Kiln Mechanical Problems

MECHANICAL PROBLEMS OF ROTARY KILNS

Journal bearing

Thrust collar

OPEN

TIGHT

SLEEVE BEARING SELF-ALIGNING

THRUST COLLAR GAP

THRUST BEARING

NORMAL POSITION: ROLLER DOWNHILL

DOWNHILL

UPHILL Thrust ring

Roller

Thrust ring

No Gap Gap ¼ - ½” (6-12 mm)

Thrust bearing

Axial Float

Shell cracks

Kiln shell

CRACKS WEAR

ROLLER PROBLEMS An Irregular Surface Increases The Power Needed To Turn The Kiln = Increase In Gear And Pinion Wear Point Loading Causes Shaft Failures

Bearing

Bearing High Thrust Loads Cause Hot Bearings

CRACKS

WEAR

Filler bars worn

Kiln tyre worn

Tyre&Roller wear

Kiln Axis

0

-3

0

Horizontal axis

0

2

Vertical axis

0

Moving the roller station According to measurement

Kiln Thrust

Hydraulic Thrust

Thrust problems

A

Tire

Kiln

B

C

Roller

Tire Rotation Upward

Rotation Downward

Kiln

D

Roller

A

B

A

B

Support Roller

a.

C

Bearing

D

C

D

Support Roller

b.

Bearing

Measuring of Axial Balance

Bearing Temperature

Rotary Inclinometer

Kiln Crank

Crank Measurement

Permanent deformation Shell constriction (restricted expansion)

Buckling (local overheating) Crankshaft (excessive circumferential temp. difference)

Heat correction of mechanical crank

Shell Ovality

Absolute Absolute ovality ovality  D  == D Do,v o,v Do,h o,h Relative Relative ovality ovality  - D o,h)/D  == (D (Do,v )/Doo o,v - Do,h

=0

>0 Do

D > Do

D < Do

How to measure Ovality

Adjustment of kiln shell ovality

Tire Wobbling

Diameter Measurement

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