Kiln Mechanics 222222
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8/19/2019 Kiln Mechanics 222222
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Krupp Polysius Corp.
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 1
Rotary K i ln
Mechan ical Training
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Krupp Polysius Corp.
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 2
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
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Krupp Polysius Corp.
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 3
POLRO ® 2-support rotary kiln
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Krupp Polysius Corp.
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 4
Kiln General
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Krupp Polysius Corp.
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 5
Rotary kiln assembly
1 Rotary kiln shell 7 Guard for rack and pinion drive
2 Kiln inlet with inlet seal with lubrication device
3 Tires with fastening 8 Kiln drive
system 9 Kiln outlet with outlet seal
4 Supporting roller stations 10 Kiln hood
5 Kiln longitudinal guide 11 Clinkering zone cooling (optional)
6 Rack and pinion drive
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Krupp Polysius Corp.
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 6
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
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Krupp Polysius Corp.
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 7
Process- technological dimensions
Kilnwithpreheater
Kilnwithcalciner
10 12 1415 17
L/Dratio
3- Stations
Numberof stationsandL/ Dratio
2- Stations
10 12 14 17
L/Dratio
3- Stations
Design of rotary kilns
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Krupp Polysius Corp.
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 8
3 - support kiln versa 2 - support kiln
3-support kiln 2-support kiln
Statically undefined
• possibility of
- extreme overload
- plastic deformation
• requirement for
- etxra safety margin
- regular adjustment
Statically defined
• constant support loading
•
elastic deformation only
• no sensitivity to misalignment
long enough for process?
L\DATA\D 1 0\P l i P i d T i i \P l i T i i \P i \Kil \kil h i 140 TEI 140 CD
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Krupp Polysius Corp.
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 9
Kiln Inlet
L\DATA\D t150\P l i P t ti d T i i \P l i T i i \P i \Kil \kil h i t 140 TEI 140 CDP 10
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Krupp Polysius Corp.
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 10
“Low-dust” kiln inlet
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln mechanics ppt 140 TEI 140 CDPage 11
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Krupp Polysius Corp.
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 11
Air cooled segmented inlet through
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln mechanics ppt 140 TEI 140 CDPage 12
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Krupp Polysius Corp.
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 12
Kiln inlet seal
Seal principle
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln mechanics ppt 140 TEI 140 CDPage 13
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Krupp Polysius Corp.
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 13
• Slot adjustment between support ring
and slide ring
Cardanical fastening
Kiln inlet
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln mechanics ppt 140 TEI 140 CDPage 14
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L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 14
Air pressure system Kiln inlet
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln mechanics.ppt 140 TEI, 140 CDPage 15
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Krupp Polysius Corp.
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 15
Kiln Outlet
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln mechanics.ppt 140 TEI, 140 CDPage 16
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Krupp Polysius Corp.
p y g y g y p g _ pp ,g
Kiln outlet sealing
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 17
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Krupp Polysius Corp.
p y g y g y p g _ ppg
Slide ring
Support ring
Wear ring
Wear ring
Pneumatic
cylinder
Cord
Cooling jacket
Principle of kiln outlet sealing
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 18
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Principle kiln outlet Kiln outlet with dust chute
Kiln outlet
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 19
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Krupp Polysius Corp.
Outlet of kiln Outlet cooling
Kiln outlet
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 20
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Kiln outlet
Air pressure system
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 21
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Krupp Polysius Corp.
Kiln Shell
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 22
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Krupp Polysius Corp.
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 factorsfor 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.
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 23
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Krupp Polysius Corp.
Functions of the kiln shell
• Conveys material
• Guides gas from cooler to kiln
• Creates a constant moving material bed
allows heat exchange between gasand material
• Holds the brick lining
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 24
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Splined Tires
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 25
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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 %
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 26
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Distribution of forces First splined tire in 1950
Splined tires
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 27
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Principle splined tire Splined fixing
Splined tires
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 28
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The Floating Shim Plates
Form the Connection
Between the Tire Teeth
and the X Shaped
Retaining Blocks
Splined tires
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 29
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Krupp Polysius Corp.
Kiln shell ovality Wedge pre-tensioning device
Kiln shell ovality [%]
Floating tire
Kiln Dia. [m]
Splined tire
Splined tires
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 30
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Splined tire
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 31
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Floating Tires
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L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 33
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Krupp Polysius Corp.
Steps for radial play reduction
Floating tires
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 34
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Floating tires
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 35
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Splined kiln tire Floating kiln tire
Comparison of kiln shell ovalities
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L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 37
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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
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 38
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Roller station
1 Base frame
2 Bearing housing
assembly
3 Roller and shaftassembly
5 Guide block
12 Oil level indicator
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L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 40
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Kiln Drives
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 41
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Girth gear drive system
1 Bridge support
2 Bridge plate
3,4 Plate bolts
5 Girth gear
6 Heat shield
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 42
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Self-aligning pinion
Permitted tilting: ± 10 mm
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 43
El h d li d i
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Electro-hydraulic drive system
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 44
El t h d li d i t
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Electro-hydraulic drive system
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 45
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Electro - mechanical drive
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L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 47
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Kiln hood
1 Lower part of hood
2 Upper part of hood3 Suspension door
4 Trolley arrangement
5 Burner seal
6 Inspection port
7 Access door
8 Sub plate
9 Collar segment
10 Seal to cooler
11 Opening for measuring
socket
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 48
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Maintenance
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 49
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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
Maintenance kiln inlet
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 50
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Air pressure net:
• Air pressure for pneumatic-cylinder
• Check of water separator
•
Check of lubricator of pressurized air
• Check for leakages
Maintenance kiln inlet
Air pressure system
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 51
M i t kil tl t
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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
Maintenance kiln outlet
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 52
Maintenance splined tires
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Check of splined tire fastening:
• Check of wedge pre-tension
• Visual check of tire area
• Check of welds
Maintenance splined tires
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L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 54
Maintenance floating tires
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Krupp Polysius Corp.
Damages at base plates by defficient lubrication
Maintenance floating tires
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 55
Maintenance / lubrication points
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Krupp Polysius Corp.
Maintenance / lubrication points
1 Girth gear
2 Compressor plant
3 Oil atomizer
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 56
Maintenance / lubrication points
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Maintenance / lubrication points
4 Self-aligning pinion and stock bin
5 Splash lubrication girth gear pinion
6 Pinion bearing
7 Rotary kiln drive
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L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 58
Maintenance / lubrication points
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Maintenance / lubrication points
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
L\DATA\Dept150\Polysius Presentations and Training\Polysius Training\Pyroprocessing\Kiln\kiln_mechanics.ppt 140 TEI, 140 CDPage 59
Maintenance / lubrication points
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Maintenance / lubrication points
26 Thrust roller
27 Safety thrust roller
28 Slide pin
29 Hydraulic kilns
longitudinal guide
30 Graphite lubrication
equipment