Read more about Rotary Kiln Alignment

Definition of a rotary kiln:


The rotary kiln is a pyro-processing form of equipment. It is useful in raising the temperature (calcination)---very high of materials and doing so continually. Materials used in coordination with rotary kilns include lime and cement.

Read more about rotary kiln alignment.


Aligning the tube or rotary kiln alignment is the key to operational success:


The most general problem when it comes to alignment of the cylinder is that it is misaligned. Interestingly though, this is common and easy enough to correct. Here is the thing: alignment is specific to all elements. When the kiln is not in proper alignment the parts start to wear thin. There is another issue too: increased wear places the heat--tubular construction in receiving significant damage when it fails prematurely. Prolonged life and optimum efficiency is of paramount importance. It is best to routinely inspect it. The inspection is made a part of a general maintenance program. If there are alignment problems---these critical issues are best taken care of on an immediate basis. Alignment is nothing that is new. Too: recent innovations have made aligning the tube even more effective.


Alignment methods have been greatly improved:


There are a number of alignment methods used. The methods are designed to attain the exact same objective---that is, aligning the trunnion wheels with that of the centre-line of the drum. This is done in accord with the overall slope of the drum. The preceding objective ensures that the entirety of the load is naturally distributable on an even basis---across all elements. The preceding additionally promotes an even and very efficient operation. The wear, as such, is greatly minimised.


Innovations in technology have made aligning the cylinder easier and more precise:


Reasonably, the procedure of aligning has come a long way: the provincial methods involve measuring certain points by hand and following up by using a myriad of calculations to make determination of the proper adjustment. The process is: yes--effective---however, it is also very slow. Also, the method of doing everything without supportive tools opens up everything to the possibility of error---regardless of the care taken as to calculation. The mechanical means is still used greatly nowadays; however, new laser tracking devices have made alignments a great deal easier and have brought the entire process up one level. The laser tracking devices make precise alignment a good deal quicker and more accurate. The laser tracking system makes use of laser beams in order to establish a 3 dimensional spatial map. This type of device is used in conjunction with highly innovative software programs. This method again offers precise results in a time period which is significantly less in duration.


When kiln alignment is required:


Some persons ask the clever question: When precisely is a kiln alignment necessary? The tubular construction is apt to fall out of alignment for several reasons. The misalignment can come about from structural issues. In example, the area around it may have a foundation which is sinking. The shifting of steel or the process within the surrounding environment in way of dust in the air or overall humidity can cause it to become misaligned. The reasons are many. The issue is most difficult to determine. A regular inspection is highly recommended. The inspection is best conducted by persons located at the site. The personnel can determine signs of misalignment before the misalignment becomes worse.


The necessity of an OEM inspection is a given:


Inspections are also suggested to occur by OEM manufacturers at a predetermined, regular date. The OEM inspection is most generally performed on an annualised basis. This annual inspection is necessary in order to properly predict issues that may crop up at future dates and how to treat those issues.


Alignment is necessary during installation:


Alignment is of great importance when the tubular construction is installed. Care is taken during the installation process accounting for the hot kiln load, how the hot kiln operates under the conditions of load and so on and so forth. The tubular construction behaves in a totally different way under conditions where it is hot than when it is empty and cold. Alignment of a cold kiln without accounting for thermal stress and operational load during a production process can result in improper alignment from the beginning. Kilns are realigned after any primary component, such as when trunnion wheels have undergone resurfacing or replacement. The preceding event can easily cause the heating construction to fall out of the preferred optimal alignment. Also changes in processing can greatly impact the load associative to the cylinder construction. The preceding insight is correct because the kiln was designed and aligned specific to certain operational limits; so a change in condition, more than likely requires a realignment.


Signs indicative that alignment is essential:


There are specific signs, too, that the tubular construction is not properly aligned. The signs mentioned can serve as indicators that other problems, with regard to the kiln, exist too. A trained professional, as it pertains to the preceding, is the only individual who realises the reasons the kiln is not in the proper alignment.


The signs or indications that the kiln is not properly aligned include:


- Wear after the tire or trunnion surface undergoes resurfacing or repair;

- Vibrational noise,

- A great deal of wear with regard to the tire/wheel,

- Excessive wear with regard to the thrust roller, and

- A great deal of wear or damage to the girth/pinion gear.


Conclusion:


Once it is determined that the kiln requires alignment, a trained aftermarket engineer is the best individual to rely upon with respect to the process of realignment.