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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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    Krupp Polysius Corp.

    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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    Krupp Polysius Corp.

    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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    Krupp Polysius Corp.

    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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    Krupp Polysius Corp.

    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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    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

      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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    Krupp Polysius Corp.

    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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    Krupp Polysius Corp.

    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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    Krupp Polysius Corp.

    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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    Krupp Polysius Corp.

    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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    Krupp Polysius Corp.

    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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    Krupp Polysius Corp.

    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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    Krupp Polysius Corp.

    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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    Krupp Polysius Corp.

    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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    Krupp Polysius Corp.

    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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    Krupp Polysius Corp.

    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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    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 

    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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    Krupp Polysius Corp.

    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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    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