Kiln Mechanics

59 

Full text

(1)

Krupp Polysius Corp.

Rotary Kiln

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Krupp Polysius Corp.

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

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Krupp Polysius Corp.

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Krupp Polysius Corp.

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Krupp Polysius Corp.

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.

• 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.

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Krupp Polysius Corp.

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

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Krupp Polysius Corp.

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Krupp Polysius Corp.

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Krupp Polysius Corp.

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Krupp Polysius Corp.

Kiln inlet seal

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Krupp Polysius Corp.

• Slot adjustment between support ring

and slide ring

Cardanical fastening

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Krupp Polysius Corp.

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Krupp Polysius Corp.

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Krupp Polysius Corp.

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Krupp Polysius Corp.

Slide ring

Support ring

Wear ring

Wear ring

Pneumatic

cylinder

Cord

Cooling jacket

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Krupp Polysius Corp.

Principle kiln outlet

Kiln outlet with dust chute

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Krupp Polysius Corp.

Outlet of kiln

Outlet cooling

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Krupp Polysius Corp.

Kiln outlet

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Krupp Polysius Corp.

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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 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

.

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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 gas

and material

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Krupp Polysius Corp.

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Krupp Polysius Corp.

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

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Krupp Polysius Corp.

Distribution of forces

First splined tire in 1950

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Krupp Polysius Corp.

Principle splined tire

Splined fixing

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Krupp Polysius Corp.

The

Floating Shim Plates

Form the Connection

Between the Tire Teeth

and the

X-Shaped

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Krupp Polysius Corp.

Kiln shell ovality

Wedge pre-tensioning device

Kiln shell ovality [%]

Floating tire

Kiln Dia. [m]

Splined tire

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Krupp Polysius Corp.

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Krupp Polysius Corp.

Distribution of forces

Principle of floating tires

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Krupp Polysius Corp.

Steps for radial play reduction

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Krupp Polysius Corp.

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Krupp Polysius Corp.

Splined kiln tire

Floating kiln tire

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Krupp Polysius Corp.

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Krupp Polysius Corp.

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

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Krupp Polysius Corp.

Roller station

1

Base frame

2

Bearing housing

assembly

3

Roller and shaft

assembly

5

Guide block

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Krupp Polysius Corp.

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Girth gear drive system

1

Bridge support

2

Bridge plate

3,4

Plate bolts

5

Girth gear

6

Heat shield

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Krupp Polysius Corp.

Self-aligning pinion

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Krupp Polysius Corp.

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Krupp Polysius Corp.

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Krupp Polysius Corp.

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Krupp Polysius Corp.

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Krupp Polysius Corp.

Kiln hood

1

Lower part of hood

2

Upper part of hood

3

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

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Krupp Polysius Corp.

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Krupp Polysius Corp.

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

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Krupp Polysius Corp.

Air pressure net:

• Air pressure for pneumatic-cylinder

• Check of water separator

• Check of lubricator of pressurized air

• Check for leakages

Maintenance kiln inlet

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Krupp Polysius Corp.

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

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Krupp Polysius Corp.

Check of splined tire fastening:

• Check of wedge pre-tension

• Visual check of tire area

• Check of welds

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Krupp Polysius Corp.

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

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Krupp Polysius Corp.

Damages at base plates by defficient lubrication

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Krupp Polysius Corp.

Maintenance / lubrication points

1

Girth gear

2

Compressor plant

3

Oil atomizer

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Krupp Polysius Corp.

Maintenance / lubrication points

4

Self-aligning pinion and stock bin

5

Splash lubrication girth gear pinion

6

Pinion bearing

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Krupp Polysius Corp.

Maintenance / lubrication points

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

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Krupp Polysius Corp.

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

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Krupp Polysius Corp.

Maintenance /

lubrication

points

26

Thrust roller

27

Safety thrust roller

28

Slide pin

29

Hydraulic kilns

longitudinal guide

30

Graphite lubrication

Figure

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References

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