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8 - 105.07 e
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15 16
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Main drive Auxiliary drive
14
1 Main motor 9 Internal combustion engine
12
2 Flexible coupling with brake drum 10 Centrifugal clutch
3 Double shoe brake 11 11 Electrical auxiliary motor
5
4 Main gear box 12 Centrifugal clutch / brake
5 Lubricating oil system 10 13 Auxiliary gear box
6 Flexible coupling 14 Flange pump
7 Pinion gear 9
15 Free - wheel
8 Gearwheel guard 16 Flexible coupling

The drive components

Either single, double or triple reduc- One special feature of the gear drive, as a single drive with two pinions,
tion gearboxes are used, depending is that it can operate with only one main motor. This type of drive is often
on the torque to be transmitted. used to increase productivity using the existing girth gear.
These are the most common types This variant, which was developed by KHD Humboldt Wedag, has two
of drive for rotary kilns because positive advantages:
they have a high degree of efficiency • no additional foundation is necessary for a second drive unit
and long-term economical design. • each pinion transmits precisely half of the torque

Nothing can shake them Feel free to create friction


The even, smooth operation of the Alternatively, it’s possible to transmit the drive torque from the rollers to
kiln and optimal contact pattern the tire. This type of drive is only suitable for two station kilns. The
with the pinion is achieved by characteristics of both types of drive are listed in the adjacent table.
mounting the girth gear on the kiln
shell using tangential springs. The Hydraulic drives – acting directly or via gears on the driven shaft – also
centered action of the girth gear is permit smooth kiln operation but are less efficient. This is why they are
adjustable. also considerably less economical.
Compact and Efficient
Gear drive (form-fit) Roller drive (friction-fit)
Function Transmission of loads via tyres and rollers, Transmission of loads and torque via tyres Rotary Kilns
transmission of torque via pinions and girth gear and rollers
Optimal separation of functions without Bearing and drive function in one unit means:
reciprocal influence functional compromise
Design Components are optimised for the relevant Additional drive forces requires stronger roller
function bearings
Efficiency Maximum degree of efficiency, minimum Slipping and friction result in wear and tear to
wear and tear tyres and rollers and impair efficiency
Maintenance Ensure lubrication Ascertain friction values

KHD Humboldt Wedag ZAB Zementanlagenbau GmbH & Humboldt Wedag India Private Ltd. KHD Humboldt (Shanghai)
GmbH Industrietechnik & Service GmbH Espire Campus International Industries Ltd.
Colonia - Allee 3 Brauereistraße 13 A - 41, Mohan Co - op Estate, Office Beijing Guo Ji Da Sha 25 - A
51067 Cologne / Germany 06847 Dessau / Germany Mathura Road 19, Jiangou Menwai Dajie
Phone +49 221 6504 0 Phone +49 340 5029 0 New Delhi - 110044 / India Beijing / PR China
Phone +91 11 4210 1100 Phone +86 10 6500 4101

Humboldt Wedag, Inc. OOO KHD Humboldt Engineering KHD Humboldt Wedag Rep. Humboldt Wedag SA (Pty) Ltd.
400 Technology Parkway Mjasnizkaja ul., 24 / 7 Iran Branch Office 36 Wankel Street, Jet Park
Norcross GA 30092 / USA Office 108 3rd Floor, No. 244 Boksburg, 1459 / South Africa
Phone +1 770 810 7315 Moscow 10100 / Russia Navak Building, Africa Avenue, Phone +27 11 397 4660
www.khdhumboldt.com
Phone +7 495 9233480 Tehran 15186 / I.R. Iran
Phone +98 21 8888 9880
1
2

PYRORAPID ® kiln
1
2
3

3-station-kiln

It all started with a revolution


Kiln plants from KHD Humboldt Wedag are top of the line. One reason: highly efficient precalcining systems, All good things For example
which were developed by KHD Humboldt Wedag, revolutionizing the clinkering process. Rotary kilns no longer From time to time, special circum- • optimized kiln These kiln com-
have to function as calciners which mean that they can be substantially smaller in size. stances necessitate a kiln with a configuration ponents, essential
The advantage for customers is lower investment and operating costs. No wonder these systems quickly gained greater length to diameter ratio ensures even load for ensuring maximum
excellent reputations among our customers. which means that a three-station and force distribution availability, are furnished
kiln is needed. The three-station • the low shell stresses ensures low with high levels of safety and
This is what you can save
kiln from KHD Humboldt Wedag shell deformation and low con- service factors. Further information
In addition the PYRORAPID kiln offers:
® The main criteria for rotary kilns are
is a classic kiln which has been sumption of refractory material about these kiln components are on
• Investment costs approx. 15 % lower than three station kilns. high availability, considerable flexi-
thoroughly tried and tested over • the floating tire fastening system the following pages.
• The lower space requirements and lower weights lead to more bility and cost-effectiveness. They
the decades. Its proven standardi- ensures optimal load transmission
favorable construction costs. must also meet all process techno-
zed parts are also used in the to the rollers supported in double
• Mechanical overloading is impossible. This results in higher levels logy requirements for the clinkering
PYRORAPID ® kiln. Regular optimi- slide bearings
of operational reliability and lower maintenance costs. process. The KHD PYRORAPID ® ro-
zation of standardized parts leads • the large service factor of the kiln
• Lower consumption of refractory lining. tary kiln fulfills all of these require-
to even greater operational reliabi- drive ensures extremely flexible
• The reduced required power and lower radiation losses reduces ments. With two tire stations, length
lity and efficiency. The interaction plant operation
energy costs. to diameter ratio of approx. 11:1
of all components ensures the • the repeatedly proven kiln inlet
• The tire at the kiln discharge is to 12:1 and a statically defined be-
overall problem-free continuous and outlet seals ensure minimum
outside the sintering zone. aring arrangement, the PYRORAPID ®
operation of the kiln. false air infiltration.
kiln offers superior advantages over
Convincing arguments for the a two / three station kiln with a
benefit of our customers. greater length to diameter ratios.
Thermal plant with PYRORAPID ® kiln
1
2

PYRORAPID ® kiln
1
2
3

3-station-kiln

It all started with a revolution


Kiln plants from KHD Humboldt Wedag are top of the line. One reason: highly efficient precalcining systems, All good things For example
which were developed by KHD Humboldt Wedag, revolutionizing the clinkering process. Rotary kilns no longer From time to time, special circum- • optimized kiln These kiln com-
have to function as calciners which mean that they can be substantially smaller in size. stances necessitate a kiln with a configuration ponents, essential
The advantage for customers is lower investment and operating costs. No wonder these systems quickly gained greater length to diameter ratio ensures even load for ensuring maximum
excellent reputations among our customers. which means that a three-station and force distribution availability, are furnished
kiln is needed. The three-station • the low shell stresses ensures low with high levels of safety and
This is what you can save
kiln from KHD Humboldt Wedag shell deformation and low con- service factors. Further information
In addition the PYRORAPID kiln offers:
® The main criteria for rotary kilns are
is a classic kiln which has been sumption of refractory material about these kiln components are on
• Investment costs approx. 15 % lower than three station kilns. high availability, considerable flexi-
thoroughly tried and tested over • the floating tire fastening system the following pages.
• The lower space requirements and lower weights lead to more bility and cost-effectiveness. They
the decades. Its proven standardi- ensures optimal load transmission
favorable construction costs. must also meet all process techno-
zed parts are also used in the to the rollers supported in double
• Mechanical overloading is impossible. This results in higher levels logy requirements for the clinkering
PYRORAPID ® kiln. Regular optimi- slide bearings
of operational reliability and lower maintenance costs. process. The KHD PYRORAPID ® ro-
zation of standardized parts leads • the large service factor of the kiln
• Lower consumption of refractory lining. tary kiln fulfills all of these require-
to even greater operational reliabi- drive ensures extremely flexible
• The reduced required power and lower radiation losses reduces ments. With two tire stations, length
lity and efficiency. The interaction plant operation
energy costs. to diameter ratio of approx. 11:1
of all components ensures the • the repeatedly proven kiln inlet
• The tire at the kiln discharge is to 12:1 and a statically defined be-
overall problem-free continuous and outlet seals ensure minimum
outside the sintering zone. aring arrangement, the PYRORAPID ®
operation of the kiln. false air infiltration.
kiln offers superior advantages over
Convincing arguments for the a two / three station kiln with a
benefit of our customers. greater length to diameter ratios.
Thermal plant with PYRORAPID ® kiln
It’s what’s inside that counts 1 Inlet chamber
2 Brick retaining dish, air - cooled
3 Kiln tube
In order to ensure a long service ment. Depending on the layout, Both types of seals are designed to 4 Conical inlet ring
life of the refractory lining, the kiln there is a tertiary air take-off on ensure a continuous seal despite 5 Scoop ring, air - cooled
1

shell is optimized for minimum either the front or back side of the shifts in the position of the kiln due 6 Spring-loaded segment seal
7 Spring 2
stress and deformation. The shell kiln hood. A large door opening to the influence of temperature and
8 Lever
plate thickness changes with corre- permits easy access to the kiln and longitudinal movement, as well as
sponding shell stresses, which enables the use of portable convey- any possible "deformations" to the
are determined from bending and ors for servicing. kiln shell. This also prevents false
tangential shell stress loads. This air infiltration in the kiln.
6
ensures optimal safety to material We know what we’re The pressure forces 4

elasticity limits at operating tempe- talking about when it are adjustable


rature. Elastic shell deformations comes to seals on either type
remain within narrow limits. The high effi- of seal. 8

ciency and low


The kiln inlet
Put it all in wear rates of area with pneu-
3

Precalcined raw meal is fed from KHD kiln seals matically-opera-


ted seal ... ... or with spring-loaded segment seal.
the inlet chamber via the refractory make important 7
5
lined and air-cooled brick retaining contributions to
ring into the kiln. The simultane- economical kiln
ously rotating scoop ring safely operation. The
returns any hot meal backspill into proven spring-loa-
the inlet chamber. ded segmented seals,
which were developed by
What comes out KHD Humboldt Wedag, are fitted
The outlet end of the rotary kiln is to the kiln inlet and outlet. The pres-
protected by heat-resistant outlet sure elements, springs and levers,
segments. The air cooling of this rotate with the kiln, so they can be
3
large surface ensures long life of easily accessed at any time. KHD
the segments. Their bracket moun- rotary kilns can also be supplied
ting prevents flaring of the kiln with pneumatically operated seals. 1
shell. The kiln hood is supplied with Pressure is applied to the movable
monitoring and sampling openings, suspended sealing ring by a num-
connections for the burner and for ber of stationary mounted pneuma-
the control and measuring equip- tic cylinders.
2

4
The kiln outlet area
with spring-loaded
segment seal.

1 Outlet segments
2 Bracket
3 Brick retaining ring
4 Kiln tube
5 Cooling ring
6
6 Kiln hood 7
7 Spring-loaded segment seal
It’s what’s inside that counts 1 Inlet chamber
2 Brick retaining dish, air - cooled
3 Kiln tube
In order to ensure a long service ment. Depending on the layout, Both types of seals are designed to 4 Conical inlet ring
life of the refractory lining, the kiln there is a tertiary air take-off on ensure a continuous seal despite 5 Scoop ring, air - cooled
1

shell is optimized for minimum either the front or back side of the shifts in the position of the kiln due 6 Spring-loaded segment seal
7 Spring 2
stress and deformation. The shell kiln hood. A large door opening to the influence of temperature and
8 Lever
plate thickness changes with corre- permits easy access to the kiln and longitudinal movement, as well as
sponding shell stresses, which enables the use of portable convey- any possible "deformations" to the
are determined from bending and ors for servicing. kiln shell. This also prevents false
tangential shell stress loads. This air infiltration in the kiln.
6
ensures optimal safety to material We know what we’re The pressure forces 4

elasticity limits at operating tempe- talking about when it are adjustable


rature. Elastic shell deformations comes to seals on either type
remain within narrow limits. The high effi- of seal. 8

ciency and low


The kiln inlet
Put it all in wear rates of area with pneu-
3

Precalcined raw meal is fed from KHD kiln seals matically-opera-


ted seal ... ... or with spring-loaded segment seal.
the inlet chamber via the refractory make important 7
5
lined and air-cooled brick retaining contributions to
ring into the kiln. The simultane- economical kiln
ously rotating scoop ring safely operation. The
returns any hot meal backspill into proven spring-loa-
the inlet chamber. ded segmented seals,
which were developed by
What comes out KHD Humboldt Wedag, are fitted
The outlet end of the rotary kiln is to the kiln inlet and outlet. The pres-
protected by heat-resistant outlet sure elements, springs and levers,
segments. The air cooling of this rotate with the kiln, so they can be
3
large surface ensures long life of easily accessed at any time. KHD
the segments. Their bracket moun- rotary kilns can also be supplied
ting prevents flaring of the kiln with pneumatically operated seals. 1
shell. The kiln hood is supplied with Pressure is applied to the movable
monitoring and sampling openings, suspended sealing ring by a num-
connections for the burner and for ber of stationary mounted pneuma-
the control and measuring equip- tic cylinders.
2

4
The kiln outlet area
with spring-loaded
segment seal.

1 Outlet segments
2 Bracket
3 Brick retaining ring
4 Kiln tube
5 Cooling ring
6
6 Kiln hood 7
7 Spring-loaded segment seal
The roller bearing in indefinable changes to the ratio the roller to an optimal position in motion of the rotary kiln is hydrauli-
of forces. This controlled absorption relation to the tire by way of the cally controlled. The hydraulic thrust
of the axial forces is easy to recog- linear adjustment of the bearing roller mechanism counteracts the
nize at all times. It helps to preci- block. forces which are generated by
sely adjust the bearing position and the slope of the kiln. It operates
to make any necessary corrections No fear of contact automatically and is controlled by
during operation. One special ad- In order to ensure uniform use of non-contact measurement.
vantage is that it offers the opportu- the contact surfaces between tires
nity, in the event of changed linear and supporting rollers, as well as
expansion of the kiln shell, to return the girth gear and pinion, the axial

This is our drive


The drives for all kilns are designed for the reliable operation of the kiln under
any operating conditions. This means that even greater safety factors and
torque reserve, are installed for nominal operation. All drive components
are designed for the installed motor torque plus all safety factors and
not only for effective torque generated at nominal capacity.

The installed reserves and safety factors ensure the extremely


flexible operation of the kiln, including higher clinker throughput,
without overloading the drive.

The pressure’s on the hydraulic thrust roller mechanism KHD Humboldt Wedag offers various types of drives for kilns opera-
tion, depending on the application. We differentiate between form-fit
Always up to date drives (pinion / girth gear) for all kilns with two and three stations and
friction drives (roller / tire) for kilns with two stations.
The forged rollers and cast tires contact pattern between the tire station kiln during operation, the Single drive with two pinions
have solid rectangular profiles. and rollers. system is equipped to do so. The This is where the power is
They are manufactured without extremely robust and solid The drive units consist of the main and auxiliary drive. Variable speed AC or DC motors are used as drive
Based on a very simple principle
relief or drilled holes to ensure that with nearly no weld seams: construction of the be- motors. The auxiliary drive is furnished with an electric motor and / or a combustion engine. In conjunction with
the tyre fastening.
no notch stresses or stress concen- aring arrangement, multi-stage or planetary gearboxes and elastic, practically maintenance-free couplings, the drives offer maximum
trations occur. The tires of the kiln with double slide operational safety and outstanding efficiency.
are designed according to Nies The sophisti- bearing blocks The gear drive

for maximum ovality of 0.15 to 0.2 cated and which remain


percent of the nominal kiln diame- thousand- aligned, is desi-
ter. This guarantees the rigidity of fold proven gned to ensure
the tires. KHD roller that the roller
bearings stations have
One special feature is the constraint offer optimal a centering
free and low-maintenance tire faste- reliability. effect on the kiln.
ning system, which reliably transmits They are dimen- They absorb the re-
all loads via large contact surfaces sioned to ensure establishing forces of
at low surface pressure from the kiln they are not affected by the distorted kiln and do
shell to the tire. This also applies any types of load resulting from va- not deflect as flexible or moving
to the driving torque if the kiln is rious operating conditions. Howe- bearings would. The axial for-
powered by a friction drive. This ver, in the event that it is necessary ces are also effectively con-
connection also maintains a perfect to straighten a bent shell of a three- trolled and do not result
The roller bearing in indefinable changes to the ratio the roller to an optimal position in motion of the rotary kiln is hydrauli-
of forces. This controlled absorption relation to the tire by way of the cally controlled. The hydraulic thrust
of the axial forces is easy to recog- linear adjustment of the bearing roller mechanism counteracts the
nize at all times. It helps to preci- block. forces which are generated by
sely adjust the bearing position and the slope of the kiln. It operates
to make any necessary corrections No fear of contact automatically and is controlled by
during operation. One special ad- In order to ensure uniform use of non-contact measurement.
vantage is that it offers the opportu- the contact surfaces between tires
nity, in the event of changed linear and supporting rollers, as well as
expansion of the kiln shell, to return the girth gear and pinion, the axial

This is our drive


The drives for all kilns are designed for the reliable operation of the kiln under
any operating conditions. This means that even greater safety factors and
torque reserve, are installed for nominal operation. All drive components
are designed for the installed motor torque plus all safety factors and
not only for effective torque generated at nominal capacity.

The installed reserves and safety factors ensure the extremely


flexible operation of the kiln, including higher clinker throughput,
without overloading the drive.

The pressure’s on the hydraulic thrust roller mechanism KHD Humboldt Wedag offers various types of drives for kilns opera-
tion, depending on the application. We differentiate between form-fit
Always up to date drives (pinion / girth gear) for all kilns with two and three stations and
friction drives (roller / tire) for kilns with two stations.
The forged rollers and cast tires contact pattern between the tire station kiln during operation, the Single drive with two pinions
have solid rectangular profiles. and rollers. system is equipped to do so. The This is where the power is
They are manufactured without extremely robust and solid The drive units consist of the main and auxiliary drive. Variable speed AC or DC motors are used as drive
Based on a very simple principle
relief or drilled holes to ensure that with nearly no weld seams: construction of the be- motors. The auxiliary drive is furnished with an electric motor and / or a combustion engine. In conjunction with
the tyre fastening.
no notch stresses or stress concen- aring arrangement, multi-stage or planetary gearboxes and elastic, practically maintenance-free couplings, the drives offer maximum
trations occur. The tires of the kiln with double slide operational safety and outstanding efficiency.
are designed according to Nies The sophisti- bearing blocks The gear drive

for maximum ovality of 0.15 to 0.2 cated and which remain


percent of the nominal kiln diame- thousand- aligned, is desi-
ter. This guarantees the rigidity of fold proven gned to ensure
the tires. KHD roller that the roller
bearings stations have
One special feature is the constraint offer optimal a centering
free and low-maintenance tire faste- reliability. effect on the kiln.
ning system, which reliably transmits They are dimen- They absorb the re-
all loads via large contact surfaces sioned to ensure establishing forces of
at low surface pressure from the kiln they are not affected by the distorted kiln and do
shell to the tire. This also applies any types of load resulting from va- not deflect as flexible or moving
to the driving torque if the kiln is rious operating conditions. Howe- bearings would. The axial for-
powered by a friction drive. This ver, in the event that it is necessary ces are also effectively con-
connection also maintains a perfect to straighten a bent shell of a three- trolled and do not result
8
8 - 105.07 e
6 4

7 7

15 16
2
1
13
Main drive Auxiliary drive
14
1 Main motor 9 Internal combustion engine
12
2 Flexible coupling with brake drum 10 Centrifugal clutch
3 Double shoe brake 11 11 Electrical auxiliary motor
5
4 Main gear box 12 Centrifugal clutch / brake
5 Lubricating oil system 10 13 Auxiliary gear box
6 Flexible coupling 14 Flange pump
7 Pinion gear 9
15 Free - wheel
8 Gearwheel guard 16 Flexible coupling

The drive components

Either single, double or triple reduc- One special feature of the gear drive, as a single drive with two pinions,
tion gearboxes are used, depending is that it can operate with only one main motor. This type of drive is often
on the torque to be transmitted. used to increase productivity using the existing girth gear.
These are the most common types This variant, which was developed by KHD Humboldt Wedag, has two
of drive for rotary kilns because positive advantages:
they have a high degree of efficiency • no additional foundation is necessary for a second drive unit
and long-term economical design. • each pinion transmits precisely half of the torque

Nothing can shake them Feel free to create friction


The even, smooth operation of the Alternatively, it’s possible to transmit the drive torque from the rollers to
kiln and optimal contact pattern the tire. This type of drive is only suitable for two station kilns. The
with the pinion is achieved by characteristics of both types of drive are listed in the adjacent table.
mounting the girth gear on the kiln
shell using tangential springs. The Hydraulic drives – acting directly or via gears on the driven shaft – also
centered action of the girth gear is permit smooth kiln operation but are less efficient. This is why they are
adjustable. also considerably less economical.
Compact and Efficient
Gear drive (form-fit) Roller drive (friction-fit)
Function Transmission of loads via tyres and rollers, Transmission of loads and torque via tyres Rotary Kilns
transmission of torque via pinions and girth gear and rollers
Optimal separation of functions without Bearing and drive function in one unit means:
reciprocal influence functional compromise
Design Components are optimised for the relevant Additional drive forces requires stronger roller
function bearings
Efficiency Maximum degree of efficiency, minimum Slipping and friction result in wear and tear to
wear and tear tyres and rollers and impair efficiency
Maintenance Ensure lubrication Ascertain friction values

KHD Humboldt Wedag ZAB Zementanlagenbau GmbH & Humboldt Wedag India Private Ltd. KHD Humboldt (Shanghai)
GmbH Industrietechnik & Service GmbH Espire Campus International Industries Ltd.
Colonia - Allee 3 Brauereistraße 13 A - 41, Mohan Co - op Estate, Office Beijing Guo Ji Da Sha 25 - A
51067 Cologne / Germany 06847 Dessau / Germany Mathura Road 19, Jiangou Menwai Dajie
Phone +49 221 6504 0 Phone +49 340 5029 0 New Delhi - 110044 / India Beijing / PR China
Phone +91 11 4210 1100 Phone +86 10 6500 4101

Humboldt Wedag, Inc. OOO KHD Humboldt Engineering KHD Humboldt Wedag Rep. Humboldt Wedag SA (Pty) Ltd.
400 Technology Parkway Mjasnizkaja ul., 24 / 7 Iran Branch Office 36 Wankel Street, Jet Park
Norcross GA 30092 / USA Office 108 3rd Floor, No. 244 Boksburg, 1459 / South Africa
Phone +1 770 810 7315 Moscow 10100 / Russia Navak Building, Africa Avenue, Phone +27 11 397 4660
www.khdhumboldt.com
Phone +7 495 9233480 Tehran 15186 / I.R. Iran
Phone +98 21 8888 9880