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Machine manual

en-KP.CPT.001.A

POLRO® two support rotary kiln

Code word

Order number

POLYSIUS Order Code (POC)


Machine manual Contents
®
POLRO two support rotary kiln

Contents

1 Safety 1-1
2 Technical data 2-1
3 Components and mode of functioning 3-1
3.1 Components 3-1
3.2 Mode of functioning3-4
4 Transport and assembly 4-1
4.1 Transport and storage instructions 4-1
4.2 Measuring work 4-2
4.3 Assembly 4-3
4.4 Assembly description 4-4
5 Lubrication 5-1
6 Commissioning 6-1
6.1 Preparation for test run 6-1
6.2 Checks prior to the test run 6-1
6.3 Test run 6-1
7 Maintenance 7-1
7.1 Safety instructions 7-1
7.2 Inspection 7-3
7.3 Servicing 7-3
7.4 Repair 7-3
8 Trouble shooting 8-1
9 Spare parts9-1
9.1 Suggestions for enquiries and orders of spare parts 9-1
10 Appendix 10-1
10.1 Technical drawings 10-1
10.2 Records of measured data 10-1
10.3 Subsuppliers' documentation 10-1

en-KP.CPT.001.A
Machine manual Safety
®
POLRO two support rotary kiln 1

1 Safety
Note
Be sure to comply with the general safety instructions in the supplement
Important notes on the documentation.
Use

● Be sure to comply with the specification of the intended use in section


Technical data.
● Any use other than the intended use is forbidden. POLYSIUS AG is not
responsible for damage resulting from any use other than the intended use. All
other use is at the owner's own risk.
● The intended use also includes observance of the instructions in the machine
manual and compliance with the maintenance instructions.
Transport and assembly
● All transport instructions in this machine manual refer exclusively to the
transport of the machine at the plant site.
● Only use suitable hoisting and load-carrying equipment which is in serviceable
order and has a sufficient load-bearing capacity.
● Never work under a suspended load.
● When work is being performed inside the machine, make absolutely sure that
fresh air is supplied continuously (by injection or suction), so that the inhaled
air remains free from noxious constituents. Aeration with pure oxygen is
forbidden.
● Wear dust protection masks when work is carried out in the machine, as a
large amount of dust has to be expected.
Safety measures for refractory lining work
● Carry out an inspection and maintenance of the holding brake of the rotary
kiln drive in accordance with the subsupplier's instructions before you start
any refractory lining work (see machine manual of the Rotary kiln drive). The
holding brake must always be in a safe and reliable condition.
● Ensure that the holding brake of the rotary kiln drive is always closed as long
as personnel or movable equipment are in the rotary kiln.
● Do not open the holding brake for turning the rotary kiln until all personnel and
movable equipment have been removed from the rotary kiln.
● Refractory lining work may only be carried out section by section to prevent
the torque from exceeding the permissible holding torque of the rotary kiln
drive's holding brake.
Operation
● Any safety checks before or during operation depend on the relevant national
regulations. The plant management is responsible for the performance and
recording of such checks.

en-KP.CPT.001.A
Safety Machine manual
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2 POLRO two support rotary kiln

● The plant management has to ensure that the whole area of the rotary kiln is
cordoned off, so that it is impossible for persons to come into contact with
rotating parts.
● If changes in the machine or its operating behaviour occur that are relevant to
safety, shut it down immediately.
Maintenance
● Make absolutely sure that all machines and motors whose operation might
endanger persons or equipment are switched off and safeguarded against
restarting for the entire duration of the maintenance work.
● Before beginning any repair work, make absolutely sure that the rotary kiln
has swung to a complete stop in its centre of gravity position and has been
secured by means of the holding brake of the rotary kiln drive.
● Before performing any work on the machine, make sure that there is no risk of
burns when touching the machine.
● Do not permit work on the stopped rotary kiln to be carried out without suitable
fall protection.
● Ensure that all rotating parts of the machine have come to a complete
standstill before you remove any protection devices or open any covers.
● Only specially authorised and trained personnel may open the inspection
ports. There is danger of being burned by hot gas or spattering hot material!
● Before performing any work on the machine, make sure that no hot material is
in the machine when inspection covers and service covers are opened.
● Switch off the power supply to the electrical components before beginning any
maintenance work.
● Make absolutely sure that the pneumatic piping is relieved of pressure before
disconnecting it.
● Keep the machine free of oily and combustible substances and materials.
Never use gasoline or other easily inflammable substances for cleaning the
machine.

en-KP.CPT.001.A
Machine manual Safety
®
POLRO two support rotary kiln 3

● When work is being performed inside the machine, make absolutely sure that
fresh air is supplied continuously (by injection or suction), so that the inhaled
air remains free from noxious constituents. Aeration with pure oxygen is
forbidden.
● Wear dust protection masks when work is carried out in the machine, as a
large amount of dust has to be expected.
● Remove incrustations and possibly loose refractory lining at the ceiling before
inspecting the machine.
● Make absolutely sure that the material has an adequate bearing capacity or
suitably cover the material before inspecting the machine.
● Only use 24 volt lamps to illuminate the interior of the machine.
● Strictly observe the welding instructions when performing any welding work.
● When electric arc welding or cutting are being performed, you must ensure
that personnel cannot come into contact with electrically conductive
components. Use insulating underlays for this purpose.
● If you carry out electric welding on any part of the machine, never conduct the
welding current through plain or antifriction bearings, other moving connecting
elements or measuring devices. Always directly connect the welding current
return lead to the part being welded.
● Remount all protection devices when the maintenance work has been
finished. Make absolutely sure that no persons are inside the plant component
before you properly close the inspection and service covers.
● After all maintenance work, check that there are no leaks in joints and
connections.
● Check that all signs are complete and distinctly legible. Provide new signs, if
necessary.

en-KP.CPT.001.A
Machine manual Technical data
®
POLRO two support rotary kiln 1

2 Technical data
Note
Information concerning the electrical equipment is contained in the separate
electrical documentation or in the subsuppliers' documentation.

Specification of the intended use


Feed material

Basic data
Year of manufacture

Nominal diameter of the rotary kiln mm

Length of the rotary kiln mm

Rotational speed of the rotary kiln rpm

Slope of the rotary kiln %

Rotary kiln shell


See machine manual No.

Rotary kiln inlet with seal


See machine manual No.

Tyre with fastening


See machine manual No.

Supporting roller stations


See machine manual No.

Rotary kiln axial thrust system


See machine manual No.

Rotary kiln drive


See machine manual No.

Rotary kiln outlet with seal


See machine manual No.

en-KP.CPT.001.A
Technical data Machine manual
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2 POLRO two support rotary kiln

Kiln hood
See machine manual No.

en-KP.CPT.001.A
Machine manual Components and mode of functioning
®
POLRO two support rotary kiln 1

3 Components and mode of functioning

3.1 Components
Note
Some details of the drawings in this manual may not be identical with the
drawings supplied under the contract.

en-KP.CPT.001.A
Components and mode of functioning Machine manual
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2 POLRO two support rotary kiln

Fig. 1

en-KP.CPT.001.A
Machine manual Components and mode of functioning
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POLRO two support rotary kiln 3

No. Name Description


1 Rotary kiln shell
2 Rotary kiln inlet with inlet seal
3 Tyres with kiln tyre fastening system
4 Supporting roller stations
5 Rotary kiln axial thrust with thruster (not illustrated)
system
8 Rotary kiln drive
9 Rotary kiln outlet with outlet seal (and outlet cooling system)
10 Kiln hood
11 Shell-cooling optional
12 Tertiary air supply optional
13 Measuring device optional
I Roller station No. 1
II Roller station No. 2

en-KP.CPT.001.A
Components and mode of functioning Machine manual
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4 POLRO two support rotary kiln

3.2 Mode of functioning


The rotary kiln is designed for burning powdery, small-sized or sludgy feed
material.
For this purpose, a rotary kiln burner is located in the kiln hood (10) at the rotary
kiln outlet (9).
Due to the slope and rotation of the rotary kiln, the material fed in at the kiln inlet
(2) is conducted to the rotary kiln outlet (9). The downstream kiln hood (10)
serves as an airlock and as a connection to the subsequent unit.
In order to protect the rotary kiln shell (1) and the components attached to it, as
well as to prevent excessive heat losses, the rotary kiln is equipped with a special
refractory lining.
The rotary kiln shell (1) consists of individual sections that are welded in the
workshop or at site depending on size and transportability and is provided with a
refractory lining.
The plate thicknesses meet the calculated stresses in the respective areas.
The material quality is selected in accordance with the temperature stresses to be
expected.
The rotary kiln is supported on the supporting roller stations (4). In axial direction,
the kiln is guided by a rotary kiln axial thrust system (5).
The driving torque is transmitted from the rotary kiln drive (8) directly via the
supporting rollers of the supporting roller station (4) to the tyre (3) and to the
rotary kiln shell.
As a transition to the downstream units, a kiln hood (10) is located at the outlet
end of the rotary kiln which is equipped with openings providing access to the
rotary kiln and passage for the rotary kiln burner.
Seals at the rotary kiln's inlet (2) and outlet (9) prevent the infiltration of false air.

en-KP.CPT.001.A
Machine manual Transport and assembly
®
POLRO two support rotary kiln 1

4 Transport and assembly

4.1 Transport and storage instructions


The machine is transported in individual parts or in subassemblies. Make
absolutely sure that suitable lifting equipment is employed for lifting all the parts
from the transport vehicles and transferring them to the storage area.
When they arrive at the site, all parts must be inspected for transport damage and
placed on wooden beams with the provision of suitable protection against
moisture, soiling and damage. Never place the parts directly on the ground.
Components such as motors, couplings, gear units, pumps, hydraulic/pneumatic
components, measurement and control equipment must be stored in well-
ventilated rooms and must be protected against moisture. Covers, plugs, etc.
must not be removed until the final assembly.
Make absolutely sure that the wear protection lining and the refractory materials
are stored in accordance with the subsupplier's instructions.
If lengthy storage is required, check the protective coating and repair it if
necessary.

en-KP.CPT.001.A
Transport and assembly Machine manual
®
2 POLRO two support rotary kiln

4.2 Measuring work

Elevation reference point

The starting point of all measuring work is the elevation reference point which
applies to the entire plant and which has a fixed relationship to the zero datum
line shown in the general arrangement drawing. The companies responsible for
construction of the foundations and buildings determine the elevation reference
point and inform our assembly superintendent accordingly.
To facilitate the measurements of axes and heights for the purpose of assembling
the machine components, inscribe a benchmark of, for instance, 1000 mm above
zero datum line on the rotary-kiln and drive foundations. For this purpose, the
construction firm anchored steel plates sized 200 x 200 m in the foundation.
Determine the height by levelling instrument and permanently chisel it as
benchmark into the steel plates.

Fig. 2: Elevation reference point

A datum mark
B steel plate
C anchorage
D concrete
E drill hole for nailed connection to formwork

en-KP.CPT.001.A
Machine manual Transport and assembly
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POLRO two support rotary kiln 3

4.3 Assembly

Required personnel

To ensure correct performance of the work, it is important that all the assigned
personnel have received special training for the tasks to be performed.

Note
It is a prerequisite of our warranty that assembly supervision and assembly
inspection are performed by a specialist from POLYSIUS AG.

Required tools

It is a prerequisite for the correct performance of the work that all tools and
appliances are carefully selected.
No special tools are required. However, you may need torque wrenches and
hydraulic pumps of a bigger size than normal.
Whether or not you need auxiliary equipment, such as scaffolds or auxiliary
mounting supports, depends on the conditions in your plant.

Note
The basic safety instructions must be complied with. Also refer to the section
Safety.

CAUTION
Welding current
Moving connecting elements or sliding surfaces could be damaged.
I. Always directly connect the welding current return lead to the part
being welded.
II. Never conduct the welding current through plain or antifriction
bearings, other moving connecting elements or measuring devices.

Note
The following assembly description does not detail the individual steps for
assembling the machine but rather gives an overview of the work to be
performed.
Changes in the planning of the plant during the processing of the contract may
lead to deviations from this assembly description.

en-KP.CPT.001.A
Transport and assembly Machine manual
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4 POLRO two support rotary kiln

4.4 Assembly description


● Inscribe the benchmarks, the longitudinal kiln axis, an axis parallel to the
longitudinal kiln axis as well as the lateral axes on the foundations (written
report and axis marks are necessary).
● Assemble the supporting roller stations (4) and the rotary kiln axial thrust
system (5). Apply graphite grease to the bearing surfaces. Mount the
supporting rollers with bearing. Fill up the bearing housings with oil in
accordance with section Lubrication. Prepare a written report.
● Assemble the rotary kiln drive (8).
● Preassemble the tyre-bearing shell sections.
Fit and position the tyres (3) on the kiln sections and secure them against
displacement. Preassemble the kiln tyre fastening systems in accordance with
local conditions.
● Assemble the kiln and kiln tyre sections beginning at the kiln inlet (the
assembly sequence may vary due to the local conditions). Align the sections
exactly with one another (axially and radially) and brace with tensioning blocks
and supporting brackets. If necessary, the kiln shell bracing element can be
removed at one side of the joints during the aligning work.
● Clean the contact surfaces of tyres and rollers; check the concentricity at the
inlet and outlet, at the circumferential kiln shell welds to be welded and at the
tyres (also measure the axial eccentricities).
● If the measured values are within the specified tolerance, you can weld the
circumferential welds in the shell.
● Check the rotary kiln welds in accordance with the instructions of
POLYSIUS AG.
● Carry out measurements of radial and axial runout at the tyres, concentricity
check at the inlet (2) and at the outlet (9) of the rotary kiln. Prepare written
reports. The tyre fixture is completed when the measured values are within
the permitted tolerances.
● Assemble the kiln inlet and outlet seals and the kiln outlet cooling system.
● Assemble the supporting roller bearing cooling system, the heat shield etc.
● Carry out a cold test run before installing the kiln refractory lining.
● Install the kiln refractory lining taking into account the instructions given in
section Checks prior to the refractory lining work.

en-KP.CPT.001.A
Machine manual Transport and assembly
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POLRO two support rotary kiln 5

Checks prior to the refractory lining work

● Is the rotary kiln shell (1) free of temporary assembly scaffolds, assembly
aids, etc.?
● Have all welded-on assembly appliances on the inside of the rotary kiln shell
(1) been removed and have the welds been ground level without any
notches?
● Has the circumferential assembly weld been checked for defects?
● Is edge misalignment plus assembly weld cap on the inner surface of the
assembly weld seam less than 4 mm?
● Have the outlet segments of the rotary kiln outlet (9) been properly tightened
and secured?

en-KP.CPT.001.A
Machine manual Lubrication
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POLRO two support rotary kiln 1

5 Lubrication
Note
The POLYSIUS table of lubricants with the lubricant reference numbers is
contained in the supplement Important notes on the documentation. The
supplement is contained in this folder or at the beginning of the overall
documentation. Each lubricant has a unique reference number to which the
lubrication instructions in this section relate. The table gives a complete list of all
suppliers and products approved by POLYSIUS AG. It is the responsibility of the
lubricant supplier to select appropriate lubricants corresponding to the lubricant
reference numbers. POLYSIUS AG accepts no liability for the correctness of
these data. If you wish to use a lubricant that is not included in the Table of
lubricants, you have to first obtain the express permission of POLYSIUS AG.
The supplement Important notes on the documentation also contains the
generally valid Notes on lubrication.

CAUTION
Lubricants that are not properly stored, used and disposed of are an
environmental hazard.
They can harm humans, animals and plants.
Ensure that the environment is not polluted when lubricants are stored,
used and disposed of and carefully observe the relevant national
legislation for the protection of the environment when handling lubricants.

Lubrication points

No. Designation Remark

1 Rotary kiln inlet (2) with inlet seal

2 Tyre (3) [only with loose-tyre fastening]

3 Supporting roller stations (4) See separate machine manual


The numbers of the machine manuals are
4 Rotary kiln axial thrust system (5) shown in section Technical data.

5 Rotary kiln outlet (9) with outlet seal

6 Rotary kiln drive (8)

7 Shell-cooling (11) (optional)


See subsuppliers' documentation
8 Tertiary air supply (12) (optional)

en-KP.CPT.001.A
Machine manual Commissioning
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POLRO two support rotary kiln 1

6 Commissioning

6.1 Preparation for test run


Note
It is a prerequisite of our warranty that the first test run is carried out in the
presence of specialists from POLYSIUS AG and in accordance with their
instructions.

6.2 Checks prior to the test run


After completing the assembly work and prior to the first test run, check all parts
of the plant in accordance with the list below. Make absolutely sure that all
material remnants, tools and auxiliary assembly devices have been carefully
removed.
● Does a rotary kiln measurement diagram exist for the actual condition?
● You must carry out further checks in accordance with the checklists in the
separate machine manuals of the individual subassemblies.
● Has the refractory lining been installed in accordance with the supplier's
instructions?
● Has all auxiliary assembly equipment been removed from the outer shell?
● Have all welded-on assembly aids on the outer shell been removed and have
the welds been ground level without any notches?
● Is the design radial free space between the rotating rotary kiln shell (1) and
the static subassemblies (rotary kiln inlet (2) / kiln hood (10)) maintained
during the entire rotation?

6.3 Test run


As a rule, cold test runs are dispensed with to protect the refractory lining.

en-KP.CPT.001.A
Machine manual Maintenance
®
POLRO two support rotary kiln 1

7 Maintenance

7.1 Safety instructions


DANGER
The rotary kiln is hot.
You may suffer very severe burns.
Always use the required protective clothing.

DANGER
It is forbidden to carry out work at rotating machines.
You could be severely injured.
The plant management has to ensure that the whole area of the machine is
cordoned off, so that it is impossible for persons to come into contact with
rotating parts.

DANGER
Never open doors or manholes during operation!
You could be very severely injured by material falling out or spattering.
I. Always observe the respective signs!
II. Only specially authorised and trained personnel may open the
inspection ports.

DANGER
Before beginning any maintenance work, make absolutely sure that the
rotary kiln has swung to a complete stop in its centre of gravity position
and has been secured by means of the holding brake.
You could fall from the rotary kiln.
Do not work on the rotary kiln without suitable fall protection.

DANGER
The machine contains parts under voltage.
You could be severely injured.
Switch off the power supply to all electrical components before starting
any maintenance work.

DANGER
There is hot combustion gas inside the rotary kiln.
There is mortal danger due to carbon monoxide!
Make absolutely sure that there is no longer any carbon monoxide in the
rotary kiln and wait until it has cooled down before going inside.

en-KP.CPT.001.A
Maintenance Machine manual
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2 POLRO two support rotary kiln

DANGER
Coatings in the rotary kiln shell can fall down or give way.
You could be buried alive or sink into the material.
I. Remove incrustations and possibly loose refractory lining at the ceiling
before inspecting the rotary kiln shell.
II. Make absolutely sure that the material has an adequate bearing
capacity or suitably cover the material before inspecting the rotary kiln
shell.

CAUTION
Welding current
Moving connecting elements or sliding surfaces could be damaged.
I. Always directly connect the welding current return lead to the part
being welded.
II. Never conduct the welding current through plain or antifriction
bearings, other moving connecting elements or measuring devices.

en-KP.CPT.001.A
Machine manual Maintenance
®
POLRO two support rotary kiln 3

7.2 Inspection
Work to be performed Frequency Comments
Inspection work on the individual subassemblies: In accordance with section
Maintenance under point
Inspection of the separate
machine manuals for the
subassemblies.
The numbers of the
manuals are shown in
section Technical data.

7.3 Servicing
Work to be performed Frequency Comments
Maintenance work on the individual subassemblies: In accordance with section
Maintenance under point
Servicing of the separate
machine manuals for the
subassemblies.
The numbers of the
manuals are shown in
section Technical data.

7.4 Repair

Required personnel

To ensure correct performance of the work, it is important that all the assigned
personnel have received special training for the tasks to be performed.

Note
We recommend having the repair work carried out under the supervision of an
expert from POLYSIUS AG.

Required tools

It is a prerequisite for the correct performance of the work that all tools and
appliances are carefully selected.
No special tools are required. However, you may need torque wrenches of a
bigger size than normal.
Whether or not you need auxiliary equipment, such as scaffolds or hoists,
depends on the operating conditions in your plant.

en-KP.CPT.001.A
Maintenance Machine manual
®
4 POLRO two support rotary kiln

For a correct measurement you need a calibrated theodolite and a levelling


instrument.

General

The basic safety instructions must be complied with. Also refer to the section
Safety.
Switch off the power supply to all electrical components before beginning any
repair work.
Ensure absolute cleanliness at all times during the repair work in order to prevent
dirt from entering the bearings, the drives or other sensitive parts of the machine
or plant.
Do not remove or open any covers or protection devices before all rotating parts
have come to a complete standstill.
Check that lubrication and compressed air piping are depressurised before
disconnecting them.
● After carrying out work which changes the position of the centre axis of the
rotary kiln (e.g. replacement of tyre stations, replacement of individual kiln
sections etc.), be sure to check the centre axis of the rotary kiln with a suitable
measuring process and realign it.
● A correct rotary kiln alignment can only be obtained under operating
conditions.
● As a general principle, we recommend that you check the rotary kiln alignment
at intervals of max. 2 years to correct foundation settlements and tilting in
good time. In the case of large settlements (tilting) we recommend carrying
out readjustments at shorter intervals of time.
● Depending on the kiln geometry, station settlements of 5 mm can already
cause stress increases of up to 30 % in the kiln shell.

Note
After you have completed the repair work, you must check the machine/plant
again in accordance with sections Preparation for test run of the individual
machine manuals.

en-KP.CPT.001.A
Machine manual Trouble shooting
®
POLRO two support rotary kiln 1

8 Trouble shooting

CAUTION
It is forbidden to carry out work at the rotating rotary kiln.
You could be severely injured.
I. The plant management has to ensure that the whole area of the rotary
kiln is cordoned off, so that it is impossible for persons to come into
contact with rotating parts.
II. Before beginning any repair work, make absolutely sure that the rotary
kiln has swung to a complete stop in its centre of gravity position and
has been secured by means of the holding brake.
III. Switch off the power supply to all electrical components before starting
any maintenance work.

Note
As a rule, trouble shooting is limited to mechanical faults.

Note
For mechanical faults and their elimination see the separate machine manuals
for the subassemblies.

en-KP.CPT.001.A
Machine manual Spare parts
®
POLRO two support rotary kiln 1

9 Spare parts

9.1 Suggestions for enquiries and orders of spare parts


Spare parts for the following subassemblies are shown in section Spare parts of
the separate machine manuals.
● Rotary kiln shell
● Rotary kiln inlet with seal
● Rotary kiln outlet with seal
● Tyre with fastening
● Supporting roller stations
● Rotary kiln axial thrust system
● Rotary kiln drive
● Kiln hood
The numbers of the machine manuals are shown in section Technical data.

en-KP.CPT.001.A
Machine manual Appendix
®
POLRO two support rotary kiln 1

10 Appendix

10.1 Technical drawings


Note
For drawing numbers, please refer to the table of contents of this folder.

General arrangement drawing

10.2 Records of measured data

Measurement record

10.3 Subsuppliers' documentation

Shell-cooling
Tertiary air supply

en-KP.CPT.001.A

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