Kiln Miscellaneous PDF

Rotary Kiln Maintenance
Seminar
Kiln Miscellaneous
Kiln Miscellaneous
Kiln Inlet Seal

Kiln Outlet Seal
Thrust Roller
Hydraulic Thrust Roller
Kiln Maintenance Checklist
The Good Old Days
Kiln Inlet Seal
Kiln Inlet 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.
Kiln Pneumatic Inlet Seal
Pneumatic
Cylinders
The pneumatic seal consists of two sliding

surfaces pushed together by pneumatic cylinders.
Kiln Inlet Seal
Pneumatic
Cylinders
Seal Detail
Spring Loaded
Graphite Plug
Kiln Inlet Seal Detail
Sliding Contact
Stationary Sealing Rotating Sealing
Surface Surface
Graphite Plugs
Wire Rope
Graphite Seal Cord
Stationary Kiln Rotating Kiln

Inlet Hood Shell
Kiln Inlet Seal
Carriage
Turnbuckle
The seal is suspended by a carriage which allows it to

move longitudinally as the kiln expands and contracts.
Pneumatic Inlet Seal
Stationary Rotating Seal

Seal Half Half
The pneumatic cylinders, when pressurized,

will press the two seal halves tightly together.
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.
Filter, Regulator, Lubricator
Kiln Inlet Seal
Spring Loaded Graphite Plugs in

Graphite Plug Seal Plate
The seal’s sliding surfaces are graphite lubricated.

Kiln Inlet Castings
Castings on the inlet hood and kiln inlet

cone keep the castable refractory in
place. Inspect them at annual shutdown.
Spring Plate Inlet Seal
No, covering the spring plates with plastic won’t help.

Outlet Seal
Kiln Outlet Seal
The spring plate outlet seal has become the

outlet seal of choice. The seal can withstand
the harsh conditions at the kiln hood.
Kiln Outlet Seal
Spring Plate Wire

Rope
Kiln Outlet Seal
Counterweight
Spring plates are wrapped with a counterweighted wire

rope arrangement to keep them tight against the cowl.
Kiln Outlet Seal
Forced
Air
Cooling
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.
Kiln Outlet Seal
Spring plates are bolted on and are easily replaced.

Kiln Outlet Seal
The Old Way The Better Way
Dust from kiln hood puffing falls down the chutes to

the drag chain conveyor or into the clinker cooler.
Kiln Outlet Sector
The kiln nose rings sees severe service and must be

regularly inspected for refractory and casting failure.
Kiln Outlet Seal
This alternate spring plates design features

outwardly protruding spring plates.
Kiln Outlet Seal
Outwardly protruding spring plate design.

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.
Thrust Roller
Thrust Roller Assembly
Clearance
Oil
Tire
Seal
Spherical
Tie Bearings
Oil Level
Rod
Pipe
Shims
Keep the clearance to a minimum (6mm),

and adjust the shims to keep the kiln gear
in proper longitudinal alignment.
Thrust Roller Assembly
Set
Screws
The kiln position can be controlled by

adjusting set screws on this thrust roller base.
Thrust Roller 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.
Thrust Roller Misalignment
Roller Tilted to Left Roller Tilted to Right
Roller Offset to Left Roller Offset to Right
A misaligned thrust roller will result in vertical forces

on the roller as shown above.
Thrust Roller Misalignment
An improperly aligned thrust roller can ride out of

its socket, causing damage to tire stop blocks.
Thrust Roller
Thrust rollers can become overloaded if the kiln’s

supporting rollers are improperly skewed. This thrust
roller base became deformed from excessive force.
Fuller Thrust Roller
Fuller Thrust Roller
The hydraulic thrust roller maintains a constant,

controlled force on the thrust tire and keeps the
kiln in an electronically determined position.
Position
Sensor
Hydraulic Cylinder Guide Bar

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.
Thrust Roller
The roller surface is graphite lubricated.

Hydraulic Cabinet
The hydraulic power unit is normally

placed beneath the kiln’s thrust pier.
Hydraulic Cabinet
Relief
Valve
Tank
Accumulator
Directional
Valve
Pump
Hydraulic Pump
The axial piston pump has manual

adjustments for pressure and flow rate.
Directional Valve
A directional valve directs fluid to the thrust

cylinder, or allows the cylinder to bleed down.
Hydro-pneumatic Accumulator
An accumulator 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.
Gas Valve
Nitrogen Gas
Bladder
Anti-Extrusion
Valve
Shell
Port
The accumulator contains a rubber bladder

which is charged with nitrogen gas.
1000 1000 1000

500 1500 500 1500 500 1500
0 2000 0 2000 0 2000

psig psig psig
System Pressure System Pressure System Pressure

Less Than pprecharge at pmax at pmin
When hydraulic pressure increases and decreases

the gas is compressed and expanded.
Danger!
Do not charge with

air or oxygen!
The accumulator is pre-charged with nitrogen

to approximately half of the expected average
operating hydraulic pressure.
Pressure Relief Valve
A pressure relief valve limits hydraulic pressure in

the system. This prevents excessive downhill kiln
force from damaging the thrust roller.
Hydraulic Filter
An in-tank filter with a 10 micron element

keeps hydraulic fluid clean. The protruding red
button indicates the element needs changing.
Thrust Cylinder LVDT
An LVDT (linear variable differential transformer)

mounted in the hydraulic cylinder measures the
distance that the cylinder rod is extended.
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.
Fuller Hydraulic Thrust Roller
Fuller Hydraulic Thrust Roller
Preventive Maintenance Checklist
Daily
Thrust Roller
• Kilns with 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.
Daily
Seals
• Visually check feed 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
Temperatures
• Record kiln shell temperatures and

include a night visual inspection for “hot
spots”
Weekly
• Check and record 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.
Weekly
• Check general condition 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.
Annually
• Perform complete check 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.
The Good Old Days
The Good Old Days
The Good Old Days
Rivets
Don’t Be Mean to Your Kiln

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Rotary Kiln Maintenance

Kiln Inlet Seal

The pneumatic seal consists of two sliding

Graphite Seal Cord

Stationary Kiln Rotating Kiln

The seal is suspended by a carriage which allows it to

Stationary Rotating Seal

The pneumatic cylinders, when pressurized,

Cylinder force is controlled by adjusting the air pressure.

Spring Loaded Graphite Plugs in

The seal’s sliding surfaces are graphite lubricated.

Castings on the inlet hood and kiln inlet

No, covering the spring plates with plastic won’t help.

The spring plate outlet seal has become the

Spring Plate Wire

Spring plates are wrapped with a counterweighted wire

A stainless steel cowl at the kiln outlet provides an

Spring plates are bolted on and are easily replaced.

The Old Way The Better Way

Dust from kiln hood puffing falls down the chutes to

The kiln nose rings sees severe service and must be

This alternate spring plates design features

Outwardly protruding spring plate design.

Keep the clearance to a minimum (6mm),

The kiln position can be controlled by

The thrust roller is positioned to maintain proper hot

Roller Tilted to Left Roller Tilted to Right

Roller Offset to Left Roller Offset to Right

A misaligned thrust roller will result in vertical forces

An improperly aligned thrust roller can ride out of

Thrust rollers can become overloaded if the kiln’s

The hydraulic thrust roller maintains a constant,

Hydraulic Cylinder Guide Bar

The spherical bearings are lubricated with ISO VG

The roller surface is graphite lubricated.

The hydraulic power unit is normally

The axial piston pump has manual

A directional valve directs fluid to the thrust

An accumulator stores hydraulic energy. It is used to

The accumulator contains a rubber bladder

1000 1000 1000

0 2000 0 2000 0 2000

System Pressure System Pressure System Pressure

When hydraulic pressure increases and decreases

Do not charge with

The accumulator is pre-charged with nitrogen

A pressure relief valve limits hydraulic pressure in

An in-tank filter with a 10 micron element

An LVDT (linear variable differential transformer)

The LVDT signal goes to a cabinet where the kiln’s hot

• Kilns with one thrust roller (mech. or hyd.)

• Kilns with two thrust rollers

• Visually check feed and discharge seals

• Visually check the gear and pinion

Rollers and Live Rings

• Visually check all roller and tire surfaces

• Record kiln shell temperatures and

• Check and record direction of thrust on all

• Check general condition of kiln