Rotary Kiln

Maintenance Seminar

Introduction
Institute

Introduction

Institute

Kiln Seminar Agenda

Types of Kilns Systems
The Clinker Production Process
Terminology
Kiln Safety

Introduction

Kiln Seminar Agenda

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Introduction

Kiln Seminar Agenda

1.
2.
3.
4.
5.
6.
7.
8.

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Introduction, Kiln Safety

Kiln Shell
Tires and Ovality
Kiln Supports
Kiln Bearings
Kiln Drive
Kiln Alignment
Seals, Thrust Rollers,
Maintenance Schedule

Introduction

Types of Kiln Systems

Institute

Introduction

Pyro-processing System
4-Stage Preheater
Calciner String

4-Stage Preheater
Kiln String

Tertiary Air
Duct
Calciner

Clinker
Cooler

Rotary Kiln

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

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Introduction

Preheater Arrangements
SP

ILC

SLC

These are some of the many different

configurations of preheaters that have
been installed.
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Introduction

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.
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Introduction

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.
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Introduction

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.
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Introduction

10

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.
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Introduction

11

Rotax-2 Kiln

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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

The Clinker Production Process

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Introduction

13

Clinker Production
CO2
CaCO3
Limestone

CaO

1650 F
900 C
SiO2 + Al2O3
2650 F
1450 C

Clay/Sand

Clinker

Fe2O3

Iron Ore
Institute

Introduction

14

Clinker Production

The Four Oxides of Cement Clinker

Calcium Oxide

CaO (C)

Silicon Oxide SiO2 (S)

67%
22%

Aluminum Oxide Al2O3 (A) 3.5%

Iron Oxide

Fe2O3 (F) 3.5%

96%

Impurities

4%
100%

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Introduction

15

Clinker Production
Raw Materials
67%
C
22%
S
2650 F
3.5% A
1450 C
3.5% F
4% Impurities
100%

Institute

Clinker
67%

C 3S

14%

C 2S

5%

C3A

10%
4%

C4AF
Impurities

100%

Introduction

16

Clinker Production

C aC O

F re e C a O

C 3S

C 2S
Q u a rtz
C la y s

C 3A
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.
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Introduction

17

Terminology

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Introduction

18

Kiln Terminology
Discharge
Hood

Tertiary
Air Duct
Rotation1
Tire

Inlet Hood
Kiln
Shell

Gear

Inlet
Seal

Pier 1 2

Outlet
Seal

Kiln
Pier

Drive
Pier
Support
Roller

Pier no. 3 Right

Uphill Bearing 3

Rotation, as seen from discharge hood

For FLS and Fuller kilns, pier numbering starts at discharge

end

Bearing right and left a seen from discharge end

Introduction

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19

System Terminology
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

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Preheater Top Stage

Downcomer Duct
Kiln Seal
Preheater Intermediate Stage
Preheater Intermediate Stage
Preheater Lower Stage
Rotary Kiln
Induced Draft Fan
Kiln Burner
Clinker Cooler
Cooler Vent System

Introduction

20

Kiln Safety

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Introduction

21

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.
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Introduction

22

Preheater Flush

These men were working inside a kiln when a

preheater flush occurred. Two fatalities resulted.
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Introduction

23

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.
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Introduction

24

Protective Clothing

When working with hot dust a

complete fireproof suit must be worn.
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Introduction

25

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.
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Introduction

26

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.
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Introduction

27

Dust Hazard

Know where your shower and eyewash stations are!

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Introduction

28

Fall Protection

Always wear your safety harness

when working above ground.
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Introduction

29

Heights

High places can be dizzying.

Always tie off with a safety belt.
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Introduction

30

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.
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Introduction

31

Air Blasters

Shut off
the Air

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Discharge
the Tank

Lock Out the

Air Valve

Introduction

Test That
the Tank is
Empty

32

Lockout/Tagout

Follow your plants safety lockout procedures. Lock out all

equipment affecting the area in which you are working.
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Introduction

33

Drive Guards

All moving parts must be completely guarded.

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Introduction

34

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.
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Introduction

35

Coating Collapse

Do not work under loose kiln coating.

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Introduction

36

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.
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Introduction

37

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.
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Introduction

38

Electrical Safety

When working inside a kiln make sure electrical

cables do not short out on the kiln shell.
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Introduction

39

Rigging Safety

Before making heavy lifts, make sure you

have received the necessary rigging training.
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Introduction

40

Carbon Dioxide

Carbon dioxide is a normal product of the

biological process, but too much CO2 can kill.
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Introduction

41

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.
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Introduction

42

Combustibles

Lock out all fuel systems before entering the kiln.

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Introduction

43

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.
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Introduction

44

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.
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Introduction

45

Questions?

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Introduction

46

Rotary Kiln
Maintenance Seminar

Kiln Shell
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Kiln Shell

Shell Details

Kiln Crank

Measuring Kiln Crank

Heat Correction of Kiln Crank

Shell Repair

Shell Welding

Submerged Arc Welding

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Introduction

48

Shell Details

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Introduction

49

Shell Details
Inlet
Cone

Tire
No. 3

30 mm

Tire
No. 1

Tire
No. 2

40 mm
(gear)

40 mm 75 mm
(under tire)

30 mm

40 mm

30 mm
80 mm
(under tire)

40 mm

Outlet
Shroud
50
mm

75 mm
(under tire)

Typical shell plate thicknesses.

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Introduction

50

Kiln Crank

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Introduction

51

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.
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Introduction

52

Kiln Crank

Kiln crank can cause severe cyclical loads, leading to

shell cracks and fatigue cracks in the roller shafts.

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Introduction

53

Kiln Crank

Kiln crank will result in gear misalignment

which can destroy gear teeth.

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Introduction

54

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.
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Introduction

55

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.

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Introduction

56

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.

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Introduction

57

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.
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Introduction

58

Kiln Crank

Damaged refractory will cause a hot spot in

the shell.

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Introduction

59

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.
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Introduction

60

Heat Damaged Kiln Shell

A heat-wrinkled kiln shell will also shorten

the kiln, causing tires to run off-center.
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Introduction

61

Kiln Crank

Kiln crank can be caused by poor alignment

of kiln sections during assembly or repair.

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Introduction

62

Kiln Crank

Kiln crank can be caused by weld

shrinkage at a temporary shell patch.
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Introduction

63

Measuring Kiln Crank

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Introduction

64

Measuring Kiln Crank

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.
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Introduction

65

Measuring Kiln Crank

A roller that deflects cyclically with kiln

rotation by over 0.3 mm typically indicates
a crank in the shell that should be repaired.

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Introduction

66

Measuring Kiln Crank

Kiln crank can be measured by measuring shell runout. A polar diagram is generated on which the
deviation from the true kiln center can be seen.
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Introduction

67

Measuring Kiln Crank

A series of polar diagrams gives a

picture of the shell crank.
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Introduction

68

Heat Correction of Kiln Crank

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Introduction

69

Heat Correction of Kiln Crank

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.
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Introduction

70

Heat Correction of Kiln Crank

Temperature sensors are installed to

carefully monitor shell temperatures beneath
the insulation during the correction process.
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Introduction

71

Heat Correction of Kiln Crank

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Introduction

72

Shell Repair

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Introduction

73

Shell Repair

Major shell defects are normally repaired by

replacing the damaged section. The bandaid approach is at best a temporary solution.
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Introduction

74

Field Joint Hardware

New shell sections are joined

with adjustable erection lugs.
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Introduction

75

Shell Alignment

By adjusting the erection lugs the

shell sections are straightened until
a perfect centerline is achieved.

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Introduction

76

Tire Handling

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Introduction

77

Shell Rigging

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Introduction

78

Shell Rigging

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Introduction

79

Shell Handling

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Introduction

80

Spider Bracing

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Introduction

81

Spider Bracing

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Introduction

82

Spider Bracing

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Introduction

83

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.
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Introduction

84

Shell Welding

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Introduction

85

Joint Preparation

Prior to welding the shell plate ends are carefully prepared.

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Introduction

86

Weld Shrinkage

The 60 double V weld results in less shrinkage and

less weld metal being required. Weld distortion is
minimized, avoiding the gull-wing effect.
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Introduction

87

Weld Shrinkage

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Introduction

88

Shell Welding

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Introduction

89

Shell Welding

After completing the outside weld, the root

pass is removed using carbon arc gouging.

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Introduction

90

Shell Welding

After gouging, the joint is carefully

cleaned and inspected to ensure that
no defects from the root pass remain.
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Introduction

91

Shell Welding

When welding is finished, the joint is

inspected radiography or ultrasound.
Defects are marked and then repaired.
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Introduction

92

Submerged Arc Welding

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Introduction

93

Submerged Arc Welding

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Introduction

94

Submerged Arc Welding

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Introduction

95

Submerged Arc Welding

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Introduction

96

Submerged Arc Welding

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Introduction

97

Submerged Arc Welding

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Introduction

98

Submerged Arc Welding

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Introduction

99

Submerged Arc Welding

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Introduction

100

Submerged Arc Welding

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Introduction

101

Submerged Arc Welding

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Introduction

102

Submerged Arc Welding

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Introduction

103

Submerged Arc Welding

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Introduction

104

Submerged Arc Welding

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Introduction

105

Submerged Arc Welding

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Introduction

106

Submerged Arc Welding

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Introduction

107

Submerged Arc Welding

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Introduction

108

Submerged Arc Welding

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Introduction

109

Submerged Arc Welding

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Introduction

110

Rotary Kiln
Maintenance Seminar

Tires and Ovality

Institute

Tires and Ovality

Institute

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

Tires and Tire Mounting

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Introduction

113

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.
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Introduction

114

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.
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Introduction

115

Tire Attachment
Guide
Bars

Stop
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.
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Introduction

116

Tire Attachment

This shows a slightly different version

of the floating pad, stop ring design.
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Introduction

117

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.
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Introduction

118

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.
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Introduction

119

Tire Attachment

On kilns without wear rings, when the

blocks eventually wear down, they have to
be cut off and new ones re-welded.
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Introduction

120

Tangential Suspension

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Introduction

121

Tangential Suspension

The tire is fixed and does not creep inside

the shell. Shell expansion is accommodated
with a system of spring-loaded wedges.
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Introduction

122

Tangential Suspension

Tangential suspension reduces ovality. Forces

on the shell are tangent rather than radial.
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Introduction

123

Tangential Suspension
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.
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Introduction

124

Tangential Suspension
Dog Bone

Tire Bracket

Spring Rod

Wedge
Retainer

Wedge

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Introduction

125

Tangential Suspension

A completed tire section ready for installation.

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Introduction

126

Tangential Suspension

Wedges are held in position with retainer

brackets bolted to the top of the dog bones.
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Introduction

127

Tangential Suspension

The spring rod pushes the wedge in to maintain

a tight fit between dog bones and brackets as
the kiln shell expands and contracts.
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Introduction

128

Tangential Suspension

As the wedges wear, the spring length

increases. Periodically, check the distance
and adjust the spring tension as required.
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Introduction

129

Tangential Suspension

Dog bones are attached to the shell with heavy

welds. Periodically inspect the welds for cracks.
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Introduction

130

Tangential Suspension

Tire bolts are hydraulically tightened to

specification.
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Introduction

131

Hydraulic Bolt Tensioning Tool

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Introduction

132

Tire Clearance

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Introduction

133

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.
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Introduction

134

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.
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Introduction

135

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 ().
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Introduction

136

Rate of Expansion
Rule of Thumb
Expansion of Steel (approx):
1mm / Meter/ 100C

Example. A kiln shell with 5 meter (5000 mm) diameter

at 20 C is heated to 320 C. The shell expands
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Introduction

137

Ovality

A kiln shell is not stiff enough to support its own weight.

When placed on the ground it collapses to an oval shape.
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Introduction

138

Ovality

When placed inside a rigid tire the shells 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.
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Introduction

139

Shell and Tire Deformation

Difference in
diameters

Actual Top
Clearance

Deformed Shell
and Tire

Perfectly
Round
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.
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Introduction

140

Ovality and Brick Problems

Kiln shell ovality causes continuous

flexing of the brick lining as the kiln turns.
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Introduction

141

Ovality Refractory Damage

Excessive ovality will damage the refractory lining,

typically with scattered spalling and single brick
fall-out among otherwise undamaged areas.
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Introduction

142

Shell Cracks Due to Ovality

Excessive ovality may cause longitudinal

cracks in the shell beneath the tires.
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Introduction

143

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.
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Introduction

144

Definition of Ovality

Dh
Dv

Absolute Ovality
= Dh - D v

Relative Ovality
= (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.
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Introduction

145

Relative Ovality

Relative Ovality

Relative Ovality

=0

>0

(shell is round)

(shell is deformed)

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Introduction

146

Ovality Limits

Ovality as a function of kiln diameter. Exceeding

these limits will cause refractory and shell problems.
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Introduction

147

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.
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Introduction

148

Causes of Excessive Ovality

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.
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Introduction

149

Causes of Excessive Ovality

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.
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Introduction

150

Measuring Ovality

The shell-test device measures the kiln shells actual radius

of curvature during rotation. From this data the shell stresses
can be precisely calculated.
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Introduction

151

Measuring Ovality

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Introduction

152

Measuring Ovality

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Introduction

153

Measuring Ovality

Shell-test device
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Introduction

154

Ovality Calculation
Ovality (%) = 4D 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)

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Introduction

155

Ovality
Sample Calculation
Tire #1, Station #1, Downhill
ovality (%) = 4D x 100%
3dn
ovality (%) = 4(3.727m)(12mm/15) x 100%
3(3657.60mm)
ovality (%) = 0.406%

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Introduction

156

Tire Creep and Top Clearance

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Introduction

157

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.
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Introduction

158

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.
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Introduction

159

Measuring Creep
Creep

Creep is the difference in circumference. Therefore,

Creep

Institute

= Difference in Diameter
Introduction

160

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.
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Introduction

161

Measuring Creep and Top Clearance

Top clearance and creep can be measured with this

simple device.
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Introduction

162

Measuring Creep and Top Clearance

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Introduction

163

Measuring Creep and Top Clearance

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).
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Introduction

164

Measuring Creep and Top Clearance

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Introduction

165

Measuring Creep and Top Clearance

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Introduction

166

Correcting Ovality

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Introduction

167

Correcting Ovality

Shims

Excessive clearance can be removed with the

installation of shims beneath the support pads.
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Introduction

168

Correcting Ovality

Shim

Shim thickness is calculated to give a hot running clearance

of about 3 mm ().
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Introduction

169

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.
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Introduction

170

Correcting Ovality

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Introduction

171

Correcting Ovality

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Introduction

172

Correcting Ovality

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Introduction

173

Correcting Ovality

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Introduction

174

Correcting Ovality

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Introduction

175

Correcting Ovality

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Introduction

176

Correcting Ovality

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Introduction

177

Correcting Ovality

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Introduction

178

Correcting Ovality

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Introduction

179

Correcting Ovality

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Introduction

180

Correcting Ovality

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Introduction

181

Correcting Ovality

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Introduction

182

Correcting Ovality

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Introduction

183

Correcting Ovality

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Introduction

184

Correcting Ovality

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Introduction

185

Tire Pad and Stop Block Repairs

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Introduction

186

Tire Pad and Stop Block Repairs

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.
Institute

Introduction

187

Tire Pad and Stop Block Repairs

Replace stop blocks when wear becomes excessive. Do

not use shims as shown, as they probably wont last.
Institute

Introduction

188

Tire Pad and Stop Block Repairs

Excessive stop block wear on the thrust tire

is especially problematic since it can affect
the gears position on the pinion.
Institute

Introduction

189

Tire Pad and Stop Block Repairs

Heavy welds directly on supporting pads frequently

crack due to temperature fluctuations and fatigue stress.
The floating pad design solves these problems.
Institute

Introduction

190

Floating Tire Pad Design

Institute

Introduction

191

Wear Ring Installation

Wear
Rings

AntiRotation
Bars

Institute

Introduction

192

Wear Ring Installation

Institute

Introduction

193

Wear Ring Installation

Institute

Introduction

194

Fractures at Shell Pads

Institute

Introduction

195

Fractures at Shell Pads

Institute

Introduction

196

Fractures at Shell Pads

Institute

Introduction

197

Fractures at Shell Pads

Institute

Introduction

198

Fractures at Shell Pads

Institute

Introduction

199

Tire Crack Repair

Institute

Introduction

200

Ultrasonic Inspection of Tires

Institute

Introduction

201

Tire Repair Welding

Institute

Introduction

202

Tire Repair Welding

Institute

Introduction

203

Tire Repair Welding

Institute

Introduction

204

Tire Repair Welding

Institute

Introduction

205

Tire Repair Welding

Institute

Introduction

206

Tire Repair Welding

Institute

Introduction

207

Tire Repair Welding

Institute

Introduction

208

Tire Repair Welding

Institute

Introduction

209

Tire Repair Welding

Institute

Introduction

210

Rotary Kiln
Maintenance Seminar

Kiln Supports
Institute

Kiln Supports

Institute

Types of Kiln Supports

Roller Adjustments
Roller Inclination
Roller and Tire Defects
Roller and Tire Re-conditioning

Introduction

212

Types of Kiln Supports

Institute

Introduction

213

Rigid Kiln Support

A kiln support consists of two rollers with bearings mounted

on a base frame. This rigid support is the most common.
Institute

Introduction

214

Self-Aligning Kiln Support

Tire
Roller
Bearing

Hinge
Pivot Point

On this support the bearings are

mounted on a pivoting frame.
Institute

Introduction

215

Self-Aligning Kiln Support

Self-aligning
support

Traditional
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.
Institute

Introduction

216

Self-Aligning Kiln Support

Institute

Introduction

217

FLS Kiln Support Type SRB

Institute

Introduction

218

FLS Kiln Support Type RA

FLS kilns have supports with self aligning bearings in spherical sockets.
Hornos FLS han soportes con cojinetes auto alineacin en los zcalos esfrica.

Institute

Introduction

219

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.
Institute

Introduction

220

Fuller Kiln Support

The Fuller support has rigid bearings.

Institute

Introduction

221

Roller Adjustments

Institute

Introduction

222

Axial Forces on a Kiln

Las fuerzas axiales en un horno

2 - 4% slope
Kilns Downhill Force Horno de descenso de la Fuerza

Thrust
Roller
Force

Friction Force
La friccin 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 tender a moverse hacia abajo a medida que gira. Ese movimiento hacia abajo es resistido tanto por la fuerza
de friccin entre los rodillos y neumticos, y por la fuerza en el rodillo de empuje

Institute

Introduction

223

Roller Friction Force

Rodillo de la fuerza de friccin

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 direccin de esta fuerza (hacia arriba o hacia abajo) depende de cmo el rodillo es sesgada, y en el sentido de rotacin del
horno.

Institute

Introduction

224

Roller Adjustment
Counter-Clockwise Kiln
Horno de rodillos de ajuste contra el sentido del reloj

Direction of Kiln Thrust

Direccin 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).

Institute

Introduction

225

Roller Adjustment
Clockwise Kiln
Ajuste de rodillos Las agujas del reloj del horno

Direction of Kiln Thrust

Direccin 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.

Institute

Introduction

226

Roller Adjustment
Ajuste de rodillos

Neutral

Neutral
Feed
End

Discharge
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.

Institute

Introduction

227

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 presin correcta en el cilindro de
empuje hidrulico)

Institute

Introduction

228

Roller -Tire Forces

Fuerzas rodillo-neumtico

Direction of Kiln Thrust

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 neumtico / horno es cuesta arriba, la fuerza sobre el rodillo es cuesta abajo. La direccin de empuje se
puede determinar mediante la observacin del contacto o la brecha en la parada de empuje dentro del rodamiento.

Institute

Introduction

229

Bearing Thrust Arrangements

Downhill
Bearing

Uphill
Bearing

Teniendo
descenso

Teniendo cuesta
arriba

FLS Type RA
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

Institute

Introduction

230

Bearing Thrust Arrangements

Teniendo Rgimen de empuje

FLS Type RA

Gap

Contact

FLS Type RB

Direction of
Force on Kiln
Direccin de la fuerza de
Horno

Contact

Gap
Direction of
Force on Roller

Fuller

Direccin del Trabajo

sobre rodillo

Contact

Institute

Gap
Introduction

231

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.

Institute

Introduction

232

FLS Bearing Type RA

Institute

Introduction

233

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.

Institute

Introduction

234

FLS Bearing Type RB

Institute

Introduction

235

Fuller Bearing

Thrust
Washer

The Fuller bearing takes the thrust load on a thrust

washer which is bolted onto to the housing end cover.
Institute

Introduction

236

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 direccin de empuje del rodillo en un cojinete de la RA se determina mediante la observacin 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 est
empujando hacia arriba el horno.

Institute

Introduction

237

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 est empujando hacia arriba el horno.

Institute

Introduction

238

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.
Institute

Introduction

239

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.
Institute

Introduction

240

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.
Institute

Introduction

241

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.
Institute

Introduction

242

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.
Institute

Introduction

243

Roller Adjustment

Rollers should be adjusted to float the kiln between the

upper and lower thrust rollers.
Institute

Introduction

244

Roller Adjustment
Pressure Gage

For kilns with hydraulic thrust rollers, support rollers are

adjusted to keep the hydraulic pressure within specification.
Institute

Introduction

245

Hydraulic Pressure

Force = Pressure x Area

Area = (Piston Diameter) 2 x

4
The force on the thrust roller can be calculated
from the
hydraulic pressure indicated on the gage.
Institute

Introduction

246

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

Institute

Pressure = 60,000 = 764 PSI

78.5 Introduction

247

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.
Institute

Introduction

248

Jacks for Roller Adjustment

Pancake Jacks are available with forces over 100 tons

to aid in pushing bearings in for roller adjustment.
Institute

Introduction

249

Roller Adjustment

Moving a bearing out is easier.

A small jack may be needed.
Institute

Introduction

250

Roller Adjustment

Always measure and record every bearing adjustment.

To keep from changing the kiln center, make equal and
opposite movements on each bearing.
Institute

Introduction

251

Measuring Roller Thrust

Measuring precise roller thrust is possible on FLS

bearings using this axial measuring device.
Institute

Introduction

252

Measuring Roller Thrust

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.
Institute

Introduction

253

Measuring Roller Thrust

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.
Institute

Introduction

254

FLS

FLS

Type RA

Type RB

Data assumes a
jack piston with
16.6 cm2 surface
area.

Institute

Introduction

255

Measuring Roller Thrust

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.
Institute

Introduction

256

Determining Roller Thrust

Trial and Error Method

Find the rollers 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 kilns thrust rollers to ensure
that they are not being overloaded.

Institute

Introduction

257

Roller Inclination

Institute

Introduction

258

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.
Institute

Introduction

259

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.
Institute

Introduction

260

Measuring Roller Slope

Roller slope is measured with an inclinometer.

Institute

Introduction

261

Inclinometer

1 mm
micrometer
scale

100 mm
Spacing

Due to its dimensioning, the inclinometer reads the

percent slope directly.
Institute

Introduction

262

Inclinometer

When the leveling bubbles are centered, the

percent slope is read on the micrometer dial.
Institute

Introduction

263

Inclinometer

Magnets allow mounting the inclinometer on

horizontal or vertical surfaces. The inclinometer
has a precision bubble level for each position.
Institute

Introduction

264

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.
Institute

Introduction

265

Inclinometer

This arrangement can be used to measure

the roller slope while the kiln is turning.

Institute

Introduction

266

Inclinometer

Using an inclinometer on a precision straight edge

across a kiln base to determine the correct slope.
Institute

Introduction

267

Roller and Tire Defects

Institute

Introduction

268

Tire and Roller Defects

If kiln rollers are skewed too much the

wear rate can be quite severe.
Institute

Introduction

269

Tire and Roller Defects

Excessive hertz pressures on under-designed or poorly

cast tires and rollers can result in severe pitting.
Institute

Introduction

270

Tire and Roller Defects

The old practice of running a roller in a water bath is now

thought to promote surface pitting and is no longer
recommended.
Institute

Introduction

271

Tire and Roller Defects

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 estn desalineados o de forma cnica, la carga del horno se extiende sobre la zona son demasiado
pequeas. Esto hace que la superficie de alta tensiones resultantes de las picaduras.

Institute

Introduction

272

Tire and Roller Defects

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

Institute

Introduction

273

Tire and Roller Defects

Roller or tires may wear to a conical shape.

Rodillo o llantas pueden llevar a una forma cnica

Institute

Introduction

274

Tire and Roller Defects

A tire running off the roller for a long time will wear into a step pattern.
Un neumtico corriendo el rodillo durante mucho tiempo se gastar en un paso patrn

Institute

Introduction

275

Tire and Roller Defects

Tire wobble can create a concave roller surface.

Bamboleo de neumticos puede crear una superficie del rodillo cncavo

Institute

Introduction

276

Roller and Tire Re-conditioning

Institute

Introduction

277

Roller and Tire Re-conditioning

Rollers and tires may be re-conditioned by machining or grinding. Shown above is a lathe adapted for this purpose.
Rodillos y los neumticos pueden ser re-acondicionado por maquinado o esmerilado. Arriba se muestra un torno adaptados para
este fin.

Institute

Introduction

278

Roller and Tire Re-conditioning

Rollers are re-conditioned while the kiln is in operation.

Los rodillos son re-acondicionado, mientras que el horno est en funcionamiento

Institute

Introduction

279

Roller and Tire Re-conditioning

Machining a kiln tire while the kiln is in operation.

Mecanizado de un neumtico del horno, mientras que el horno est en funcionamiento

Institute

Introduction

280

Roller and Tire Re-conditioning

The machinist is protected with a heat shield.

El maquinista est protegido con un escudo trmico

Institute

Introduction

281

Roller and Tire Re-conditioning

This roller is being resurfaced by grinding rather than machining.

Este rodillo se resurgido por desgaste en vez de mecanizado

Institute

Introduction

282

Roller and Tire Re-conditioning

Re-surfacing a tire by grinding

Re-pavimentacin de un neumtico por desgaste

Institute

Introduction

283

Roller and Tire Re-conditioning

Tire and roller edge defects must also be removed.

Edges should then be chamfered.
Institute

Introduction

284

Rotary Kiln
Maintenance Seminar

Kiln Bearings
Institute

Kiln Bearings
FLS Bearing Type RA - 1958 Design
FLS Bearing Type RB - 1974 Design
Fuller Bearing

Institute

Kiln BearingsIntroduction

286

FLS Kiln Support Type RA

FLS kilns have supports with self aligning bearings in

spherical sockets.
Institute

Introduction

287

FLS Bearing Type RA

Felt Oil
Seal

Oil
Oil Tray
Scraper

Heat
Shield
Oil
Scoop
Thrust
Plate
Oil Level
Gage

Spherical Socket
with Water Jackets

Institute

Bronze
Bearing
Liner

Introduction

288

FLS Bearing Type RA

Heat Shield

Inspection
Port

Water
Piping

Stop Block

Institute

Introduction

289

Type RA Oil Seal and Scraper

Felt Seal
Rubber
Oil
Scraper

Institute

Introduction

290

FLS Bearing Type RA

Institute

Introduction

291

Inspection Ports
Oil Flow

Oil Flow

Thrust
Contact/Gap

The FLS type A bearing has three inspection ports for

monitoring lubrication and thrust direction.
Institute

Introduction

292

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.
Institute

Introduction

293

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.
Institute

Introduction

294

FLS Bearing Type RB

Oil
Scoops

Adjustable
Oil Tray

Oil Seal

End Cover
with
Inspection
Door

Thrust
Ring

Bronze
Bearing Liner
Bearing
Base

Institute

Spherical Socket with

Water Jacket
Introduction

295

FLS Bearing Type RB

Heat
Shield
Inspection
Port
Oil Tray

Temperature
Detector
Water
Piping

Retainer
Clamp
Dowel
Pin

Institute

Introduction

296

Type RB Oil seal

Grease
Fitting

The RB bearing has a split rubber oil seal which requires

monthly greasing.
Institute

Introduction

297

FLS Bearing Type RB

Institute

Introduction

298

Fuller Kiln Support

The Fuller support has rigid (nonspherical) bearings.

Institute

Introduction

299

Fuller Bearing
Inspection
Port
Oil Tray
End Cover
Thrust
Washer
Oil Scoop
Oil Level
Indicator
Bronze
Bearing Liner

Institute

Introduction

300

Bearing Liners

Institute

Introduction

301

FLS Bearing Liner Details

Institute

Introduction

302

Liner Clamps

Liners and sockets are clamped to prevent from rotating out

of the housing.
Institute

Introduction

303

Liner Clearance

Liner side clearances should be checked with a feeler

gage at all four liner corners after installing a new liner.
Institute

Introduction

304

Bearing Tolerances

Institute

Introduction

305

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.
Institute

Introduction

306

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.
Institute

Introduction

307

Checking Liner Contact

A well-fitting liner will pick up the blue only in the

center down its entire length.
Institute

Introduction

308

Checking Liner Contact

This liner shows less than full contact along its length,
indicating a high spot in its center.
Institute

Introduction

309

Checking Liner Contact

High spots are removed by scraping the bronze away

at the heavily blued areas.
Institute

Introduction

310

Bearing Lubrication

Institute

Introduction

311

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.
Institute

Introduction

318

Viscosity

Viscosity, or the resistance of a liquid to flow, is the most

important property of lubricating oil. Oil viscosity changes
drastically with temperature.
Institute

Introduction

319

Viscosity

Oil viscosity is selected based on equipment operating

temperature range.
Institute

Introduction

320

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.
Institute

Introduction

321

ISO Viscosity Grade

International Standards Organization
designation for oil viscosity grade.
Measured as Centistoke (cSt) at 40 C.
Becoming more common than SSU
(Saybolt Seconds Universal).
Multiply ISO VG by 5 to approximate
SSU at 100 F.

Institute

Introduction

322

Viscosity
Equivalent
s

Institute

Introduction

323

Kiln Bearing Lubricants

Gear oils with EP additives
Viscosity
ISO VG 460
ISO VG 680

ambient temperature
below 5 C
above 5 C

Synthetic oils are preferred over

mineral oils, due to their increased
viscosity index, lower pour point and
effectiveness at high temperatures.

Institute

Introduction

324

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.
Institute

Introduction

325

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.
Institute

Introduction

326

Bearing Lube Pump

Bearings can be equipped with lube pumps to

provide oil to the tray prior to kiln start-up.
Institute

Introduction

327

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.
Institute

Introduction

328

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 80C
indicate a lubrication problem
Institute

Introduction

329

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 80-90C.
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.

Institute

Introduction

330

Lubrication Failure

Institute

Introduction

331

Lubrication Failure

Institute

Introduction

332

Severe Lubrication Failure

Institute

Introduction

333

Catastrophic Lubrication Failure

Institute

Introduction

334

Catastrophic Lubrication Failure

Institute

Introduction

335

Catastrophic Lubrication Failure

Institute

Introduction

336

Catastrophic Lubrication Failure

Institute

Introduction

337

Catastrophic Lubrication Failure

Institute

Introduction

338

Rigging

Institute

Introduction

339

Rigging for Fuller Roller Assembly

Institute

Introduction

340

Rigging for Fuller Bearing

Feed End
Stamp

Institute

Introduction

341

Bearing End Cover Removal

Bearing inspection can be facilitated by the preparation

of two 24 rods on which to slide off the end cover.
Institute

Introduction

342

Rigging for FLS Bearing Liner

Institute

Introduction

343

FLS Kiln Support Type RA

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.
Institute

Introduction

344

Rotary Kiln
Maintenance Seminar

Kiln Drive
Institute

Kiln Drive

Gear and Pinion Drive

Friction Drive
Hydraulic Friction Drive
Coupling Basics
Institute

Introduction

346

Gear and Pinion Drive

Free
Bearing

Fixed
Bearing Jack Shaft

Reversible
Pinion

Institute

Motor Cooling
Fans
Tachometer

Main
Reducer

Tandem Variable Speed

Motors

Introduction

347

Kiln Inching Drive

One-way Clutch

Inching Drive
Reducer
Inching Drive
Motor

Backstop

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.
Institute

Introduction

348

Kiln Drive

A jackshaft is used to improve the layout of the drive

pier. This one is equipped with gear couplings.
Institute

Introduction

349

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.
Institute

Introduction

350

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.
Institute

Introduction

351

Inching Drive

Main
Reducer

Institute

One-Way
Clutch

Inching
Drive
Reducer

Backstop

Introduction

Inching
Motor
352

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.
Institute

Introduction

353

One-Way Clutch
Automatic
Transmission
Fluid

Most one-way clutches have locking steel

pawls inside, which require lubrication with
automatic transmission fluid only.
Institute

Introduction

354

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.
Institute

Introduction

355

Backstop

The backstop prevents kiln roll-back. Most backstops

aslo have locking steel pawls inside, which require
lubrication with automatic transmission fluid.
Institute

Introduction

356

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.
Institute

Introduction

357

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.
Institute

Introduction

358

Pillow Block Bearing

Stabilizing
Ring for Fixed
Bearing only

Oil Level
No Stabilizing
Ring for Free
Bearing

Institute

Introduction

359

Kiln Drive

This drive arrangement has a jack shaft with

flexible disc couplings. The backstop is integrally
mounted on the inching drive reducer.
Institute

Introduction

360

Friction Drive

Institute

Introduction

361

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.
Institute

Introduction

362

Friction Drive

Both rollers are driven. The motors are

balanced to prevent slippage.
Institute

Introduction

363

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.
Institute

Introduction

364

Friction Drive

A special torque arm is used to prevent reducer rotation

while still permitting movement of the roller shaft.

Institute

Introduction

365

Hydraulic Friction Drive

A friction drive may use a hydraulic motor to turn the rollers.

Institute

Introduction

366

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

Institute

Introduction

367

Hydraulic Friction Drive

This hydraulic drive uses an axial piston motor and

a planetary reducer mounted on the roller shaft.
Institute

Introduction

368

Hydraulic Friction Drive

Shaft-mounted planetary reducer with torque, with

integral hydraulic motor and inching drive.
Institute

Introduction

369

Hydraulic Friction Drive

This hydraulic drive uses four radial piston motors

mounted directly on the roller shaft.
Institute

Introduction

370

Hydraulic Friction Drive

This Hagglunds radial piston motor develops extremely

high torque, and a reducer is therefore not needed.
Institute

Introduction

371

Hydraulic Friction Drive

The load is equally shared and each roller

receives the same power and torque.
Institute

Introduction

372

Hydraulic Friction Drive

The typical kiln drive will have multiple

pumps for increased efficiency.
Institute

Introduction

373

Hydraulic Friction Drive

Hydraulic drive power curve.

Institute

Introduction

374

Hydraulic Friction Drive

DC drive power curve.

Institute

Introduction

375

Hydraulic Friction Drive

Hydraulic drive power losses.

Institute

Introduction

376

Hydraulic Friction Drive

DC drive power losses.

Institute

Introduction

377

Couplings

Institute

Introduction

378

Coupling Alignment

Couplings must be precisely aligned to minimize

parallel and angular misalignment.
Institute

Introduction

379

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.
Institute

Introduction

380

Coupling Alignment

Couplings are usually aligned with a dial indicator.

Institute

Introduction

381

Coupling Alignment

Align the coupling as accurately as possible to promote

long bearing life (not just to within coupling
manufacturers specs).
Institute

Introduction

382

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 manufacturers data.
Institute

Introduction

383

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.
Institute

Introduction

385

Laser Alignment

Aligning a kiln inching drive with

laser alignment method.
Institute

Introduction

386

Rotary Kiln
Maintenance Seminar

Kiln Alignment
Institute

Kiln Alignment

Alignment Principles
Internal Alignment
Hot Kiln Alignment

Institute

Introduction

388

Alignment Principles

Institute

Introduction

389

Kiln Alignment

A kiln is considered aligned when the

center of rotation of the kiln shell at
every support lies on a straight line.

Institute

Introduction

390

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.

Institute

Introduction

391

Kiln Alignment

Horizontal Axis

Vertical Axis

A kiln can be misaligned in the

horizontal or in the vertical plane.
Institute

Introduction

392

Consequences of Misalignment
3902 kN

3597 kN

6491 kN

3067 kN

7048 kN

2815 kN

10 mm

Misalignment changes the loading on the kiln supports

and causes overstressing of the shell and supports.
Institute

Introduction

393

Consequences of Misalignment

Misalignment can result in all of the

load being concentrated on one roller.

Institute

Introduction

394

Internal Alignment

Institute

Introduction

395

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.
Institute

Introduction

396

Internal Alignment

New kiln sections usually have steel spider

bracing with precisely marked centers. If
not, wooden batter boards can be prepared.
Institute

Introduction

397

Internal Alignment

The kiln shells center is found by scribing four

arcs on a target card tacked onto the batter board.
Institute

Introduction

398

Internal Alignment

Drawing diagonals at the arcs

intersections will locate the center.
Institute

Introduction

399

Internal Alignment

Removable targets with marked shell centers are

placed at each tire center and shell end. The
theodolites line of sight is marked on the target and
the offset is measured.
Institute

Introduction

400

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.
Institute

Introduction

401

Correcting Misalignment

Field Joint
Adjustment

Roller
Adjustment

After measurements are taken the kiln is

aligned by adjusting rollers and field joints.
Institute

Introduction

402

Correcting Misalignment

Moving both rollers horizontally will move

the kiln center by the same amount.
Institute

Introduction

403

Correcting Misalignment

A 2 + B2 = C2
Roller adjustments to correct vertical alignment can
be calculated from the relationship of right triangles.
Institute

Introduction

404

Correcting Misalignment

Moving one roller horizontally will move the kiln

center horizontally by half and vertically by one
quarter (approximately) of the distance.
Institute

Introduction

405

Correcting Misalignment

Caution! Moving a roller on the piers

immediately uphill and downhill from the
kiln gear will affect the gear alignment.
Institute

Introduction

406

Hot Kiln Alignment

Institute

Introduction

407

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.

Institute

Introduction

408

Hot Kiln Alignment

Mechanical Hot Kiln Survey Method

Laser Kiln Survey (LKS) Method

Institute

Introduction

409

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.

Institute

Introduction

410

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.
Institute

Introduction

411

Mechanical Alignment

Tire centre

s
Kiln centre

dleft

f
dright

c
q
cleft

j
cright

Using an optical level the elevations of

the bearing base frames are determined.
Institute

Introduction

412

Mechanical Alignment

Elevation
Markers

Elevation markers on kiln piers should

be checked to see if a kiln pier has sunk.

Institute

Introduction

413

Roller and Tire Circumference

Using a precision measuring wheel and

tachometer the circumference of the roller
and tire are measured.
Institute

Introduction

414

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.
Institute

Introduction

415

Mechanical Alignment

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.
Institute

Introduction

416

Mechanical Alignment

dleft

Institute

c
q
cleft

drightf

cright

Introduction

417

Laser Kiln Survey

Tire elevation and location can be determined

utilizing a laser theodolite from ground level.

Institute

Introduction

418

Laser Kiln Survey

Kiln Center Tolerances

Horizontal Plane

Vertical Plane

1.5 mm
2.5 mm

Laser measurement provides the most

accurate method of kiln alignment.

Institute

Introduction

419

Laser Kiln Survey

Institute

Introduction

420

Laser Kiln Survey

Institute

Introduction

421

Laser Kiln Survey

Institute

Introduction

422

Laser Kiln Survey

Institute

Introduction

423

Questions?

Institute

Introduction

424

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

Institute

Introduction

426

Kiln Inlet Seal

Institute

Introduction

427

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.
Institute

Introduction

428

Kiln Pneumatic Inlet Seal

Pneumatic
Cylinders

The pneumatic seal consists of two sliding

surfaces pushed together by pneumatic cylinders.
Institute

Introduction

429

Kiln Inlet Seal

Pneumatic
Cylinders
Seal Detail

Spring Loaded
Graphite Plug

Institute

Introduction

430

Kiln Inlet Seal Detail

Sliding Contact
Stationary Sealing
Surface

Rotating Sealing
Surface

Graphite Plugs
Wire Rope
Graphite Seal Cord

Stationary Kiln
Inlet Hood
Institute

Rotating Kiln
Shell
Introduction

431

Kiln Inlet Seal

Carriage

Turnbuckle

The seal is suspended by a carriage which allows it to

move longitudinally as the kiln expands and contracts.
Institute

Introduction

432

Pneumatic Inlet Seal

Stationary Seal
Half

Rotating Seal
Half

The pneumatic cylinders, when pressurized,

will press the two seal halves tightly together.
Institute

Introduction

433

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.
Institute

Introduction

434

Filter, Regulator, Lubricator

Institute

Introduction

435

Kiln Inlet Seal

Spring Loaded
Graphite Plug

Graphite Plugs in
Seal Plate

The seals sliding surfaces are graphite lubricated.

Institute

Introduction

436

Kiln Inlet Castings

Castings on the inlet hood and kiln inlet

cone keep the castable refractory in
place. Inspect them at annual shutdown.
Institute

Introduction

437

Spring Plate Inlet Seal

Institute

Introduction

438

Spring Plate Inlet Seal

Institute

Introduction

439

Spring Plate Inlet Seal

Institute

Introduction

440

Spring Plate Inlet Seal

No, covering the spring plates with plastic wont help.

Institute

Introduction

441

Outlet Seal

Institute

Introduction

442

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.
Institute

Introduction

443

Kiln Outlet Seal

Spring Plate

Institute

Wire
Rope

Introduction

444

Kiln Outlet Seal

Counterweight

Spring plates are wrapped with a counterweighted wire

rope arrangement to keep them tight against the cowl.
Institute

Introduction

445

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.
Institute

Introduction

446

Kiln Outlet Seal

Spring plates are bolted on and are easily replaced.

Institute

Introduction

447

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.
Institute

Introduction

448

Kiln Outlet Sector

The kiln nose rings sees severe service and must be

regularly inspected for refractory and casting failure.

Institute

Introduction

449

Kiln Outlet Seal

This alternate spring plates design features

outwardly protruding spring plates.
Institute

Introduction

450

Kiln Outlet Seal

Outwardly protruding spring plate design.

Institute

Introduction

451

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.
Institute

Introduction

452

Thrust Roller

Institute

Introduction

453

Thrust Roller Assembly

Clearance
Oil
Seal
Oil Level
Pipe

Tire
Spherical
Bearings

Tie
Rod

Shims

Keep the clearance to a minimum (6mm),

and adjust the shims to keep the kiln gear
in proper longitudinal alignment.
Institute

Introduction

454

Thrust Roller Assembly

Set
Screws

The kiln position can be controlled by

adjusting set screws on this thrust roller base.

Institute

Introduction

455

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.

Institute

Introduction

456

Thrust Roller Misalignment

Roller Tilted to Left

Roller Offset to Left

Roller Tilted to Right

Roller Offset to Right

A misaligned thrust roller will result in vertical forces

on the roller as shown above.
Institute

Introduction

457

Thrust Roller Misalignment

An improperly aligned thrust roller can ride out of

its socket, causing damage to tire stop blocks.
Institute

Introduction

458

Thrust Roller

Thrust rollers can become overloaded if the kilns

supporting rollers are improperly skewed. This thrust
roller base became deformed from excessive force.

Institute

Introduction

459

Fuller Thrust Roller

Institute

Introduction

460

Fuller Thrust Roller

Institute

Introduction

461

Hydraulic Thrust Roller

Institute

Introduction

462

Hydraulic Thrust Roller

The hydraulic thrust roller maintains a constant,

controlled force on the thrust tire and keeps the
kiln in an electronically determined position.

Institute

Introduction

463

Hydraulic Thrust Roller

Position
Sensor

Hydraulic Cylinder

Institute

Guide Bar

Introduction

464

Hydraulic Thrust Roller

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.
Institute

Introduction

465

Thrust Roller

The roller surface is graphite lubricated.

Institute

Introduction

466

Hydraulic Thrust Roller

Institute

Introduction

467

Hydraulic Cabinet

The hydraulic power unit is normally

placed beneath the kilns thrust pier.
Institute

Introduction

468

Hydraulic Cabinet

Relief
Valve

Tank

Accumulator
Directional
Valve
Pump

Institute

Introduction

469

Hydraulic Pump

The axial piston pump has manual

adjustments for pressure and flow rate.
Institute

Introduction

470

Directional Valve

A directional valve directs fluid to the thrust

cylinder, or allows the cylinder to bleed down.
Institute

Introduction

471

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.
Institute

Introduction

472

Hydro-pneumatic Accumulator
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

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
The accumulator
which is charged with nitrogen gas.
C O P Y R IG H T C

Institute

(1 9 9 9 ) V IC K E R S , IN C O R P O R A T E D

Introduction

473

Hydro-pneumatic Accumulator

1000

1000

500

1500

2000

p s ig

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

1000

500

1500

500

2000

p s ig

S y s te m P re s s u re
a t p m ax

1500
2000

p s ig

S y s te m P re s s u re
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

Institute

Introduction

474

Hydro-pneumatic Accumulator

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.
Institute

Introduction

475

Pressure Relief Valve

A pressure relief valve limits hydraulic pressure in

the system. This prevents excessive downhill kiln
force from damaging the thrust roller.
Institute

Introduction

476

Hydraulic Filter

An in-tank filter with a 10 micron element

keeps hydraulic fluid clean. The protruding red
button indicates the element needs changing.
Institute

Introduction

477

Thrust Cylinder LVDT

An LVDT (linear variable differential transformer)

mounted in the hydraulic cylinder measures the
distance that the cylinder rod is extended.
Institute

Introduction

478

Thrust System LVDT Cabinet

The LVDT signal goes to a cabinet where the kilns hot

running axial position is set and where alarms are
programmed for excessive uphill and downhill kiln position.
Institute

Introduction

479

Fuller Hydraulic Thrust Roller

Institute

Introduction

480

Fuller Hydraulic Thrust Roller

Institute

Introduction

481

Preventive Maintenance
Checklist

Institute

Introduction

482

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.

Institute

Introduction

483

Daily

Visually check feed and discharge seals

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.

Institute

Introduction

484

Daily

Institute

Temperatures

Record kiln shell temperatures and include a

night visual inspection for hot spots

Introduction

485

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.

Institute

Introduction

486

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.

Institute

Introduction

487

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.

Institute

Introduction

488

The Good Old Days

Institute

Introduction

489

The Good Old Days

Institute

Introduction

490

The Good Old Days

Institute

Introduction

491

Rivets

Institute

Introduction

492

Dont Be Mean to Your Kiln

Institute

Introduction

493