
 Kiln Safety
Introduction 2
Institute ™
Kiln Seminar Agenda
Introduction 3
Institute ™
Kiln Seminar Agenda
1. Introduction, Kiln Safety

2. Kiln Shell
3. Tires and Ovality
4. Kiln Supports
5. Kiln Bearings
6. Kiln Drive
7. Kiln Alignment
8. Seals, Thrust Rollers,
Maintenance Schedule
Introduction 4
Institute ™
Types of Kiln Systems
Introduction 5
Institute ™
Pyro-processing System
4-Stage Preheater
4-Stage Preheater Kiln String
Calciner String
Tertiary Air
Duct Clinker
Calciner Cooler
Rotary Kiln
The rotary kiln is part of the pyro-processing system.
Introduction 6
Institute ™
Preheater Arrangements
SP ILC SLC
These are some of the many different

configurations of preheaters that have
been installed.
Introduction 7
Institute ™
SP Preheater System
Fuel Consumption
800 Kcal/kg Clinker
The SP (Suspension Preheater) system features four

preheater cyclones. Most calcining is done inside the
kiln. Some fuel (15%) may be added in the riser duct.
Introduction 8
Institute ™
ILC Calciner
Fuel Consumption
700 Kcal/kg Clinker
The ILC (In Line Calciner) system adds a separate

vessel for calcining. Up to 60% of total fuel may be
added here. Raw meal entering the kiln is 92% calcined.
Introduction 9
Institute ™
SLC Calciner
Fuel Consumption
700 Kcal/kg Clinker
The SLC (Separate Line Calciner) system has two

preheater strings, one string attached to the kiln and a
second string with calciner attached to the tertiary air duct.
Introduction 10
Institute ™
Wet Process System
Fuel Consumption
1400 Kcal/kg Clinker
In the wet process system, drying, preheating,

calcining and burning are all done inside the kiln.
Introduction 11
Institute ™
Rotax-2 Kiln
 State of the art kiln technology

 Two supports
 production rates to 7500 mtpd
 Tangential tire suspension
 Gearless, friction drive
 Self-aligning roller supports
Introduction 12
Institute ™
The Clinker Production Process
Introduction 13
Institute ™
Clinker Production
CO2
CaCO3 CaO
1650º F
Limestone 900º C
SiO2 + Al2O3
2650º F
1450º C
Clay/Sand Clinker
Fe2O3
Iron Ore
Introduction 14
Institute ™
Clinker Production
The Four Oxides of Cement Clinker
Calcium Oxide CaO (C) 67%
Silicon Oxide SiO2 (S) 22%
Aluminum Oxide Al2O3 (A) 3.5%
Iron Oxide Fe2O3 (F) 3.5%
96%
Impurities 4%
100%
Introduction 15
Institute ™
Clinker Production
Raw Materials Clinker
67% C 67% C3S

22% S 14% C2S
2650 ºF
3.5% A 5% C 3A
1450 ºC
3.5% F 10% C4AF
4% Impurities
4% Impurities
100%
100%
Introduction 16
Institute ™
Clinker Production
F re e C a O C 3S
C aC O 3
C 2S
Q u a rtz
C 3A
C la y s L iq u id p h a s e
C 4A F
Inside the kiln, the iron and alumina melt to form a

flux in which the calcium and silica dissolve. Upon
cooling the mixture crystallizes into clinker.
Introduction 17
Institute ™
Terminology
Introduction 18
Institute ™
Kiln Terminology
Discharge Tertiary
Hood Air Duct
Inlet Hood
Rotation1
Tire Kiln
Gear Inlet
Shell
Seal
Outlet Pier 1 2
Seal Kiln Drive
Pier Pier
Pier no. 3 Right
Support Uphill Bearing 3
Roller
1
Rotation, as seen from discharge hood
2
For FLS and Fuller kilns, pier numbering starts at discharge
end
3
Bearing right and left a seen from discharge end
Introduction 19
Institute ™
System Terminology
1. Preheater Top Stage
2. Downcomer Duct
3. Kiln Seal
4. Preheater Intermediate Stage
5. Preheater Intermediate Stage
6. Preheater Lower Stage
7. Rotary Kiln
8. Induced Draft Fan
9. Kiln Burner
10. Clinker Cooler
11. Cooler Vent System
Introduction 20
Institute ™
Kiln Safety
Introduction 21
Institute ™
Preheater Flush
Never work anywhere on a kiln system while a preheater

vessel is plugged. If the plug breaks free it will rush like
water through the system, burning everything in its path.
Introduction 22
Institute ™
Preheater Flush
These men were working inside a kiln when a

preheater flush occurred. Two fatalities resulted.
Introduction 23
Institute ™
Preheater Flush
These men were working outside a clinker cooler

when a preheater flush occurred, spewing hot material
through an open man-door. Two fatalities resulted.
Introduction 24
Institute ™
Protective Clothing
When working with hot dust a

complete fireproof suit must be worn.
Introduction 25
Institute ™
Hot Dust
Hot dust can unexpectedly blow out through any

opening in the system. Keep doors and ports closed!
Hot dust can ignite flammable materials in the area.
Introduction 26
Institute ™
Dust Hazard
Be careful around kiln seals. Hot dust can blow

out during process upsets. Kiln dust also
contains lime, which can burn skin and eyes.
Introduction 27
Institute ™
Dust Hazard
Know where your shower and eyewash stations are!
Introduction 28
Institute ™
Fall Protection
Always wear your safety harness

when working above ground.
Introduction 29
Institute ™
Heights
High places can be dizzying.

Always tie off with a safety belt.
Introduction 30
Institute ™
Air Blasters
Kiln Inlet Hood Cooler Inlet
Air blasters are often placed near the kiln inlet and
outlet. They must be disabled when working nearby.
Introduction 31
Institute ™
Air Blasters
Shut off Discharge Lock Out the Test That

the Air the Tank Air Valve the Tank is
Empty
Introduction 32
Institute ™
Lockout/Tagout
Follow your plant’s safety lockout procedures. Lock out all

equipment affecting the area in which you are working.
Introduction 33
Institute ™
Drive Guards
All moving parts must be completely guarded.
Introduction 34
Institute ™
Roller Guards
Kiln rollers are nowadays completely guarded. Note that

the old practice of running lead wire between tires and
rollers to check alignment is no longer encouraged.
Introduction 35
Institute ™
Coating Collapse
Do not work under loose kiln coating.
Introduction 36
Institute ™
Kiln Rollback
Load Center
of Gravity
Due to the feed material being dragged up one

side of the kiln as it turns, an offset load exists
which tries to make the kiln rotate backwards.
Introduction 37
Institute ™
Kiln Roll-Back
Release Switch
Safety Padlock
The backstop can be released manually to allow the kiln

to roll back. Warning! Rolling back too fast can explode
the inching drive and cause serious injury. Keep a lock on
the release switch to prevent unauthorized use.
Introduction 38
Institute ™
Electrical Safety
When working inside a kiln make sure electrical

cables do not short out on the kiln shell.
Introduction 39
Institute ™
Rigging Safety
Before making heavy lifts, make sure you

have received the necessary rigging training.
Introduction 40
Institute ™
Carbon Dioxide
Carbon dioxide is a normal product of the

biological process, but too much CO2 can kill.
Introduction 41
Institute ™
Carbon Dioxide
Kiln exhaust gas contains approximately 35% CO2.

This heavier-than-air gas tends to accumulate in low
lying areas. Make sure all enclosed areas are
properly vented before entering.
Introduction 42
Institute ™
Combustibles
Lock out all fuel systems before entering the kiln.
Introduction 43
Institute ™
Steam Explosions
Use of water around a kiln can be deadly. Water

coming into contact with hot kiln feed or clinker can
vaporize in an instant, causing a steam explosion.
Especially, be careful around wet process kilns.
Introduction 44
Institute ™
Steam Explosions
This man was working in a clinker transport tunnel

when hot material flushed out into standing water in
the elevator pit. He was killed by the steam explosion.
Introduction 45
Institute ™
Questions?
Introduction 46
Institute ™
Rotary Kiln
Maintenance Seminar
Kiln Shell
Institute ™
Kiln Shell
 Shell Details
 Kiln Crank
 Measuring Kiln Crank
 Heat Correction of Kiln Crank
 Shell Repair
 Shell Welding
 Submerged Arc Welding
Introduction 48
Institute ™
Shell Details
Introduction 49
Institute ™
Shell Details
Inlet Tire Tire Tire Outlet

Cone No. 3 No. 2 No. 1 Shroud
40 mm 30 mm 30 mm 50
30 mm
(gear) mm
40 mm 75 mm 80 mm 75 mm
(under tire) 40 mm (under tire) 40 mm (under tire)
Typical shell plate thicknesses.
Introduction 50
Institute ™
Kiln Crank
Introduction 51
Institute ™
Kiln Crank
Kiln crank occurs when a kiln shell is not perfectly

straight. As the shell turns, cyclical loads and
stresses occur in the shell and the kiln supports.
Introduction 52
Institute ™
Kiln Crank
Kiln crank can cause severe cyclical loads, leading to

shell cracks and fatigue cracks in the roller shafts.
Introduction 53
Institute ™
Kiln Crank
Kiln crank will result in gear misalignment

which can destroy gear teeth.
Introduction 54
Institute ™
Kiln Crank
Kiln crank can be temporary, as in the case of

a rain warped shell, or permanent, as in the
case of a shell damaged by heat blisters.
Introduction 55
Institute ™
Kiln Crank
When a hot kiln is stopped during a heavy

rainstorm, one side of the shell cools off and
contracts, causing a concave up curvature.
Introduction 56
Institute ™
Kiln Crank
When a hot kiln is stopped too long without

rotation, heat will rise and the top of the shell
will expand, causing a convex-up curvature.
Introduction 57
Institute ™
Kiln Crank
Irregular coating formation or refractory wear can

cause one side of the shell to heat up more than the
other. The result is a temporary crank in the shell.
Introduction 58
Institute ™
Kiln Crank
Damaged refractory will cause a hot spot in

the shell.
Introduction 59
Institute ™
Kiln Crank
A hot spot left unattended will wrinkle the shell and create a
crank. Refractory bricks will no longer stay in place and the
shell section will have to be replaced at great expense.
Introduction 60
Institute ™
Heat Damaged Kiln Shell
A heat-wrinkled kiln shell will also shorten

the kiln, causing tires to run off-center.
Introduction 61
Institute ™
Kiln Crank
Kiln crank can be caused by poor alignment

of kiln sections during assembly or repair.
Introduction 62
Institute ™
Kiln Crank
Kiln crank can be caused by weld

shrinkage at a temporary shell patch.
Introduction 63
Institute ™
Measuring Kiln Crank
Introduction 64
Institute ™
Kiln crank can be identified by measuring roller

deflection. The load on the roller will change as the
kiln turns and this results in bending of the roller shaft.
Introduction 65
Institute ™
A roller that deflects cyclically with kiln

rotation by over 0.3 mm typically indicates
a crank in the shell that should be repaired.
Introduction 66
Institute ™
Kiln crank can be measured by measuring shell run-

out. A polar diagram is generated on which the
deviation from the true kiln center can be seen.
Introduction 67
Institute ™
A series of polar diagrams gives a

picture of the shell crank.
Introduction 68
Institute ™
Heat Correction of Kiln Crank
Introduction 69
Institute ™
A kiln shell can sometimes be straightened by heat

correction. Insulation is wrapped around the shell,
allowing the shell steel to overheat. Shell stresses then
diminish as the kiln sags into place on the rollers.
Introduction 70
Institute ™
Temperature sensors are installed to

carefully monitor shell temperatures beneath
the insulation during the correction process.
Introduction 71
Institute ™
Introduction 72
Institute ™
Shell Repair
Introduction 73
Institute ™
Shell Repair
Major shell defects are normally repaired by

replacing the damaged section. The band-
aid approach is at best a temporary solution.
Introduction 74
Institute ™
Field Joint Hardware
New shell sections are joined

with adjustable erection lugs.
Introduction 75
Institute ™
Shell Alignment
By adjusting the erection lugs the

shell sections are straightened until
a perfect centerline is achieved.
Introduction 76
Institute ™
Tire Handling
Introduction 77
Institute ™
Shell Rigging
Introduction 78
Institute ™
Shell Rigging
Introduction 79
Institute ™
Shell Handling
Introduction 80
Institute ™
Spider Bracing
Introduction 81
Institute ™
Spider Bracing
Introduction 82
Institute ™
Spider Bracing
Introduction 83
Institute ™
Shell Stiffening Rings
Many older kilns had shell stiffening rings. These rings

would eventually cause shell cracks due to heat expansion.
Field-cutting expansion slots may help this problem.
Introduction 84
Institute ™
Shell Welding
Introduction 85
Institute ™
Joint Preparation
Prior to welding the shell plate ends are carefully prepared.
Introduction 86
Institute ™
Weld Shrinkage
The 60º double V weld results in less shrinkage and

less weld metal being required. Weld distortion is
minimized, avoiding the “gull-wing” effect.
Introduction 87
Institute ™
Weld Shrinkage
Introduction 88
Institute ™
Shell Welding
Introduction 89
Institute ™
Shell Welding
After completing the outside weld, the root

pass is removed using carbon arc gouging.
Introduction 90
Institute ™
Shell Welding
After gouging, the joint is carefully

cleaned and inspected to ensure that
no defects from the root pass remain.
Introduction 91
Institute ™
Shell Welding
When welding is finished, the joint is

inspected radiography or ultrasound.
Defects are marked and then repaired.
Introduction 92
Institute ™
Submerged Arc Welding
Introduction 93
Institute ™
Introduction 94
Institute ™
Introduction 95
Institute ™
Introduction 96
Institute ™
Introduction 97
Institute ™
Introduction 98
Institute ™
Introduction 99
Institute ™
Introduction 100
Institute ™
Introduction 101
Institute ™
Introduction 102
Institute ™
Introduction 103
Institute ™
Introduction 104
Institute ™
Introduction 105
Institute ™
Introduction 106
Institute ™
Introduction 107
Institute ™
Introduction 108
Institute ™
Introduction 109
Institute ™
Introduction 110
Institute ™
Rotary Kiln
Maintenance Seminar
Tires and Ovality
Institute ™
Tires and Ovality
 Tires and Tire Mounting
 Tangential Suspension
 Tire Clearances
 Ovality
 Tire Creep and Top Clearance
 Correcting Ovality
 Tire Pad and Stop Block Repairs
 Tire Crack Repair
Introduction 112
Institute ™
Tires and Tire Mounting
Introduction 113
Institute ™
Kiln Tire Support System
Machined
Surface
Machined
Surface
Tires are mounted over support pads with machined

O.D.’s. Precise clearances are maintained to allow for
different rates of expansion between kiln tire and kiln shell.
Introduction 114
Institute ™
Tire Attachment
Pads are not welded to the shell, but are trapped in

place by guide bars. Stop blocks are welded on one
side only, alternating from one side to the other.
Introduction 115
Institute ™
Tire Attachment
Guide Stop
Bars Ring
Stop
Block
Machined
Support Pad
A loose stop ring is placed between the stop block and

the tire. Wear takes place on the replaceable ring, not
on the stop blocks.
Introduction 116
Institute ™
Tire Attachment
This shows a slightly different version

of the floating pad, stop ring design.
Introduction 117
Institute ™
Bolted Support Pads
Some FLS kilns have bolted support pads. Bolting avoids

heavy welds which lead to shell cracks. The above
arrangement uses a wear ring between stop blocks and tire.
Introduction 118
Institute ™
Bolted Support Pads
This arrangement for smaller, light duty

kilns uses stop blocks directly against the
tire, i.e., without the use of wear rings.
Introduction 119
Institute ™
Tire Attachment
On kilns without wear rings, when the

blocks eventually wear down, they have to
be cut off and new ones re-welded.
Introduction 120
Institute ™
Tangential Suspension
Introduction 121
Institute ™
The tire is fixed and does not creep inside

the shell. Shell expansion is accommodated
with a system of spring-loaded wedges.
Introduction 122
Institute ™
Tangential suspension reduces ovality. Forces

on the shell are tangent rather than radial.
Introduction 123
Institute ™
Tire Bracket
Wedge
Spring
“Dog Bone”
Brackets are bolted onto the tire. “Dog bones” keep

the tire in position. Wedges keep the brackets tight
against the dog bones. Springs keep the wedges
tight as dimensions change with heat expansion.
Introduction 124
Institute ™
“Dog Bone” Tire Bracket
Spring Rod
Wedge
Wedge Retainer
Introduction 125
Institute ™
A completed tire section ready for installation.
Introduction 126
Institute ™
Wedges are held in position with retainer

brackets bolted to the top of the “dog bones”.
Introduction 127
Institute ™
The spring rod pushes the wedge in to maintain

a tight fit between dog bones and brackets as
the kiln shell expands and contracts.
Introduction 128
Institute ™
As the wedges wear, the spring length

increases. Periodically, check the distance
and adjust the spring tension as required.
Introduction 129
Institute ™
“Dog bones” are attached to the shell with heavy

welds. Periodically inspect the welds for cracks.
Introduction 130
Institute ™
Tire bolts are hydraulically tightened to

specification.
Introduction 131
Institute ™
Hydraulic Bolt Tensioning Tool
Introduction 132
Institute ™
Tire Clearance
Introduction 133
Institute ™
Tire Clearance
Machined
Surface
Tires are mounted over support pads with machined O.D.’s.

Precise clearances are maintained to allow for different
rates of expansion between kiln tire and kiln shell.
Introduction 134
Institute ™
Tire Clearance
Normal Cold
Clearance
It is necessary to have clearance between the tire support

pads and tire I.D. to accommodate heat expansion of the
shell. Cold clearance is typically 6-12 mm for a new kiln,
depending on the location of the tire.
Introduction 135
Institute ™
Tire Clearance
Normal Hot Running
Clearance, 0-3 mm
The shell will heat up faster and expand more than the tire,
and clearance will diminish. Normal hot running clearance
should be from 0 to 3 mm (⅛”).
Introduction 136
Institute ™
Rate of Expansion
Rule of Thumb
Expansion of Steel (approx):
1mm / Meter/ 100ºC
Example. A kiln shell with 5 meter (5000 mm) diameter

at 20º C is heated to 320º C. The shell expands
Introduction 137
Institute ™
Ovality
A kiln shell is not stiff enough to support its own weight.

When placed on the ground it collapses to an oval shape.
Introduction 138
Institute ™
Ovality
When placed inside a rigid tire the shell’s deformation is

reduced, but it will still collapse if there is any clearance
present. The amount it collapses depends on the amount of
clearance and on the stiffness of the shell.
Introduction 139
Institute ™
Shell and Tire Deformation
Difference in Actual Top
diameters Clearance
Perfectly Deformed Shell

Round and Tire
Shell and
Tire
Shell deformation also occurs because the tire is not absolutely

rigid. Due to elasticity of both shell and tire, the actual top
clearance is 1.5 to 2 times the difference in diameter.
Introduction 140
Institute ™
Ovality and Brick Problems
Kiln shell ovality causes continuous

flexing of the brick lining as the kiln turns.
Introduction 141
Institute ™
Ovality Refractory Damage
Excessive ovality will damage the refractory lining,

typically with scattered spalling and single brick
fall-out among otherwise undamaged areas.
Introduction 142
Institute ™
Shell Cracks Due to Ovality
Excessive ovality may cause longitudinal

cracks in the shell beneath the tires.
Introduction 143
Institute ™
Shell Cracks Due to Ovality
This shell crack was caused by excessive ovality. The

heavy welding used to attach the support pad was a
contributing factor.
Introduction 144
Institute ™
Definition of Ovality
Dh
Dv
Absolute Ovality Relative Ovality

 = Dh - Dv  = (Dh – Dv )/D
Different definitions of ovality are in use. This
definition takes into account both shell and tire
deformation. Ovality is usually expressed in percent.
Introduction 145
Institute ™
Relative Ovality
Relative Ovality Relative Ovality

 =0 >0
(shell is round) (shell is deformed)
Introduction 146
Institute ™
Ovality Limits
Ovality as a function of kiln diameter. Exceeding

these limits will cause refractory and shell problems.
Introduction 147
Institute ™
Causes of Excessive Ovality
Heating the kiln up too fast can result in bottle-necking

(pinching) of the shell inside the tire. Excessive heating,
i.e., after loss of refractory under the tire, will also cause
bottlenecking.
Introduction 148
Institute ™
Because of its massive size, the tire will change temperature

more slowly than the shell. If the kiln is heated up too fast
the shell will become restricted inside the tire and
deformation will result.
Introduction 149
Institute ™
Excessive Running
Clearance
After the shell becomes deformed and temperatures

return to normal, there will be excessive running
clearance and ovality, resulting in refractory damage.
Introduction 150
Institute ™
Measuring Ovality
The shell-test device measures the kiln shell’s actual radius

of curvature during rotation. From this data the shell stresses
can be precisely calculated.
Introduction 151
Institute ™
Measuring Ovality
Introduction 152
Institute ™
Measuring Ovality
Introduction 153
Institute ™
Measuring Ovality
Shell-test device
Introduction 154
Institute ™
Ovality Calculation
Ovality (%) = 4D² x 100%

3dn
D = outside diameter of the shell at the test

location (meters)
dn = nominal inside diameter of the shell (mm)
 = /15, deflection measured from the shell
test diagram (mm)
Introduction 155
Institute ™
Ovality
Sample Calculation
Tire #1, Station #1, Downhill
ovality (%) = 4D² x 100%

3dn
ovality (%) = 4(3.727m)²(12mm/15) x 100%

3(3657.60mm)
ovality (%) = 0.406%
Introduction 156
Institute ™
Tire Creep and Top Clearance
Introduction 157
Institute ™
Creep
Because of the slight difference in diameter between the

tire ID and shell (support pad) OD, the shell rolls inside
the tire as the kiln turns. This gives the appearance that
the shell is “creeping’ inside the tire.
Introduction 158
Institute ™
Measuring Creep
Creep
Place a chalk-mark on the tire and another right next to it

on the shell. After one revolution, measure the distance
between the two marks. This distance is the creep.
Introduction 159
Institute ™
Measuring Creep
Creep
Creep is the difference in circumference. Therefore,
Creep = Difference in Diameter


Introduction 160
Institute ™
Top Clearance
Top Clearance =
Difference in Diameter x Stiffness Factor
Top clearance depends on the difference in diameter and on

the shell stiffness. The stiffness factor is normally between
1.5 and 2.0, depending on how thick the shell plate is.
Introduction 161
Institute ™
Measuring Creep and Top Clearance
Top clearance and creep can be measured with this

simple device.
Introduction 162
Institute ™
Introduction 163
Institute ™
This is a data sheet of 5 kiln revolutions. The distance

between waves is the creep. The height of the wave is
the top clearance. Always record tire and shell
temperatures and identifying data (kiln no., tire no., date).
Introduction 164
Institute ™
Introduction 165
Institute ™
Introduction 166
Institute ™
Correcting Ovality
Introduction 167
Institute ™
Correcting Ovality
Shims
Excessive clearance can be removed with the

installation of shims beneath the support pads.
Introduction 168
Institute ™
Correcting Ovality
Shim
Shim thickness is calculated to give a hot running clearance

of about 3 mm (⅛”).
Introduction 169
Institute ™
Correcting Ovality
If the kiln shell becomes deformed it is necessary to

replace the tire section. Ovality can be reduced by
installing temporary pads with filler plates, but bricks
will never fit properly on the inside of the kiln shell.
Introduction 170
Institute ™
Correcting Ovality
Introduction 171
Institute ™
Correcting Ovality
Introduction 172
Institute ™
Correcting Ovality
Introduction 173
Institute ™
Correcting Ovality
Introduction 174
Institute ™
Correcting Ovality
Introduction 175
Institute ™
Correcting Ovality
Introduction 176
Institute ™
Correcting Ovality
Introduction 177
Institute ™
Correcting Ovality
Introduction 178
Institute ™
Correcting Ovality
Introduction 179
Institute ™
Correcting Ovality
Introduction 180
Institute ™
Correcting Ovality
Introduction 181
Institute ™
Correcting Ovality
Introduction 182
Institute ™
Correcting Ovality
Introduction 183
Institute ™
Correcting Ovality
Introduction 184
Institute ™
Correcting Ovality
Introduction 185
Institute ™
Tire Pad and Stop Block Repairs
Introduction 186
Institute ™
Regularly inspect the supporting pads and stop blocks for

weld cracks and repair at the next kiln stop. Waiting too
long will only cause problems to compound.
Introduction 187
Institute ™
Replace stop blocks when wear becomes excessive. Do

not use shims as shown, as they probably won’t last.
Introduction 188
Institute ™
Excessive stop block wear on the thrust tire

is especially problematic since it can affect
the gear’s position on the pinion.
Introduction 189
Institute ™
Heavy welds directly on supporting pads frequently

crack due to temperature fluctuations and fatigue stress.
The floating pad design solves these problems.
Introduction 190
Institute ™
Floating Tire Pad Design
Introduction 191
Institute ™
Wear Ring Installation
Wear
Rings
Anti-
Rotation
Bars
Introduction 192
Institute ™
Introduction 193
Institute ™
Introduction 194
Institute ™
Fractures at Shell Pads
Introduction 195
Institute ™
Introduction 196
Institute ™
Introduction 197
Institute ™
Introduction 198
Institute ™
Introduction 199
Institute ™
Tire Crack Repair
Introduction 200
Institute ™
Ultrasonic Inspection of Tires
Introduction 201
Institute ™
Tire Repair Welding
Introduction 202
Institute ™
Tire Repair Welding
Introduction 203
Institute ™
Tire Repair Welding
Introduction 204
Institute ™
Tire Repair Welding
Introduction 205
Institute ™
Tire Repair Welding
Introduction 206
Institute ™
Tire Repair Welding
Introduction 207
Institute ™
Tire Repair Welding
Introduction 208
Institute ™
Tire Repair Welding
Introduction 209
Institute ™
Tire Repair Welding
Introduction 210
Institute ™
Rotary Kiln
Maintenance Seminar
Kiln Supports
Institute ™
Kiln Supports
 Types of Kiln Supports

 Roller Adjustments
 Roller Inclination
 Roller and Tire Defects
 Roller and Tire Re-conditioning
Introduction 212
Institute ™
Types of Kiln Supports
Introduction 213
Institute ™
Rigid Kiln Support
A kiln support consists of two rollers with bearings mounted

on a base frame. This rigid support is the most common.
Introduction 214
Institute ™
Self-Aligning Kiln Support
Tire
Roller
Bearing
Hinge
Pivot Point
On this support the bearings are

mounted on a pivoting frame.
Introduction 215
Institute ™
Self-aligning Traditional
support Rigid Support
A self aligning support maintains continuous

contact between tire and roller as the kiln turns. As
a result, there is less hertz pressure on the roller
and components can be sized more economically.
Introduction 216
Institute ™
Introduction 217
Institute ™
FLS Kiln Support Type SRB
Introduction 218
Institute ™
FLS Kiln Support Type RA
FLS kilns have supports with self aligning bearings in spherical sockets.
Hornos FLS han soportes con cojinetes auto alineación en los zócalos esférica.
Introduction 219
Institute ™
FLS Kiln Support Type RB
The RB support is similar to the RA

support, except the bearing takes the thrust
load next to the roller on a thrust ring.
Introduction 220
Institute ™
Fuller Kiln Support
The Fuller support has rigid bearings.
Introduction 221
Institute ™
Roller Adjustments
Introduction 222
Institute ™
Axial Forces on a Kiln
Las fuerzas axiales en un horno
2 - 4% slope
Kiln’s Downhill Force Horno de descenso de la Fuerza
Thrust
Roller
Force
Friction Force
La fricción de la Fuerza
A kiln on a slope will tend to move downhill as it turns. That downward movement is resisted by both the friction force
between rollers and tires, and by the force on the thrust roller.
Un horno en una pendiente tenderá a moverse hacia abajo a medida que gira. Ese movimiento hacia abajo es resistido tanto por la fuerza
de fricción entre los rodillos y neumáticos, y por la fuerza en el rodillo de empuje
Introduction 223
Institute ™
Roller Friction Force
Rodillo de la fuerza de fricción
Neutral
Neutral
When a kiln roller is not exactly parallel to the kiln axis, it imparts an axial thrust force to the kiln. The direction of
this force (uphill or downhill) depends on how the roller is skewed, and on the direction of kiln rotation.
Cuando un horno de rodillos no es exactamente paralelo al eje del horno, que imparte una fuerza de empuje axial en el horno.
La dirección de esta fuerza (hacia arriba o hacia abajo) depende de cómo el rodillo es sesgada, y en el sentido de rotación del
horno.
Introduction 224
Institute ™
Roller Adjustment
Counter-Clockwise Kiln
Horno de rodillos de ajuste contra el sentido del reloj
Direction of Kiln Thrust

Dirección de empuje del horno
To reduce the load on the thrust roller, all rollers should be skewed to push the kiln uphill, never downhill. Shown above are
the correct adjustments for a kiln that turns counter-clockwise (looking from the burner floor).
Para reducir la carga en el rodillo de empuje, los rodillos deben estar sesgadas para impulsar el horno cuesta arriba, nunca hacia abajo.
Arriba se muestran los ajustes correctos para un horno que se vuelve hacia la izquierda (mirando desde el piso del quemador).
Introduction 225
Institute ™
Roller Adjustment
Clockwise Kiln
Ajuste de rodillos Las agujas del reloj del horno

Dirección de empuje del horno
These are the correct adjustments for a clockwise turning kiln.

Estos son los ajustes correctos para un horno de las agujas del reloj girando.
Introduction 226
Institute ™
Roller Adjustment
Ajuste de rodillos
Neutral
Neutral
Feed Discharge
End End
Rollers on the discharge pier are often adjusted for neutral thrust. This avoids excessive roller wear
caused by dust from the kiln seal.
Rodillos en el muelle de descarga se han ajustado para el empuje neutral. Esto evita el desgaste excesivo de
rodillos causado por el polvo de la junta de horno.
Introduction 227
Institute ™
Good Roller Adjustment
Buen ajuste de rodillos
 All Rollers Pushing Uphill

 All Rollers Pushing Equally
 Kiln Floating Between Upper and
Lower Thrust Rollers (or, correct
pressure on hydraulic thrust cylinder)
 *Todos los rodillos empujar cuesta arriba
*Todos los rodillos de presionar igualmente
*Horno flotante entre el Alto y el Bajo rodillos de empuje (o, la presión correcta en el cilindro de
empuje hidráulico)
Introduction 228
Institute ™
Roller -Tire Forces
Fuerzas rodillo-neumático
When the force on the tire/kiln is uphill, the force on the roller is downhill. The direction of thrust can be determined
by observing the contact or gap at the thrust stop inside the bearing.
Cuando la fuerza en el neumático / horno es cuesta arriba, la fuerza sobre el rodillo es cuesta abajo. La dirección de empuje se
puede determinar mediante la observación del contacto o la brecha en la parada de empuje dentro del rodamiento.
Introduction 229
Institute ™
Bearing Thrust Arrangements
Downhill Uphill
Bearing Bearing
Teniendo cuesta
Teniendo
descenso
FLS Type RA
arriba
Takes Thrust Load on Thrust Collar
Toma de carga axial de empuje del collar
FLS Type RB
Takes Thrust Load on Thrust Ring
Toma de carga axial en el anillo de empuje
Fuller
Takes Thrust Load on Thrust Washer
Toma de carga de empuje en la arandela de empuje
Introduction 230
Institute ™
Bearing Thrust Arrangements
Teniendo Régimen de empuje
FLS Type RA
Gap Contact Direction of

FLS Type RB Force on Kiln
Dirección de la fuerza de
Horno
Contact Gap
Direction of
Force on Roller
Fuller
Dirección del Trabajo
sobre rodillo
Contact Gap
Introduction 231
Institute ™
FLS Bearing Type RA
FLS RA Tipo de cojinete
Thrust
Collar
De empuje del collar
The RA bearing takes the thrust load on a thrust plate which is bolted to the end of the shaft.
El cojinete de la RA tiene la carga de empuje en una placa de empuje que se atornilla al extremo del eje.
Introduction 232
Institute ™
FLS Bearing Type RA
Introduction 233
Institute ™
FLS Bearing Type RB
FLS RB Tipo de cojinete
Thrust
Ring
Anillo de empuje
The RB bearing takes the thrust load at a ring which is shrunk onto the shaft.
El rodamiento RB tiene la carga de empuje en un anillo que se contrae en el eje.
Introduction 234
Institute ™
FLS Bearing Type RB
Introduction 235
Institute ™
Fuller Bearing
Thrust
Washer
The Fuller bearing takes the thrust load on a thrust

washer which is bolted onto to the housing end cover.
Introduction 236
Institute ™
FLS Bearing Type RA
The direction of roller thrust in an RA bearing is determined by observing the gap between thrust plate and bronze bearing
liner. Contact in the uphill bearing and a gap in the lower bearing indicates that the roller is pushing the kiln uphill.
La dirección de empuje del rodillo en un cojinete de la RA se determina mediante la observación de la brecha entre la placa de empuje y el
revestimiento del cojinete de bronce. Contacto en el cojinete hacia arriba y una brecha en el rodamiento inferior indica que el rodillo está
empujando hacia arriba el horno.
Introduction 237
Institute ™
FLS Bearing Type RA
Contact
For FLS bearings type RA, there should always be contact between thrust plate and bronze bearing liner on the uphill
bearing. This indicates that the roller is pushing the kiln uphill.
Para FLS tipo de rodamientos de la AR, siempre debe haber contacto entre la placa de empuje y el revestimiento del cojinete de bronce
en el cojinete hacia arriba. Esto indica que el rodillo está empujando hacia arriba el horno.
Introduction 238
Institute ™
FLS Bearing Type RB
Direction of roller thrust in an RB bearing is

determined by observing the gap/contact between
thrust ring and bronze bearing liner.
Introduction 239
Institute ™
FLS Bearing Type RB
Thrust
Ring
Contact
Bearing
Liner
For FLS bearings type RB, there should always be contact

between thrust ring and bronze bearing liner on the downhill
bearing. This indicates that the roller is pushing the kiln uphill.
Introduction 240
Institute ™
FLS Bearing Type RB
Gap
For FLS bearings type RB, a gap should always be present

on the uphill bearing. This indicates that the roller is pushing
the kiln uphill.
Introduction 241
Institute ™
Fuller Bearing
For Fuller bearings, thrust direction is checked by rapping the

bearing end cover with a hammer. A solid sound indicates
contact, a hollow sound indicates a gap.
Introduction 242
Institute ™
Measuring Roller Thrust
Graphite
Block
Important! Rollers and tire surfaces must be completely

free of oil when skewing adjustments are made. Only
graphite block lubrication is permitted.
Introduction 243
Institute ™
Roller Adjustment
Rollers should be adjusted to “float” the kiln between the

upper and lower thrust rollers.
Introduction 244
Institute ™
Roller Adjustment
Pressure Gage
For kilns with hydraulic thrust rollers, support rollers are

adjusted to keep the hydraulic pressure within specification.
Introduction 245
Institute ™
Hydraulic Pressure
Area = (Piston Diameter) 2 x 

Force = Pressure x Area
4
The force on the thrust roller can be calculated from the

hydraulic pressure indicated on the gage.
Introduction 246
Institute ™
Calculation of Hydraulic Pressure
When All Rollers Are Neutral
• Calculate the weight of the rotating parts of the kiln (shell,
tires, gear, refractory, material load).
• Multiply by the % kiln slope to get the force on the thrust roller.
• Divide by the total piston area of all thrust rollers.
Example:
• 1000 short ton kiln x 2,000 pounds/short ton = 2,000,000 pounds
• 2,000,000 pounds x 3% slope = 60,000 pounds force on thrust roller
• Area of single 10” diameter piston = (10) 2 x  = 78.5 inches 2

4
Pressure = 60,000 = 764 PSI

78.5
Introduction 247
Institute ™
Roller Adjustment
Rollers are skewed by moving bearings in or out as

required. Note that the adjusting screws shown are
greased and wrapped to prevent corrosion.
Introduction 248
Institute ™
Jacks for Roller Adjustment
Pancake Jacks are available with forces over 100 tons

to aid in pushing bearings in for roller adjustment.
Introduction 249
Institute ™
Roller Adjustment
Moving a bearing out is easier.

A small jack may be needed.
Introduction 250
Institute ™
Roller Adjustment
• Always measure and record every bearing adjustment.

To keep from changing the kiln center, make equal and
opposite movements on each bearing.
Introduction 251
Institute ™
Measuring precise roller thrust is possible on FLS

bearings using this “axial measuring device”.
Introduction 252
Institute ™
The axial measuring device consists of a hand jack with

pressure gage, a mounting fixture, and an adapter with
bearing to enable readings when the roller is turning.
Introduction 253
Institute ™
The jack is pumped up until the roller begins to move

uphill off its thrust stop. At this point a pressure reading
is taken and the reading is then converted to tons force.
Introduction 254
Institute ™
FLS
FLS
Type RA
Type RB
Data assumes a
jack piston with
16.6 cm2 surface
area.
Introduction 255
Institute ™
Step-worn Roller and Tire Grooved Roller Shaft
Caution! It may not be possible to accurately measure

roller thrust if tire and roller surfaces are not
cylindrical or if roller shafts or bearings are grooved.
Introduction 256
Institute ™
Determining Roller Thrust
Trial and Error Method
 Find the roller’s neutral point (parallel to kiln axis)

by adjusting the roller skew in small increments
until the bearing thrust contact/gap changes from
one bearing to the other.
 Once the neutral point is determined, make a small
adjustment to push the kiln uphill.
 While making an adjustment of an individual roller,
always observe the kiln’s thrust rollers to ensure
that they are not being overloaded.
Introduction 257
Institute ™
Roller Inclination
Introduction 258
Institute ™
Roller Inclination
Just like horizontal skewing, vertical skewing of a roller,

i.e., having a roller slope different than the kiln slope, will
also create a thrust force.
Introduction 259
Institute ™
Roller Inclination
Roller slope must not deviate from the kiln slope by

more than 0.02% (0.04% for old kilns). The direction of
allowable deviation must be such that the roller pushes
the kiln uphill.
Introduction 260
Institute ™
Measuring Roller Slope
Roller slope is measured with an inclinometer.
Introduction 261
Institute ™
Inclinometer
1 mm
micrometer
100 mm
scale
Spacing
Due to its dimensioning, the inclinometer reads the

percent slope directly.
Introduction 262
Institute ™
Inclinometer
When the leveling bubbles are centered, the

percent slope is read on the micrometer dial.
Introduction 263
Institute ™
Inclinometer
Magnets allow mounting the inclinometer on

horizontal or vertical surfaces. The inclinometer
has a precision bubble level for each position.
Introduction 264
Institute ™
Inclinometer
Check the roller slope with the inclinometer mounted on the

shaft end. Take readings on both ends of the shaft and
average them to eliminate the effect of roller shaft deflection.
Introduction 265
Institute ™
Inclinometer
This arrangement can be used to measure

the roller slope while the kiln is turning.
Introduction 266
Institute ™
Inclinometer
Using an inclinometer on a precision straight edge

across a kiln base to determine the correct slope.
Introduction 267
Institute ™
Roller and Tire Defects
Introduction 268
Institute ™
Tire and Roller Defects
If kiln rollers are skewed too much the

wear rate can be quite severe.
Introduction 269
Institute ™
Excessive hertz pressures on under-designed or poorly

cast tires and rollers can result in severe pitting.
Introduction 270
Institute ™
The old practice of running a roller in a water bath is now

thought to promote surface pitting and is no longer
recommended.
Introduction 271
Institute ™
When rollers are misaligned or conical-shaped, the kiln load is spread over too small an area. This causes high
surface stresses resulting in pitting.
Cuando los rodillos están desalineados o de forma cónica, la carga del horno se extiende sobre la zona son demasiado
pequeñas. Esto hace que la superficie de alta tensiones resultantes de las picaduras.
Introduction 272
Institute ™
A defect on a roller may transfer to the tire, and vice-versa.

Un defecto en un rodillo puede transferir a la llanta, y viceversa
Introduction 273
Institute ™
Roller or tires may wear to a conical shape.
Rodillo o llantas pueden llevar a una forma cónica
Introduction 274
Institute ™
A tire running off the roller for a long time will wear into a step pattern.
Un neumático corriendo el rodillo durante mucho tiempo se gastará en un paso patrón
Introduction 275
Institute ™
Tire wobble can create a concave roller surface.
Bamboleo de neumáticos puede crear una superficie del rodillo cóncavo
Introduction 276
Institute ™
Roller and Tire Re-conditioning
Introduction 277
Institute ™
Rollers and tires may be re-conditioned by machining or grinding. Shown above is a lathe adapted for this purpose.
Rodillos y los neumáticos pueden ser re-acondicionado por maquinado o esmerilado. Arriba se muestra un torno adaptados para
este fin.
Introduction 278
Institute ™
Rollers are re-conditioned while the kiln is in operation.
Los rodillos son re-acondicionado, mientras que el horno está en funcionamiento
Introduction 279
Institute ™
Machining a kiln tire while the kiln is in operation.

Mecanizado de un neumático del horno, mientras que el horno está en funcionamiento
Introduction 280
Institute ™
The machinist is protected with a heat shield.

El maquinista está protegido con un escudo térmico
Introduction 281
Institute ™
This roller is being resurfaced by grinding rather than machining.
Este rodillo se resurgido por desgaste en vez de mecanizado
Introduction 282
Institute ™
Re-surfacing a tire by grinding

Re-pavimentación de un neumático por desgaste
Introduction 283
Institute ™
Tire and roller edge defects must also be removed.

Edges should then be chamfered.
Introduction 284
Institute ™
Rotary Kiln
Maintenance Seminar
Kiln Bearings
Institute ™
Kiln Bearings
 FLS Bearing Type RA - 1958 Design
 FLS Bearing Type RB - 1974 Design
 Fuller Bearing
Kiln BearingsIntroduction 286

Institute ™
FLS kilns have supports with self aligning bearings in

spherical sockets.
Introduction 287
Institute ™
FLS Bearing Type RA
Heat
Oil Oil Tray Shield
Felt Oil Scraper
Seal
Oil
Scoop
Thrust
Plate
Oil Level
Gage
Bronze
Bearing
Spherical Socket Liner
with Water Jackets
Introduction 288
Institute ™
FLS Bearing Type RA
Inspection
Heat Shield
Port
Water
Piping
Stop Block
Introduction 289
Institute ™
Type RA Oil Seal and Scraper
Felt Seal
Rubber
Oil
Scraper
Introduction 290
Institute ™
FLS Bearing Type RA
Introduction 291
Institute ™
Inspection Ports
Oil Flow Oil Flow
Thrust
Contact/Gap
The FLS type A bearing has three inspection ports for

monitoring lubrication and thrust direction.
Introduction 292
Institute ™
Oil Tray
Tray
Slope
Adjusting
Screws
Scoops
Oil scoops dip into the sump and carry oil into the oil tray.
Holes in the tray allow oil to drip onto the shaft. The tray
slope is adjustable to permit downhill flow of oil.
Introduction 293
Institute ™
FLS Kiln Support Type RB
Thrust Ring
The RB support is similar to the RA support, except there is

no thrust plate and the bearing takes the thrust load on a
thrust ring.
Introduction 294
Institute ™
FLS Bearing Type RB
Adjustable
Oil Tray Oil Seal
Oil
Scoops
End Cover
with
Inspection
Door Thrust
Ring
Bronze
Bearing Liner
Bearing
Base Spherical Socket with
Water Jacket
Introduction 295
Institute ™
FLS Bearing Type RB
Heat
Shield
Inspection
Port
Oil Tray
Temperature
Detector
Water
Retainer
Piping
Clamp
Dowel
Pin
Introduction 296
Institute ™
Type RB Oil seal
Grease
Fitting
The RB bearing has a split rubber oil seal which requires

monthly greasing.
Introduction 297
Institute ™
FLS Bearing Type RB
Introduction 298
Institute ™
Fuller Kiln Support
The Fuller support has rigid (non-

spherical) bearings.
Introduction 299
Institute ™
Fuller Bearing
Inspection
Port
Oil Tray
End Cover
Thrust
Washer
Oil Scoop
Oil Level
Indicator
Bronze
Bearing Liner
Introduction 300
Institute ™
Bearing Liners
Introduction 301
Institute ™
FLS Bearing Liner Details
Introduction 302
Institute ™
Liner Clamps
Liners and sockets are clamped to prevent from rotating out

of the housing.
Introduction 303
Institute ™
Liner Clearance
Liner side clearances should be checked with a feeler

gage at all four liner corners after installing a new liner.
Introduction 304
Institute ™
Bearing Tolerances
Introduction 305
Institute ™
Bearing Tolerances
Side
Clearance
Oil
Film
Insufficient side clearance will prevent oil from being drawn

into the bearing. Excessive side clearance will result in the
load being spread over too small an area, with a reduction of
the oil film thickness at the bottom of the shaft.
Introduction 306
Institute ™
Checking Liner Contact
Before installation of a new liner, apply Prussian blue to the

shaft to check liner to shaft contact. The liner, installed in the
socket, is lowered onto the shaft and slid back and forth
longitudinally to pick up the dye at the liner contact points.
Introduction 307
Institute ™
A well-fitting liner will pick up the blue only in the

center down its entire length.
Introduction 308
Institute ™
This liner shows less than full contact along its length,
indicating a high spot in its center.
Introduction 309
Institute ™
High spots are removed by scraping the bronze away

at the heavily blued areas.
Introduction 310
Institute ™
Bearing Lubrication
Introduction 311
Institute ™
Lubrication Film
Tiny surface asperities are kept from contacting

each other by a good oil film.
Institute ™
Hydrodynamic Lubrication
As one surface slides over another, a wave of oil

wedges them apart, creating an oil film.
Institute ™
Hydrodynamic Lubrication
When the shaft rotates, oil is drawn in between the

journal and bearing. The shaft lifts and a lubrication
film is established.
Institute ™
Elasto-hydrodynamic Effect
Under extreme forces, plastic deformation occurs

and surface area in the contact zone increases.
Lubricant viscosity multiplies under extreme
pressure. The result is a thin but stable oil film
capable of keeping surfaces separated.
Institute ™
Boundary Lubrication
When speed or oil viscosity is too low, or when loads

are excessive, surfaces may contact. Boundary
lubrication conditions are said to exist.
Institute ™
EP Additives
Extreme pressure and anti-wear additives in the oil

react to the high heat and pressures at the surfaces
to form a low-friction chemical film, thus preventing
surfaces from seizing.
Institute ™
Oil Film Thickness
L=
Oil film thickness increases with viscosity and speed and

decreases with load. A good film thickness is three times
the surface roughness.
Introduction 318
Institute ™
Viscosity
Viscosity, or the resistance of a liquid to flow, is the most

important property of lubricating oil. Oil viscosity changes
drastically with temperature.
Introduction 319
Institute ™
Viscosity
Oil viscosity is selected based on equipment operating

temperature range.
Introduction 320
Institute ™
Viscosity Index
Viscosity index is a relative measurement of how viscosity

changes with change in temperature. Oil with a higher
viscosity index can maintain its viscosity over a wider
temperature range.
Introduction 321
Institute ™
ISO Viscosity Grade
• International Standards Organization

designation for oil viscosity grade.
• Measured as Centistoke (cSt) at 40º C.
• Becoming more common than SSU
(Saybolt Seconds Universal).
• Multiply ISO VG by 5 to approximate
SSU at 100º F.
Introduction 322
Institute ™
Viscosity
Equivalents
Introduction 323
Institute ™
Kiln Bearing Lubricants
• Gear oils with EP additives

• Viscosity ambient temperature
ISO VG 460 below 5º C
ISO VG 680 above 5º C
• Synthetic oils are preferred over
mineral oils, due to their increased
viscosity index, lower pour point and
effectiveness at high temperatures.
Introduction 324
Institute ™
Oil Level Indicator
Check oil level daily. Note that the level in the uphill
bearing indicator is different than in the downhill bearing.
Make sure that the oils scoops dip into the oil.
Introduction 325
Institute ™
Inspection of Oil Flow
At start-up, especially after a long shutdown, oil is added

manually to ensure that there is lubrication before rotation
starts.
Introduction 326
Institute ™
Bearing Lube Pump
Bearings can be equipped with lube pumps to

provide oil to the tray prior to kiln start-up.
Introduction 327
Institute ™
Bearing Circulating Lube System
A circulating lube unit can filter and cool the bearing oil. This
one-pump unit serves one kiln support. It is equipped with four
flow switches, one for each bearing of the two-roller support.
Introduction 328
Institute ™
Bearing Temperature RTD
Oil film temperature can be measured with an RTD

(resistance temperature detector), which slides over the
journal as the shaft turns. Temperatures above 80ºC
indicate a lubrication problem
Introduction 329
Institute ™
Hot Bearings
 Check cooling water supply.
 Check that a bearing heat shield is in place.
 Check oil cleanliness.
 Check the oil viscosity. Switch to a higher viscosity
(ISO V.G. 1000) if oil temperature exceeds 80-90ºC.
 Use synthetic oil instead of mineral oil.
 Check thrust load and reduce by adjusting roller
skew accordingly.
 Check liner smoothness. Replace if necessary.
 Check shaft smoothness. Re-machine if necessary.
 Check liner to shaft contact.
Introduction 330
Institute ™
Lubrication Failure
Introduction 331
Institute ™
Lubrication Failure
Introduction 332
Institute ™
Severe Lubrication Failure
Introduction 333
Institute ™
Catastrophic Lubrication Failure
Introduction 334
Institute ™
Introduction 335
Institute ™
Introduction 336
Institute ™
Introduction 337
Institute ™
Introduction 338
Institute ™
Rigging
Introduction 339
Institute ™
Rigging for Fuller Roller Assembly
Introduction 340
Institute ™
Rigging for Fuller Bearing
“Feed End”
Stamp
Introduction 341
Institute ™
Bearing End Cover Removal
Bearing inspection can be facilitated by the preparation

of two 24” rods on which to slide off the end cover.
Introduction 342
Institute ™
Rigging for FLS Bearing Liner
Introduction 343
Institute ™
Lifting Eyes for
Cover Only!
Warning! Do not use cover lifting eyes to lift FLS bearings.

They are designed only to lift the covers off the bearing
housing.
Introduction 344
Institute ™
Rotary Kiln
Maintenance Seminar
Kiln Drive
Institute ™
Kiln Drive
 Gear and Pinion Drive

 Friction Drive
 Hydraulic Friction Drive
 Coupling Basics
Introduction 346
Institute ™
Gear and Pinion Drive
Motor Cooling
Fans
Free Fixed
Bearing Bearing Jack Shaft Tacho-
meter
Reversible Main Tandem Variable Speed

Pinion Reducer Motors
Introduction 347
Institute ™
Kiln Inching Drive
One-way Clutch
Inching Drive
Reducer
Backstop
Inching Drive
Motor
The inching dive arrangement permits a rotation of

approximately once every 10 minutes. A one-way clutch
prevents over-speeding when the main drive is in
operation. A backstop prevents kiln roll-back.
Introduction 348
Institute ™
Kiln Drive
A jackshaft is used to improve the layout of the drive

pier. This one is equipped with gear couplings.
Introduction 349
Institute ™
Pinion Alignment
Gear Pitch
Circle
Pinion
Pitch
Circle
The pinion must be positioned so that pitch

circles are tangent, and there is full face
contact across the width of the teeth.
Introduction 350
Institute ™
Axial Alignment
The gear and pinion must have full face contact when the
kiln is hot. It may be necessary to move the thrust rollers
or reposition the thrust tire stop blocks to achieve this.
Introduction 351
Institute ™
Inching Drive
Main One-Way Inching

Reducer Clutch Drive Backstop Inching
Reducer Motor
Introduction 352
Institute ™
One-Way Clutch
The one-way clutch prevents over-speeding of

the inching drive by locking the input and
output shafts in one rotational direction only.
Introduction 353
Institute ™
One-Way Clutch
Automatic
Transmission
Fluid
Most one-way clutches have locking steel

pawls inside, which require lubrication with
automatic transmission fluid only.
Introduction 354
Institute ™
Kiln Rollback
Load Center
of Gravity
•Due to the feed material being dragged up one side of

the kiln as it turns, an offset load exists which tries to
make the kiln rotate backwards.
Introduction 355
Institute ™
Backstop
The backstop prevents kiln roll-back. Most backstops

aslo have locking steel pawls inside, which require
lubrication with automatic transmission fluid.
Introduction 356
Institute ™
Backstop
Release Switch
Safety Padlock
The backstop can be released manually to allow the

kiln to roll back. Warning! Rolling back too fast can
over-speed and destroy the inching drive. Keep a lock
on the release switch to prevent unauthorized use.
Introduction 357
Institute ™
Pinion Bearing Oil Lubrication
Oil Level
Sight Glass
Bearing oil level should be sufficient to cover half of the

lowermost rolling element. Note that the indicator may
show different levels, depending on whether it is
mounted on the uphill or downhill side of the housing.
Introduction 358
Institute ™
Pillow Block Bearing
Stabilizing
Ring for Fixed
Bearing only
Oil Level
No Stabilizing
Ring for Free
Bearing
Introduction 359
Institute ™
Kiln Drive
This drive arrangement has a jack shaft with

flexible disc couplings. The backstop is integrally
mounted on the inching drive reducer.
Introduction 360
Institute ™
Friction Drive
Introduction 361
Institute ™
Friction Drive
Motors turn the rollers, and friction between rollers

and tires turns the kiln. There is no kiln gear.
Friction drive is used only on new two-support kilns.
Introduction 362
Institute ™
Friction Drive
Both rollers are driven. The motors are

balanced to prevent slippage.
Introduction 363
Institute ™
Friction Drive
The reducer is shaft mounted. The inching drive with

integral backstop is mounted directly on the main
reducer. The main motor is coupled with a Cardan
shaft. The inching drive motor has a fluid coupling.
Introduction 364
Institute ™
Friction Drive
A special torque arm is used to prevent reducer rotation

while still permitting movement of the roller shaft.
Introduction 365
Institute ™
Hydraulic Friction Drive
A friction drive may use a hydraulic motor to turn the rollers.
Introduction 366
Institute ™
Hydraulic Drive
Advantages
 High starting torque
 High degree of controllability
 Even load sharing between rollers
 Space savings
 No reducer necessary (when using
radial piston motors)
 Shaft mounted, simplified foundation
Introduction 367
Institute ™
This hydraulic drive uses an axial piston motor and

a planetary reducer mounted on the roller shaft.
Introduction 368
Institute ™
Shaft-mounted planetary reducer with torque, with

integral hydraulic motor and inching drive.
Introduction 369
Institute ™
This hydraulic drive uses four radial piston motors

mounted directly on the roller shaft.
Introduction 370
Institute ™
This Hagglunds radial piston motor develops extremely

high torque, and a reducer is therefore not needed.
Introduction 371
Institute ™
The load is equally shared and each roller

receives the same power and torque.
Introduction 372
Institute ™
The typical kiln drive will have multiple

pumps for increased efficiency.
Introduction 373
Institute ™
Hydraulic drive power curve.
Introduction 374
Institute ™
DC drive power curve.
Introduction 375
Institute ™
Hydraulic drive power losses.
Introduction 376
Institute ™
DC drive power losses.
Introduction 377
Institute ™
Couplings
Introduction 378
Institute ™
Coupling Alignment
Couplings must be precisely aligned to minimize

parallel and angular misalignment.
Introduction 379
Institute ™
Coupling Alignment
Imprecise alignment will cause shock and vibrations to be

transmitted to motor and machine bearings, resulting in
reduced bearing life and possible equipment damage.
Introduction 380
Institute ™
Coupling Alignment
Couplings are usually aligned with a dial indicator.
Introduction 381
Institute ™
Coupling Alignment
Align the coupling as accurately as possible to promote

long bearing life (not just to within coupling
manufacturer’s specs).
Introduction 382
Institute ™
Coupling Alignment
Feeler Gage
The coupling gap can be checked with a feeler gage. Gap

specifications are normally found on the equipment
foundation drawing, or in the coupling manufacturer’s data.
Introduction 383
Institute ™
Laser Alignment
Laser alignment offers the most accurate and easiest

coupling alignment.
Institute ™
Laser Alignment
A laser beam on one coupling half reflects back onto a

sensor from a mirror on the other half. Misalignment is
read on a hand-held computer.
Introduction 385
Institute ™
Laser Alignment
Aligning a kiln inching drive with

laser alignment method.
Introduction 386
Institute ™
Rotary Kiln
Maintenance Seminar
Kiln Alignment
Institute ™
Kiln Alignment
Alignment Principles
Internal Alignment
Hot Kiln Alignment
Introduction 388
Institute ™
Alignment Principles
Introduction 389
Institute ™
Kiln Alignment
A kiln is considered aligned when the

center of rotation of the kiln shell at
every support lies on a straight line.
Introduction 390
Institute ™
Kiln Alignment
Two Support Kiln
Note that a kiln with only two supports

is always aligned, as there is always a
straight line between two points.
Introduction 391
Institute ™
Kiln Alignment
Horizontal Axis
Vertical Axis
A kiln can be misaligned in the

horizontal or in the vertical plane.
Introduction 392
Institute ™
Consequences of Misalignment
3902 kN 6491 kN 3067 kN
3597 kN 7048 kN 2815 kN
10 mm
Misalignment changes the loading on the kiln supports

and causes overstressing of the shell and supports.
Introduction 393
Institute ™
Consequences of Misalignment
Misalignment can result in all of the

load being concentrated on one roller.
Introduction 394
Institute ™
Internal Alignment
Introduction 395
Institute ™
Internal Alignment
Internal alignment is normally used when

assembling a new kiln. A line of sight is shot
through batter boards marking the kiln centers at
the shell section ends and at the tire locations.
Introduction 396
Institute ™
Internal Alignment
New kiln sections usually have steel spider

bracing with precisely marked centers. If not,
wooden batter boards can be prepared.
Introduction 397
Institute ™
Internal Alignment
The kiln shell’s center is found by scribing four

arcs on a target card tacked onto the batter board.
Introduction 398
Institute ™
Internal Alignment
Drawing diagonals at the arcs’

intersections will locate the center.
Introduction 399
Institute ™
Internal Alignment
Removable targets with marked shell centers are

placed at each tire center and shell end. The
theodolite’s line of sight is marked on the target and
the offset is measured.
Introduction 400
Institute ™
Kiln Alignment
Top
Clearance
Tire
centre
S
Kiln
centre
Note that if there is any top clearance present, the tire

center is not the same as the kiln center. Alignment
calculations must take hot running clearance into account.
Introduction 401
Institute ™
Correcting Misalignment
Field Joint
Roller Adjustment
Adjustment
After measurements are taken the kiln is

aligned by adjusting rollers and field joints.
Introduction 402
Institute ™
h h
Moving both rollers horizontally will move

the kiln center by the same amount.
Introduction 403
Institute ™
C A C
B B
A2 + B2 = C2
Roller adjustments to correct vertical alignment can

be calculated from the relationship of right triangles.
Introduction 404
Institute ™
¼
½
Moving one roller horizontally will move the kiln

center horizontally by half and vertically by one
quarter (approximately) of the distance.
Introduction 405
Institute ™
Caution! Moving a roller on the piers

immediately uphill and downhill from the
kiln gear will affect the gear alignment.
Introduction 406
Institute ™
Hot Kiln Alignment
Introduction 407
Institute ™
Hot Kiln Alignment
Advantages
 Measurements and corrections can

be completed while the kiln is
operating.
 The data collected indicates the real

conditions as the kiln is operating.
 Alignment errors can be corrected

immediately or during a planned kiln
outage.
Introduction 408
Institute ™
Hot Kiln Alignment
 Mechanical Hot Kiln Survey Method
 Laser Kiln Survey (LKS) Method
Introduction 409
Institute ™
Hot Kiln Alignment
Both methods utilize a variety of
measured data to determine kilns axis:
 Diameter of support rollers and live rings

using electro-mechanical instrument.
 Temperature of the support rollers, live

rings and kiln shell.
 Creep and clearance between the kiln shell

support pads and live rings.
Introduction 410
Institute ™
Mechanical Alignment
Using a theodolite to establish a line of sight

along the kiln, the horizontal distances from the
line of sight to each support roller is measured.
Introduction 411
Institute ™

Tire centre
s
Kiln centre
a b
f
dleft dright F
c
q j
cleft cright
Using an optical level the elevations of

the bearing base frames are determined.
Introduction 412
Institute ™
Elevation
Markers
Elevation markers on kiln piers should

be checked to see if a kiln pier has sunk.
Introduction 413
Institute ™
Roller and Tire Circumference
Using a precision measuring wheel and

tachometer the circumference of the roller
and tire are measured.
Introduction 414
Institute ™
Roller and Tire Circumference
Magnet
DIGITAL CIRCUMFERENCE OF TIRE
A magnet and magnetic sensor record

start/stop positions. Circumference is read
on the digital readout to 0.1 mm accuracy.
Introduction 415
Institute ™
Line of sight
Using the measurements, and knowing the distance

between supports, a kiln centerline can be constructed
which best fits the existing roller positions.
Introduction 416
Institute ™
a b
dleft drightf F
j
c
q
cleft cright
Introduction 417
Institute ™
Laser Kiln Survey
Tire elevation and location can be determined

utilizing a laser theodolite from ground level.
Introduction 418
Institute ™
Laser Kiln Survey
Kiln Center Tolerances
 Horizontal Plane  1.5 mm

 Vertical Plane  2.5 mm
Laser measurement provides the most

accurate method of kiln alignment.
Introduction 419
Institute ™
Laser Kiln Survey
Introduction 420
Institute ™
Laser Kiln Survey
Introduction 421
Institute ™
Laser Kiln Survey
Introduction 422
Institute ™
Laser Kiln Survey
Introduction 423
Institute ™
Questions?
Introduction 424
Institute ™
Rotary Kiln
Maintenance Seminar
Kiln Miscellaneous
Institute ™
Kiln Miscellaneous
 Kiln Inlet Seal

 Kiln Outlet Seal
 Thrust Roller
 Hydraulic Thrust Roller
 Kiln Maintenance Checklist
 The Good Old Days
Introduction 426
Institute ™
Kiln Inlet Seal
Introduction 427
Institute ™
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.
Introduction 428
Institute ™
Kiln Pneumatic Inlet Seal
Pneumatic
Cylinders
The pneumatic seal consists of two sliding

surfaces pushed together by pneumatic cylinders.
Introduction 429
Institute ™
Kiln Inlet Seal
Pneumatic
Cylinders
Seal Detail
Spring Loaded
Graphite Plug
Introduction 430
Institute ™
Kiln Inlet Seal Detail
Sliding Contact
Stationary Sealing Rotating Sealing
Surface Surface
Graphite Plugs
Wire Rope
Graphite Seal Cord
Stationary Kiln Rotating Kiln

Inlet Hood Shell
Introduction 431
Institute ™
Kiln Inlet Seal
Carriage
Turnbuckle
The seal is suspended by a carriage which allows it to

move longitudinally as the kiln expands and contracts.
Introduction 432
Institute ™
Pneumatic Inlet Seal
Stationary Rotating Seal

Seal Half Half
The pneumatic cylinders, when pressurized,

will press the two seal halves tightly together.
Introduction 433
Institute ™
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.
Introduction 434
Institute ™
Filter, Regulator, Lubricator
Introduction 435
Institute ™
Kiln Inlet Seal
Spring Loaded Graphite Plugs in

Graphite Plug Seal Plate
The seal’s sliding surfaces are graphite lubricated.
Introduction 436
Institute ™
Kiln Inlet Castings
Castings on the inlet hood and kiln inlet

cone keep the castable refractory in
place. Inspect them at annual shutdown.
Introduction 437
Institute ™
Spring Plate Inlet Seal
Introduction 438
Institute ™
Introduction 439
Institute ™
Introduction 440
Institute ™
No, covering the spring plates with plastic won’t help.
Introduction 441
Institute ™
Outlet Seal
Introduction 442
Institute ™
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.
Introduction 443
Institute ™
Kiln Outlet Seal
Spring Plate Wire

Rope
Introduction 444
Institute ™
Kiln Outlet Seal
Counterweight
Spring plates are wrapped with a counterweighted wire

rope arrangement to keep them tight against the cowl.
Introduction 445
Institute ™
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.
Introduction 446
Institute ™
Kiln Outlet Seal
Spring plates are bolted on and are easily replaced.
Introduction 447
Institute ™
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.
Introduction 448
Institute ™
Kiln Outlet Sector
The kiln nose rings sees severe service and must be

regularly inspected for refractory and casting failure.
Introduction 449
Institute ™
Kiln Outlet Seal
This alternate spring plates design features

outwardly protruding spring plates.
Introduction 450
Institute ™
Kiln Outlet Seal
Outwardly protruding spring plate design.
Introduction 451
Institute ™
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.
Introduction 452
Institute ™
Thrust Roller
Introduction 453
Institute ™
Thrust Roller Assembly
Clearance
Oil
Tire
Seal
Spherical
Tie Bearings
Oil Level
Rod
Pipe
Shims
Keep the clearance to a minimum (6mm),

and adjust the shims to keep the kiln gear
in proper longitudinal alignment.
Introduction 454
Institute ™
Thrust Roller Assembly
Set
Screws
The kiln position can be controlled by

adjusting set screws on this thrust roller base.
Introduction 455
Institute ™
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.
Introduction 456
Institute ™
Thrust Roller Misalignment
Roller Tilted to Left Roller Tilted to Right
Roller Offset to Left Roller Offset to Right
A misaligned thrust roller will result in vertical forces

on the roller as shown above.
Introduction 457
Institute ™
Thrust Roller Misalignment
An improperly aligned thrust roller can ride out of

its socket, causing damage to tire stop blocks.
Introduction 458
Institute ™
Thrust Roller
Thrust rollers can become overloaded if the kiln’s

supporting rollers are improperly skewed. This thrust
roller base became deformed from excessive force.
Introduction 459
Institute ™
Fuller Thrust Roller
Introduction 460
Institute ™
Fuller Thrust Roller
Introduction 461
Institute ™
Hydraulic Thrust Roller
Introduction 462
Institute ™
The hydraulic thrust roller maintains a constant,

controlled force on the thrust tire and keeps the
kiln in an electronically determined position.
Introduction 463
Institute ™
Position
Sensor
Hydraulic Cylinder Guide Bar
Introduction 464
Institute ™
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.
Introduction 465
Institute ™
Thrust Roller
The roller surface is graphite lubricated.
Introduction 466
Institute ™
Introduction 467
Institute ™
Hydraulic Cabinet
The hydraulic power unit is normally

placed beneath the kiln’s thrust pier.
Introduction 468
Institute ™
Hydraulic Cabinet
Relief
Valve
Tank
Accumulator
Directional
Valve
Pump
Introduction 469
Institute ™
Hydraulic Pump
The axial piston pump has manual

adjustments for pressure and flow rate.
Introduction 470
Institute ™
Directional Valve
A directional valve directs fluid to the thrust

cylinder, or allows the cylinder to bleed down.
Introduction 471
Institute ™
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.
Introduction 472
Institute ™
G a s V a lv e
N itr o g e n G a s
B la d d e r
A n ti- E x tr u s io n
V a lv e
S h e ll
P o rt
The accumulator
F ig u re 1 7contains
. 6 B la d d e r-Ty p e A c c u m u laa
to r rubber bladder
which is charged with nitrogen gas.

C O P Y R IG H T C (1 9 9 9 ) V IC K E R S , IN C O R P O R A T E D
Introduction 473
Institute ™
1000 1000 1000

500 1500 500 1500 500 1500
0 2000 0 2000 0 2000

p s ig p s ig p s ig
S y s te m P re s s u re S y s te m P re s s u re S y s te m P re s s u re
L e s s T h a n p p re c h a rg e a t p m ax a t p m in
When hydraulic pressure increases and decreases

F ig u re 1 7 . 7 B la d d e r A c c u m u la to r O p e ra tio n
the gas is compressed and expanded.
C O P Y R IG H T C (1 9 9 9 ) V IC K E R S , IN C O R P O R A T E D
Introduction 474
Institute ™
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.
Introduction 475
Institute ™
Pressure Relief Valve
A pressure relief valve limits hydraulic pressure in

the system. This prevents excessive downhill kiln
force from damaging the thrust roller.
Introduction 476
Institute ™
Hydraulic Filter
An in-tank filter with a 10 micron element

keeps hydraulic fluid clean. The protruding red
button indicates the element needs changing.
Introduction 477
Institute ™
Thrust Cylinder LVDT
An LVDT (linear variable differential transformer)

mounted in the hydraulic cylinder measures the
distance that the cylinder rod is extended.
Introduction 478
Institute ™
Thrust System LVDT Cabinet
The LVDT signal goes to a cabinet where the kiln’s hot

running axial position is set and where alarms are
programmed for excessive uphill and downhill kiln position.
Introduction 479
Institute ™
Fuller Hydraulic Thrust Roller
Introduction 480
Institute ™
Fuller Hydraulic Thrust Roller
Introduction 481
Institute ™
Preventive Maintenance
Checklist
Introduction 482
Institute ™
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 1200-1300 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.
Introduction 483
Institute ™
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.
Introduction 484
Institute ™
Daily
• Temperatures
• Record kiln shell temperatures and include a

night visual inspection for “hot spots”
Introduction 485
Institute ™
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.
Introduction 486
Institute ™
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.
Introduction 487
Institute ™
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.
Introduction 488
Institute ™
The Good Old Days
Introduction 489
Institute ™
The Good Old Days
Introduction 490
Institute ™
The Good Old Days
Introduction 491
Institute ™
Rivets
Introduction 492
Institute ™
Don’t Be Mean to Your Kiln
Introduction 493
Institute ™

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Rotary Kiln

 Kiln Seminar Agenda

1. Introduction, Kiln Safety

The rotary kiln is part of the pyro-processing system.

These are some of the many different

The SP (Suspension Preheater) system features four

The ILC (In Line Calciner) system adds a separate

The SLC (Separate Line Calciner) system has two

In the wet process system, drying, preheating,

 State of the art kiln technology

Calcium Oxide CaO (C) 67%

Silicon Oxide SiO2 (S) 22%

Aluminum Oxide Al2O3 (A) 3.5%

Iron Oxide Fe2O3 (F) 3.5%

Raw Materials Clinker

67% C 67% C3S

Inside the kiln, the iron and alumina melt to form a

Never work anywhere on a kiln system while a preheater

These men were working inside a kiln when a

These men were working outside a clinker cooler

When working with hot dust a

Hot dust can unexpectedly blow out through any

Be careful around kiln seals. Hot dust can blow

Know where your shower and eyewash stations are!

Always wear your safety harness

High places can be dizzying.

Kiln Inlet Hood Cooler Inlet

Shut off Discharge Lock Out the Test That

Follow your plant’s safety lockout procedures. Lock out all

All moving parts must be completely guarded.

Kiln rollers are nowadays completely guarded. Note that

Do not work under loose kiln coating.

Due to the feed material being dragged up one

The backstop can be released manually to allow the kiln

When working inside a kiln make sure electrical

Before making heavy lifts, make sure you

Carbon dioxide is a normal product of the

Kiln exhaust gas contains approximately 35% CO2.

Lock out all fuel systems before entering the kiln.

Use of water around a kiln can be deadly. Water

This man was working in a clinker transport tunnel

Inlet Tire Tire Tire Outlet

Typical shell plate thicknesses.

Kiln crank occurs when a kiln shell is not perfectly

Kiln crank can cause severe cyclical loads, leading to

Kiln crank will result in gear misalignment

Kiln crank can be temporary, as in the case of

When a hot kiln is stopped during a heavy

When a hot kiln is stopped too long without

Irregular coating formation or refractory wear can

Damaged refractory will cause a hot spot in

A heat-wrinkled kiln shell will also shorten

Kiln crank can be caused by poor alignment

Kiln crank can be caused by weld

Kiln crank can be identified by measuring roller

A roller that deflects cyclically with kiln

Kiln crank can be measured by measuring shell run-

A series of polar diagrams gives a

A kiln shell can sometimes be straightened by heat

Temperature sensors are installed to

Major shell defects are normally repaired by

New shell sections are joined

By adjusting the erection lugs the