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Rotary kilns have many moving parts and as the kiln ages, these parts can start to move very differently. Whether you’re a kiln expert or a newcomer, it’s always important to review the basics, starting with the key components that make up your kiln.
Located at the point of transfer between the rotating element and the stationary hood or duct. Kiln seals are used to minimize drawing excess air and expulsion of kiln gases.
Commonly referred to as a tire, the riding ring is located at every carrying station. It wraps the kiln shell, providing radial stiffness and a contact area for kiln rotation.
Assembled sections of rolled steel, typically known as “can sections”. The overall length and diameter of kiln shells are determined by process needs.
The burner provides the heat required within the process to dry or carry out a chemical reaction in the product within the kiln or dryer. Heat is generated by burning fuels which can be gas, liquid, or solid in the presence of oxygen normally provided by an air supply.
Located at load piers, the carrying station includes the base frame and all support mechanisms (bearing assemblies, trunnions, etc.).
The drive system enables the rotary kiln to rotate. It is comprised of the main gear, a drive pinion, and a motor/reducer assembly.
Located at the point of transfer between the rotating element and the stationary hood or duct. Kiln seals are used to minimize drawing excess air and expulsion of kiln gases.
Commonly referred to as a tire, the riding ring is located at every carrying station. It wraps the kiln shell, providing radial stiffness and a contact area for kiln rotation.
Assembled sections of rolled steel, typically known as “can sections”. The overall length and diameter of kiln shells are determined by process needs.
The burner provides the heat required within the process to dry or carry out a chemical reaction in the product within the kiln or dryer. Heat is generated by burning fuels which can be gas, liquid, or solid in the presence of oxygen normally provided by an air supply.
Located at load piers, the carrying station includes the base frame and all support mechanisms (bearing assemblies, trunnions, etc.).
The drive system enables the rotary kiln to rotate. It is comprised of the main gear, a drive pinion, and a motor/reducer assembly.
Left untreated, horizontal and vertical misalignment issues on rotary kilns can lead to unpredictable operation and decreased reliability. Alignment is also a key factor in extending the lifetime of equipment and optimizing maintenance costs.
Why is alignment so important?
Alignment of the shell or drum between the support piers, gear to pinion, and tires to support rollers, is necessary for all rotary units. By maintaining alignment of the key components, the following benefits can be obtained:
Hot alignment allows adjustment of the kiln to the optimum level without interrupting production for multi-pier, refractory-lined kilns. Using the latest technology, the analysis typically includes items such as shell profile and run-out, ovality measurement, differential roller shaft deflections, gear, and tire axial run-out, as well as roller and tire diameter measurements. Corrections to alignment are made on the run. Hot kiln alignments are also beneficial in determining the shell axis prior to shutdowns where major work is planned.
Cold alignment is executed during a shutdown period to correctly realign the kiln in order to benefit production and safeguard your equipment. This is typically carried out on smaller units such as coolers, dryers, and carbon regeneration kilns, with or without refractory lining, and running spherical roller bearings.
Because OEMs and repair companies apply different methods to calculate kiln misalignment, you might find it challenging to evaluate the service proposals you receive from suppliers performing their version of a hot-kiln alignment. When looking for support in kiln alignment, there are a few considerations to
evaluate:
An Alignment Analysis of the unit is often combined with a Mechanical Survey in order to identify, diagnose, and correct any issues before they develop into major problems. Metso Outotec Alignment Analysis contains a range of measurements using different tools to ensure all key parameters are analyzed.
The use of accurate and proven procedures, performed by experienced and qualified personnel should be of paramount importance to the operator. Metso Outotec has crews with many hundreds of hours of experience on all makes and types of rotary equipment.
Proper diagnostics tools and methods should be utilized. For example, some rely on measurements of the riding ring and the associated tire slip or creep. However, given that the tire surface can be irregular due to wear and is often contaminated with lubricant and dust, basing kiln alignment on tire measurements alone is of questionable accuracy. Metso Outotec uses state-of-the-art high-frequency laser equipment to capture data with a high degree of accuracy, calculating the position of the kiln shell rotational axis at each support. Calculations include allowance for flexure, shape distortion, and eccentricity of the shell.
Why is alignment so important?
Alignment of the shell or drum between the support piers, gear to pinion, and tires to support rollers, is necessary for all rotary units. By maintaining alignment of the key components, the following benefits can be obtained:
Hot alignment allows adjustment of the kiln to the optimum level without interrupting production for multi-pier, refractory-lined kilns. Using the latest technology, the analysis typically includes items such as shell profile and run-out, ovality measurement, differential roller shaft deflections, gear, and tire axial run-out, as well as roller and tire diameter measurements. Corrections to alignment are made on the run. Hot kiln alignments are also beneficial in determining the shell axis prior to shutdowns where major work is planned.
Cold alignment is executed during a shutdown period to correctly realign the kiln in order to benefit production and safeguard your equipment. This is typically carried out on smaller units such as coolers, dryers, and carbon regeneration kilns, with or without refractory lining, and running spherical roller bearings.
Because OEMs and repair companies apply different methods to calculate kiln misalignment, you might find it challenging to evaluate the service proposals you receive from suppliers performing their version of a hot-kiln alignment. When looking for support in kiln alignment, there are a few considerations to
evaluate:
An Alignment Analysis of the unit is often combined with a Mechanical Survey in order to identify, diagnose, and correct any issues before they develop into major problems. Metso Outotec Alignment Analysis contains a range of measurements using different tools to ensure all key parameters are analyzed.
The use of accurate and proven procedures, performed by experienced and qualified personnel should be of paramount importance to the operator. Metso Outotec has crews with many hundreds of hours of experience on all makes and types of rotary equipment.
Proper diagnostics tools and methods should be utilized. For example, some rely on measurements of the riding ring and the associated tire slip or creep. However, given that the tire surface can be irregular due to wear and is often contaminated with lubricant and dust, basing kiln alignment on tire measurements alone is of questionable accuracy. Metso Outotec uses state-of-the-art high-frequency laser equipment to capture data with a high degree of accuracy, calculating the position of the kiln shell rotational axis at each support. Calculations include allowance for flexure, shape distortion, and eccentricity of the shell.
Performing regular inspections and maintenance are vital for kiln operators. They can prevent breakdowns and eliminate related safety concerns, inconvenience, and costly repairs. Overall, good maintenance habits go a long way towards keeping your kiln healthy and minimizing operating expenses.
A walk-by inspection should be performed daily.
These inspections should be performed weekly, in addition to the daily checks.
Similar to visiting a physician for an annual physical exam, the health of your rotary kiln should be followed and examined regularly as well. Keep an eye on the following core areas and key indicators.
Shell flex or ovality occurs at each pier. This condition is marked by a radial irregularity or deviation from the circular shape at the horizontal axis, and an assumed equal and opposite deviation at the vertical axis.
Causes of kiln shell ovality:
Tire migration, also known as tire creep, is the difference in the circumferential distance traveled between the tire and shell in one revolution i.e. the amount that the tire lags or “creeps” behind the shell.
Shell profile (or out-of-roundness) is a permanent deformation of the kiln shell. This is normally referred to as shell blisters, shell warp-age, shell twisting, or coke bottling.
Kiln shell run-out (or eccentricity), is the inaccuracy of kiln shell rotation about its true center. It is the radial offset about the true center of rotation of the kiln. This situation is commonly referred to as a kiln shell crank, dog leg, or a banana in the kiln shell.
Gear axial runout and radial runout refer to the misalignment of the main gear as it rotates. Radial run-out is checked to ensure proper alignment between the gear and the pinion, while the axial runout is important to ensure proper face contact between the gear and pinion.
Shell flex or ovality occurs at each pier. This condition is marked by a radial irregularity or deviation from the circular shape at the horizontal axis, and an assumed equal and opposite deviation at the vertical axis.
Causes of kiln shell ovality:
Tire migration, also known as tire creep, is the difference in the circumferential distance traveled between the tire and shell in one revolution i.e. the amount that the tire lags or “creeps” behind the shell.
Shell profile (or out-of-roundness) is a permanent deformation of the kiln shell. This is normally referred to as shell blisters, shell warp-age, shell twisting, or coke bottling.
Kiln shell run-out (or eccentricity), is the inaccuracy of kiln shell rotation about its true center. It is the radial offset about the true center of rotation of the kiln. This situation is commonly referred to as a kiln shell crank, dog leg, or a banana in the kiln shell.
Gear axial runout and radial runout refer to the misalignment of the main gear as it rotates. Radial run-out is checked to ensure proper alignment between the gear and the pinion, while the axial runout is important to ensure proper face contact between the gear and pinion.
Keeping your kiln healthy and running at its best can be a big job. Luckily, OEM partners like Metso Outotec can help you so you don’t need to take care of everything by yourself. Metso Outotec offers end-to-end services for rotary kilns, as well as for full pyro processing systems. Our services also cover the many heritage brands that are part of Metso Outotec, and we also service non-Metso Outotec equipment. With more than 100 years of experience covering numerous applications and business areas, you can count on Metso Outotec to keep your kiln turning.
OEM parts are available for a variety of brands, all held to stringent quality standards
A range of possibilities, from small tire crack repairs to a shell section replacement to a complete overhaul
Regular maintenance is a core practice that should not be overlooked
An extensive array of training programs designed for real-world operations