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Page 1

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Rotary Kiln

Mechanical Training

Krupp Polysius Corp.

140 TEI, 140 CD

Page 2

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Content: • Kiln General • Kiln Inlet Including Seal

• Kiln Outlet Including Seal • Kiln Shell • Splined Kiln Tire • Floating Kiln Tire • Supporting Roller Station • Kiln Drives • Kiln Hood • Maintenance, Lubrication

Krupp Polysius Corp.

140 TEI, 140 CD

Page 3

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

POLRO® 2-support rotary kiln

Krupp Polysius Corp.

140 TEI, 140 CD

Page 4

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Kiln General

Krupp Polysius Corp.

140 TEI, 140 CD

Page 5

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Rotary kiln assembly

1 2 3 4 5 6

Rotary kiln shell Kiln inlet with inlet seal Tires with fastening system Supporting roller stations Kiln longitudinal guide Rack and pinion drive

Krupp Polysius Corp.

7 8 9 10 11

Guard for rack and pinion drive with lubrication device Kiln drive Kiln outlet with outlet seal Kiln hood Clinkering zone cooling (optional)

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Page 6

140 TEI, 140 CD

The POLRO 2 - support kiln

• • • • •

splined tires (cold gap 0.4%) self-aligning rollers direct drive via supporting rollers pneumatically applied inlet and outlet seals air cooled kiln inlet tray

Krupp Polysius Corp.

Page 7

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Design of rotary kilns P r o c e s s t e c h n o l o g i c a l d i m e n s i o n s

K i l n w i t h c a l c i n e r K i l n w i t h p r e h e a t e r 1 0

1 2 1 41 5 L / D r a t i o

1 7

N u m b e r o f s t a t i o n s a n d L / D r a t i o 2 S t a t i o n s 3 S t a t i o n s 3 S t a t i o n s 1 0

Krupp Polysius Corp.

1 2

1 4 L / D r a t i o

1 7

Page 8

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

3 - support kiln versa 2 - support kiln 3-support kiln

Statically undefined

2-support kiln

Statically defined

• possibility of - extreme overload - plastic deformation

• constant support loading

• requirement for - etxra safety margin - regular adjustment

• no sensitivity to misalignment

Krupp Polysius Corp.

• elastic deformation only

long enough for process?

Page 9

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Kiln Inlet

Krupp Polysius Corp.

140 TEI, 140 CD

Page 10

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

“Low-dust” kiln inlet

Krupp Polysius Corp.

Page 11

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Air cooled segmented inlet through

Krupp Polysius Corp.

140 TEI, 140 CD

Page 12

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Kiln inlet seal

Seal principle

Krupp Polysius Corp.

140 TEI, 140 CD

Page 13

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Kiln inlet

• Slot adjustment between support ring and slide ring

Cardanical fastening

Krupp Polysius Corp.

Page 14

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Kiln inlet Air pressure system

Krupp Polysius Corp.

140 TEI, 140 CD

Page 15

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Kiln Outlet

Krupp Polysius Corp.

140 TEI, 140 CD

Page 16

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Kiln outlet sealing

Krupp Polysius Corp.

140 TEI, 140 CD

Page 17

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Principle of kiln outlet sealing

Wear ring

Cooling jacket Slide ring

Wear ring Pneumatic cylinder

Krupp Polysius Corp.

Cord Support ring

Page 18

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Kiln outlet

Principle kiln outlet

Krupp Polysius Corp.

Kiln outlet with dust chute

Page 19

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Kiln outlet

Outlet of kiln

Krupp Polysius Corp.

Outlet cooling

140 TEI, 140 CD

Page 20

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Kiln outlet

Air pressure system

Krupp Polysius Corp.

Page 21

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Kiln Shell

Krupp Polysius Corp.

140 TEI, 140 CD

Page 22

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Description of the kiln shell calculation basics

The shell is a rotating drum made from rolled steel plates. These shell sections have the same inside diameter but different plate thickness. All sections are welded together. The shell thickness is a result of some calculations, the so-called Kiln Static. Basic for the kiln static are some mechanical rules and some limiting factors for the shell material, the so-called Design Criteria. The design criteria for a kiln shell is the Bending Stress. Different kiln areas have different Loads.

Krupp Polysius Corp.

Page 23

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Functions of the kiln shell

• Conveys material • Guides gas from cooler to kiln • Creates a constant moving material bed allows heat exchange between gas and material • Holds the brick lining

Krupp Polysius Corp.

140 TEI, 140 CD

Page 24

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Splined Tires

Krupp Polysius Corp.

140 TEI, 140 CD

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Page 25

140 TEI, 140 CD

Description and function of the kiln tire

The tire is a steel ring on the outside of kiln shell. It works as an stiffener for the kiln shell. The kiln tires have to carry the kiln weight. Functions:

 Transfer load from shell to the rollers  Keeps the shell in a round shape  May transfer torque from roller to tire

Design criteria:

 Tire bending stress  Ovality in %

Krupp Polysius Corp.

Page 26

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Splined tires

Distribution of forces

Krupp Polysius Corp.

First splined tire in 1950

Page 27

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Splined tires

Principle splined tire

Krupp Polysius Corp.

Splined fixing

140 TEI, 140 CD

Page 28

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Splined tires

The Floating Shim Plates Form the Connection Between the Tire Teeth and the X-Shaped Retaining Blocks

Krupp Polysius Corp.

140 TEI, 140 CD

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Page 29

140 TEI, 140 CD

Splined tires

Kiln shell ovality [%]

Floating tire

Splined tire

Kiln Dia. [m]

Kiln shell ovality

Krupp Polysius Corp.

Wedge pre-tensioning device

Page 30

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Splined tire

Krupp Polysius Corp.

140 TEI, 140 CD

Page 31

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Floating Tires

Krupp Polysius Corp.

140 TEI, 140 CD

Page 32

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Floating (loose) tires

Distribution of forces

Krupp Polysius Corp.

Principle of floating tires

Page 33

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Floating tires

Steps for radial play reduction

Krupp Polysius Corp.

140 TEI, 140 CD

Page 34

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Floating tires

Krupp Polysius Corp.

140 TEI, 140 CD

Page 35

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Comparison of kiln shell ovalities Splined kiln tire

Krupp Polysius Corp.

Floating kiln tire

Page 36

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Supporting Roller Station

Krupp Polysius Corp.

140 TEI, 140 CD

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Page 37

140 TEI, 140 CD

Description and function of a kiln roller A kiln roller is a steel wheel which is supported on each side. Each tire is supported by two rollers.

Functions:

 Transfer load from tires to base plate  Supports tires and keeps them in position  Can transfer torque from rollers to tire  Allows rotation

Design criteria:

 Hertz Pressure  Bearing Pressure

Krupp Polysius Corp.

Page 38

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Roller station

Krupp Polysius Corp.

1

Base frame

2

Bearing housing assembly

3

Roller and shaft assembly

5

Guide block

12

Oil level indicator

Page 39

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Self aligning roller station for Polro kiln

Krupp Polysius Corp.

Page 40

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Kiln Drives

Krupp Polysius Corp.

140 TEI, 140 CD

Page 41

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Girth gear drive system

Krupp Polysius Corp.

1

Bridge support

2

Bridge plate

3,4

Plate bolts

5

Girth gear

6

Heat shield

Page 42

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Self-aligning pinion

Permitted tilting: ± 10 mm

Krupp Polysius Corp.

Page 43

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Electro-hydraulic drive system

Krupp Polysius Corp.

140 TEI, 140 CD

Page 44

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Electro-hydraulic drive system

Krupp Polysius Corp.

140 TEI, 140 CD

Page 45

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Electro - mechanical drive

Krupp Polysius Corp.

140 TEI, 140 CD

Page 46

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Kiln Hood

Krupp Polysius Corp.

140 TEI, 140 CD

Page 47

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Kiln hood

1 2 3 4 5 6 7 8 9 10 11

Krupp Polysius Corp.

Lower part of hood Upper part of hood Suspension door Trolley arrangement Burner seal Inspection port Access door Sub plate Collar segment Seal to cooler Opening for measuring socket

Page 48

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Maintenance

Krupp Polysius Corp.

140 TEI, 140 CD

Page 49

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Maintenance kiln inlet

Check points of kiln inlet seal: • Slot between support ring and slide ring

• Thickness of the wear ring • Visual check of sealing surfaces • Check for material leakage • Pre-tensioning of sealing robe

Krupp Polysius Corp.

140 TEI, 140 CD

Page 50

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Maintenance kiln inlet

Air pressure net:

• Air pressure for pneumatic-cylinder • Check of water separator • Check of lubricator of pressurized air • Check for leakages

Air pressure system

Krupp Polysius Corp.

Page 51

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Maintenance kiln outlet

Check of outlet seal:

(similar to inlet seal), with additional points: • Graphite lubrication of slide rings • Function of pendling hatch • Clearance of dust chute • Functioning operation of expansion joints

Krupp Polysius Corp.

140 TEI, 140 CD

Page 52

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Maintenance splined tires

Check of splined tire fastening: • Check of wedge pre-tension • Visual check of tire area

• Check of welds

Krupp Polysius Corp.

140 TEI, 140 CD

Page 53

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

Maintenance floating tires Check of floating tire fastening: • Control of relative movement • Play measurements during stop times • Control of axial retainers • Lubrication of slide surfaces • Check of welds

Krupp Polysius Corp.

140 TEI, 140 CD

Page 54

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Maintenance floating tires

Damages at base plates by defficient lubrication

Krupp Polysius Corp.

Page 55

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Maintenance / lubrication points

Krupp Polysius Corp.

1

Girth gear

2

Compressor plant

3

Oil atomizer

Page 56

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Maintenance / lubrication points

4

Self-aligning pinion and stock bin

5

Splash lubrication girth gear pinion

6

Pinion bearing

7

Rotary kiln drive

Krupp Polysius Corp.

Page 57

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Maintenance / lubrication points

Krupp Polysius Corp.

15

Kiln tire

16

Inlet seal

17

Oil atomizer for inlet seal

18

Oil atomizer for outlet seal

19

Cooling air fan

20

Fan for clinkering zone cooling system

Page 58

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Maintenance / lubrication points

Krupp Polysius Corp.

21

Supporting roller bearing station I

22

Supporting roller bearing station II

23

Supporting roller bearing staton III

24

Supporting roller bearing station IV

25

Graphite lubrication equipment

Page 59

L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt

140 TEI, 140 CD

Maintenance / lubrication points

Krupp Polysius Corp.

26

Thrust roller

27

Safety thrust roller

28

Slide pin

29

Hydraulic kilns longitudinal guide

30

Graphite lubrication equipment