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Rotax kiln_FLSmidth

3-Base Kiln

Since the 1800s, FLSmidth has been continually improving its high-quality kilns to solve complex challenges – and to deliver the market’s highest production rate

  • The basics
  • Design & Supports
  • Maintenance

Key benefits

  • Sturdy and flexible, full-welded rotary kiln
  • Long run time before maintenance is needed (low brick wear)
  • Effective inlet/outlet seals
  • Minimal kiln tyre wobbling
  • Simple, high-quality tyre support
  • Longest life span and best production rate of any 3-base kiln
  • Extra retention time achievable for materials of difficult burnability

Rotary Kilns
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How it works

The 3-base kiln is a high-quality, traditional three-support rotary kiln system ranging from 3.6–6.6m in diameter and 55–95m in length. Its balanced design ensures optimal stiffness and flexibility and minimises wobbling and misalignment.

Loose-fitting blocks are held in place by bushings bolted to the kiln shell. This allows restorative shimming to take place without dismantling bolts – lessening both maintenance costs and the chance of possible crack formations.

Optional extended design

If desired, the 3-base kiln can also include an optional extended design with a longer retention time that is ideal for processing kiln feed with a high Burnability Index (BI). This extended design is also beneficial when using certain types of alternative fuels.

Design

Drive station
The durable design of the kiln’s drive station tolerates high levels of shell expansion and contraction.

The girth gear and pinion are cast and machined from high-grade steel. The girth gear is attached by bolted-on spring plates that are welded to the kiln shell, allowing full expansion of the shell.

The pinion and the gear rim are enclosed in a gear guard, protecting the gearing from invasive dust and preventing lubrication spillage.

Supports

Each live-ring is supported by cast-steel rollers shrunk onto the enlarged diameter of the forged steel shafts. The rollers themselves are bolstered by robust bearings that can accommodate operational irregularities.

Double-lamella seals
The double-lamella seals at the inlet and outlet of the kiln reduce false air intake yet allow enough flexibility to follow the kiln’s movements.

The seals require no greasing and are practically maintenance-free.

Tips

Most mechanical problems with rotary kilns are caused by just four conditions. Regular inspections of the following can help you avoid them:

 

1. Kiln axis geometry – kiln axis geometry must be aligned, as it determines the distribution of the weight load among the kiln supports and the longitudinal distribution of bending stresses in the kiln shell.

2. Kiln ovality – make sure that the kiln shell’s radius of curvature does not change unacceptably during the kiln’s rotation.

3. Kiln crank – monitor kiln shell temperature. Check for red spots on the kiln shell and misaligned kiln shell sections.

4. Axial kiln balance – measure trust face temperatures to make sure the axial forces are not too large.


Watch the Kiln Maintenance animation:


  • Main Office

    FLSmidth A/S
    Cement Technologies & Corporate Matters
    Vigerslev Allé 77
    2500 Valby
    DENMARK
    Tel: +45 36 18 10 00
    Fax: +45 36 44 11 46
    info@flsmidth.com

  • Main Office

    FLSmidth Inc.
    Cement Projects Americas
    2040 Avenue C
    Bethlehem, PA 18017
    USA
    Tel: +1 610 264 6011
    Fax: +1 610 264 6170
    info-us@flsmidth.com

  • Main Office

    FLSmidth Pvt. Ltd
    Cement and Minerals Projects India
    FLSmidth House, 34, Egatoor, Kelambakkam
    (Rajiv Gandhi Salai – Chennai)
    Tamil Nadu – 603 103
    INDIA
    Tel: +91 44 4748 1000 / 2741 1000
    Fax: + 91-44-2747 0301/0302
    indiainfo@flsmidth.com

  • Main Office

    FLSmidth Salt Lake City, Inc.
    Minerals Processing
    7158 S. FLSmidth Drive
    Midvale, UT 84047-5559
    USA
    Tel: +1 801 871 7000
    Fax: +1 801 871 7001
    info.slc@flsmidth.com

  • Main Office

    FLSmidth Wadgassen
    Material Handling Technologies
    Karl Koch Str. 1
    D-66787 Wadgassen
    GERMANY
    Tel: +49 6834 4700
    Fax: +49 6834 470-339
    wadgassen@flsmidth.com

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Last updated 12.03.2012