Rotary Kiln Maintenance

Seminar

Kiln Shell

Kiln Shell

Shell Details

Kiln Crank

Measuring Kiln Crank

Heat Correction of Kiln Crank

Shell Repair

Shell Welding

Submerged Arc Welding

Shell Details

Shell Details
Inlet
Cone

30 mm

Tire
No. 3

Tire
No. 1

Tire
No. 2

40 mm
(gear)

40 mm 75 mm
(under tire)

30 mm

40 mm

30 mm
80 mm
(under tire)

40 mm

Typical shell plate thicknesses.

Outlet
Shroud

50
mm
75 mm
(under tire)

Kiln Crank

Kiln Crank

Kiln crank occurs when a kiln shell is not perfectly

straight. As the shell turns, cyclical loads and
stresses occur in the shell and the kiln supports.

Kiln Crank

Kiln crank can cause severe cyclical loads, leading to

shell cracks and fatigue cracks in the roller shafts.

Kiln Crank

Kiln crank will result in gear misalignment

which can destroy gear teeth.

Kiln Crank

Kiln crank can be temporary, as in the case of

a rain warped shell, or permanent, as in the
case of a shell damaged by heat blisters.

Kiln Crank

When a hot kiln is stopped during a heavy

rainstorm, one side of the shell cools off and
contracts, causing a concave up curvature.

Kiln Crank

When a hot kiln is stopped too long without

rotation, heat will rise and the top of the shell
will expand, causing a convex-up curvature.

Kiln Crank

Irregular coating formation or refractory wear can

cause one side of the shell to heat up more than the
other. The result is a temporary crank in the shell.

Kiln Crank

Damaged refractory will cause a hot spot in

the shell.

Kiln Crank

A hot spot left unattended will wrinkle the shell and create
a crank. Refractory bricks will no longer stay in place and
the shell section will have to be replaced at great expense.

Heat Damaged Kiln Shell

A heat-wrinkled kiln shell will also shorten

the kiln, causing tires to run off-center.

Kiln Crank

Kiln crank can be caused by poor alignment

of kiln sections during assembly or repair.

Kiln Crank

Kiln crank can be caused by weld

shrinkage at a temporary shell patch.

Measuring Kiln Crank

Measuring Kiln Crank

Kiln crank can be identified by measuring roller

deflection. The load on the roller will change as the
kiln turns and this results in bending of the roller shaft.

Measuring Kiln Crank

A roller that deflects cyclically with kiln

rotation by over 0.3 mm typically indicates
a crank in the shell that should be repaired.

Measuring Kiln Crank

Kiln crank can be measured by measuring shell runout. A polar diagram is generated on which the
deviation from the true kiln center can be seen.

Measuring Kiln Crank

A series of polar diagrams gives a

picture of the shell crank.

Heat Correction of Kiln Crank

Heat Correction of Kiln Crank

A kiln shell can sometimes be straightened by heat

correction. Insulation is wrapped around the shell,
allowing the shell steel to overheat. Shell stresses then
diminish as the kiln sags into place on the rollers.

Heat Correction of Kiln Crank

Temperature sensors are installed to

carefully monitor shell temperatures beneath
the insulation during the correction process.

Heat Correction of Kiln Crank

Shell Repair

Shell Repair

Major shell defects are normally repaired by

replacing the damaged section. The bandaid approach is at best a temporary solution.

Field Joint Hardware

New shell sections are joined

with adjustable erection lugs.

Shell Alignment

By adjusting the erection lugs the

shell sections are straightened until
a perfect centerline is achieved.

Tire Handling

Shell Rigging

Shell Rigging

Shell Handling

Spider Bracing

Spider Bracing

Spider Bracing

Shell Stiffening Rings

Many older kilns had shell stiffening rings. These rings

would eventually cause shell cracks due to heat expansion.
Field-cutting expansion slots may help this problem.

Shell Welding

Joint Preparation

Prior to welding the shell plate ends are carefully prepared.

Weld Shrinkage

The 60 double V weld results in less shrinkage and

less weld metal being required. Weld distortion is
minimized, avoiding the gull-wing effect.

Weld Shrinkage

Shell Welding

Shell Welding

After completing the outside weld, the root

pass is removed using carbon arc gouging.

Shell Welding

After gouging, the joint is carefully

cleaned and inspected to ensure that
no defects from the root pass remain.

Shell Welding

When welding is finished, the joint is

inspected radiography or ultrasound.
Defects are marked and then repaired.

Submerged Arc Welding

Submerged Arc Welding

Submerged Arc Welding

Submerged Arc Welding

Submerged Arc Welding

The depth of penetration increases with increased

current.

The depth of penetration is also dependant of

the welding speed.

Submerged Arc Welding

The depth of penetration is high with the welding rod as PLUS POLE and
law with the welding rod as MINUS POLE.

Submerged Arc Welding

Submerged Arc Welding

Submerged Arc Welding

Submerged Arc Welding

Submerged Arc Welding

Submerged Arc Welding

Submerged Arc Welding

Submerged Arc Welding

Submerged Arc Welding

Submerged Arc Welding

Submerged Arc Welding