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304372312-Kiln-Miscellaneous.pdf
- 1. Rotary Kiln Maintenance RotaryKiln Maintenance Seminar Seminar Kiln Miscellaneous
- 2. Kiln Inlet Seal KilnOutlet Seal Thrust Roller Hydraulic Thrust Roller Kiln Maintenance Checklist The Good Old Days Kiln Miscellaneous Kiln Miscellaneous
- 3. Kiln Inlet Seal KilnInlet Seal
- 4. Kiln Inlet Seal KilnInlet 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.
- 5. Kiln Pneumatic InletSeal Kiln Pneumatic Inlet Seal The pneumatic seal consists of two sliding surfaces pushed together by pneumatic cylinders. Pneumatic Cylinders
- 6. Kiln Inlet Seal KilnInlet Seal Spring Loaded Graphite Plug Seal Detail Pneumatic Cylinders
- 7. Kiln Inlet SealDetail Kiln Inlet Seal Detail Graphite Seal Cord Wire Rope Graphite Plugs Rotating Kiln Shell Rotating Sealing Surface Stationary Sealing Surface Sliding Contact Stationary Kiln Inlet Hood
- 8. Kiln Inlet Seal KilnInlet Seal The seal is suspended by a carriage which allows it to move longitudinally as the kiln expands and contracts. Carriage Turnbuckle
- 9. Pneumatic Inlet Seal PneumaticInlet Seal The pneumatic cylinders, when pressurized, will press the two seal halves tightly together. Stationary Seal Half Rotating Seal Half
- 10. Filter, Regulator, Lubricator 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.
- 11. Filter, Regulator, Lubricator Filter,Regulator, Lubricator
- 12. Kiln Inlet Seal KilnInlet Seal The seal’s sliding surfaces are graphite lubricated. Spring Loaded Graphite Plug Graphite Plugs in Seal Plate
- 13. Kiln Inlet Castings KilnInlet Castings Castings on the inlet hood and kiln inlet cone keep the castable refractory in place. Inspect them at annual shutdown.
- 14. Spring Plate InletSeal Spring Plate Inlet Seal
- 15. Spring Plate InletSeal Spring Plate Inlet Seal
- 16. Spring Plate InletSeal Spring Plate Inlet Seal
- 17. No, covering thespring plates with plastic won’t help. Spring Plate Inlet Seal Spring Plate Inlet Seal
- 18.
- 19. Kiln Outlet Seal KilnOutlet Seal The spring plate outlet seal has become the outlet seal of choice. The seal can withstand the harsh conditions at the kiln hood.
- 20. Kiln Outlet Seal KilnOutlet Seal Spring Plate Wire Rope
- 21. Kiln Outlet Seal KilnOutlet Seal Counterweight Spring plates are wrapped with a counterweighted wire rope arrangement to keep them tight against the cowl.
- 22. Forced Air Cooling Kiln Outlet Seal KilnOutlet Seal 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.
- 23. Kiln Outlet Seal KilnOutlet Seal Spring plates are bolted on and are easily replaced.
- 24. Kiln Outlet Kiln OutletSeal Seal Dust from kiln hood puffing falls down the chutes to the drag chain conveyor or into the clinker cooler. The Old Way The Better Way
- 25. Kiln Outlet Sector KilnOutlet Sector The kiln nose rings sees severe service and must be regularly inspected for refractory and casting failure.
- 26. Kiln Outlet Seal KilnOutlet Seal This alternate spring plates design features outwardly protruding spring plates.
- 27. Kiln Outlet Seal KilnOutlet Seal Outwardly protruding spring plate design.
- 28. The Most ExpensiveSeal 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.
- 29.
- 30. Thrust Roller Assembly ThrustRoller Assembly Oil Seal Oil Level Pipe Spherical Bearings Tie Rod Tire Shims Clearance Keep the clearance to a minimum (6mm), and adjust the shims to keep the kiln gear in proper longitudinal alignment.
- 31. Thrust Roller Assembly ThrustRoller Assembly Set Screws The kiln position can be controlled by adjusting set screws on this thrust roller base.
- 32. Thrust Roller Position ThrustRoller 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.
- 33. Thrust Roller Misalignment ThrustRoller Misalignment A misaligned thrust roller will result in vertical forces on the roller as shown above. Roller Tilted to Left Roller Tilted to Right Roller Offset to Left Roller Offset to Right
- 34. Thrust Roller Misalignment ThrustRoller Misalignment An improperly aligned thrust roller can ride out of its socket, causing damage to tire stop blocks.
- 35. Thrust Roller Thrust Roller Thrustrollers can become overloaded if the kiln’s supporting rollers are improperly skewed. This thrust roller base became deformed from excessive force.
- 36. Fuller Thrust Roller FullerThrust Roller
- 37. Fuller Thrust Roller FullerThrust Roller
- 38. Hydraulic Thrust Roller HydraulicThrust Roller
- 39. Hydraulic Thrust Roller HydraulicThrust Roller The hydraulic thrust roller maintains a constant, controlled force on the thrust tire and keeps the kiln in an electronically determined position.
- 40. Hydraulic Thrust Roller HydraulicThrust Roller Guide Bar Hydraulic Cylinder Position Sensor
- 41. Hydraulic Thrust Roller HydraulicThrust 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.
- 42. Thrust Roller Thrust Roller Theroller surface is graphite lubricated.
- 43. Hydraulic Thrust Roller HydraulicThrust Roller
- 44. Hydraulic Cabinet Hydraulic Cabinet Thehydraulic power unit is normally placed beneath the kiln’s thrust pier.
- 45.
- 46. Hydraulic Pump Hydraulic Pump Theaxial piston pump has manual adjustments for pressure and flow rate.
- 47. Directional Valve Directional Valve Adirectional valve directs fluid to the thrust cylinder, or allows the cylinder to bleed down.
- 48. Hydro Hydro- -pneumatic Accumulator pneumatic Accumulator Anaccumulator 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.
- 49. Gas Valve Bladder Shell Port Anti-Extrusion Valve Nitrogen Gas Hydro Hydro- -pneumaticAccumulator pneumatic Accumulator The accumulator contains a rubber bladder which is charged with nitrogen gas.
- 50. psig 0 500 1000 1500 2000 psig 0 500 1000 1500 2000 psig 0 500 1000 1500 2000 System Pressure Less Thanpprecharge System Pressure at pmax System Pressure at pmin Hydro Hydro- -pneumatic Accumulator pneumatic Accumulator When hydraulic pressure increases and decreases the gas is compressed and expanded.
- 51. Hydro Hydro- -pneumatic Accumulator pneumatic Accumulator Theaccumulator is pre-charged with nitrogen to approximately half of the expected average operating hydraulic pressure. Danger! Do not charge with air or oxygen!
- 52. Pressure Relief Valve PressureRelief Valve A pressure relief valve limits hydraulic pressure in the system. This prevents excessive downhill kiln force from damaging the thrust roller.
- 53. Hydraulic Filter Hydraulic Filter Anin-tank filter with a 10 micron element keeps hydraulic fluid clean. The protruding red button indicates the element needs changing.
- 54. Thrust Cylinder LVDT ThrustCylinder LVDT An LVDT (linear variable differential transformer) mounted in the hydraulic cylinder measures the distance that the cylinder rod is extended.
- 55. Thrust System LVDTCabinet Thrust System LVDT Cabinet The LVDT signal goes to a cabinet where the kiln’s hot running axial position is set and where alarms are programmed for excessive uphill and downhill kiln position.
- 56. Fuller Hydraulic ThrustRoller Fuller Hydraulic Thrust Roller
- 57. Fuller Hydraulic ThrustRoller Fuller Hydraulic Thrust Roller
- 58. Preventive Maintenance Checklist PreventiveMaintenance Checklist
- 59. Daily Daily Thrust Roller • Kilnswith 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.
- 60. Seals • Visually checkfeed and discharge 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. Daily Daily
- 61. Temperatures • Record kilnshell temperatures and include a night visual inspection for “hot spots” Daily Daily
- 62. Weekly Weekly • Check andrecord 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.
- 63. • Check generalcondition 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. Weekly Weekly
- 64. Annually Annually • Perform completecheck 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.
- 65. The Good OldDays The Good Old Days
- 66. The Good OldDays The Good Old Days
- 67. The Good OldDays The Good Old Days
- 68.
- 69. Don’t Be Meanto Your Kiln Don’t Be Mean to Your Kiln