en-KN CPT 003 G-Word

Operating manual
en-KN.CPT.003.G
Rotary kiln
Code word
Order number
Plant Order Code (POC)

en-KN.CPT.003.G Contents
Rotary kiln
Contents
1 General information ............................................................................. 1-1

1.1 Information regarding this operating manual .......................................... 1-1
1.2 Additionally applicable documents ......................................................... 1-1
1.3 Limitation on liability ............................................................................... 1-1
1.4 Copyright ................................................................................................ 1-1
1.5 Warranty provisions ................................................................................ 1-1
1.6 Symbol explanation ................................................................................ 1-2
2 Safety ..................................................................................................... 2-1
2.1 Intended use ........................................................................................... 2-1
2.2 Reasonably foreseeable misuse ............................................................ 2-1
2.3 Limits of the machine ............................................................................. 2-1
2.4 Obligation of the owner .......................................................................... 2-2
2.5 Obligation of the personnel .................................................................... 2-3
2.6 Qualifications of the personnel ............................................................... 2-4
2.7 Safety and monitoring equipment........................................................... 2-7
2.7.1 Safety devices to be retrofitted ............................................................... 2-7
2.8 Personal protective equipment ............................................................... 2-8
2.8.1 Personal protective equipment for all work ............................................ 2-9
2.8.2 Personal protective equipment for special work ................................... 2-10
2.9 Fundamental hazards ........................................................................... 2-11
2.9.1 Overview of residual risks .................................................................... 2-11
2.9.2 Mechanical hazards.............................................................................. 2-15
2.9.3 Electrical hazards ................................................................................. 2-18
2.9.4 Thermal hazards................................................................................... 2-19
2.9.5 Hazards generated by materials and substances ................................ 2-20
2.9.6 Hazards in connection with the environment in which the machine is used
.............................................................................................................. 2-21
2.9.7 Other hazards ....................................................................................... 2-22
2.10 Safety signs at the machine ................................................................. 2-24
2.10.1 Mandatory signs at the machine .......................................................... 2-24
2.10.2 Warning signs at the machine .............................................................. 2-25
3 Technical data....................................................................................... 3-1
4 Components and description of functioning .................................... 4-1
4.1 Components ........................................................................................... 4-1
4.1.1 2-support rotary kiln with friction roller drive ........................................... 4-4
4.1.2 3-support rotary kiln with girth gear and pinion drive ............................. 4-6
4.2 Description of functioning ....................................................................... 4-8
5 Transportation, storage and assembly .............................................. 5-1
5.1 Transportation ........................................................................................ 5-1
5.1.1 Safety instructions .................................................................................. 5-1
5.1.2 Identifying the transport units ................................................................. 5-2
5.1.3 Checking the transport units ................................................................... 5-3
5.1.4 Packaging ............................................................................................... 5-3
5.1.5 Transporting the transport units ............................................................. 5-3
5.2 Storage ................................................................................................... 5-4
5.2.2 Storage of transport units ....................................................................... 5-4
5.2.3 Storage conditions and long-term storage ............................................. 5-5
5.3 Assembly ................................................................................................ 5-6
Contents en-KN.CPT.003.G
Rotary kiln

5.3.2 Tightening torques for bolts with standard thread ................................ 5-10
5.3.3 Preparing for assembly ........................................................................ 5-11
5.4 Mounting the rotary kiln with girth gear and pinion drive ...................... 5-13
5.5 Mounting the rotary kiln with friction roller drive ................................... 5-16
5.6 Checks before installing the refractory lining ....................................... 5-18
6 Lubrication ............................................................................................ 6-1
6.1 Safety instructions .................................................................................. 6-1
6.2 Lubrication chart ..................................................................................... 6-2
7 Commissioning..................................................................................... 7-1
7.2 Checking the safety and monitoring equipment ..................................... 7-4
7.3 Basic settings ......................................................................................... 7-4
7.4 Checks prior to commissioning .............................................................. 7-5
7.5 Commissioning ....................................................................................... 7-6
8 Operation............................................................................................... 8-1
8.2 Operation with main drive ....................................................................... 8-1
8.3 Operation with the auxiliary drive ........................................................... 8-1
8.4 Maintenance operation ........................................................................... 8-2
9 Maintenance .......................................................................................... 9-1
9.1 Maintenance work during operation ....................................................... 9-1
9.1.2 Prior to any maintenance work ............................................................... 9-4
9.1.3 Table of maintenance work (Operation) ................................................. 9-5
9.1.4 After any maintenance work ................................................................... 9-5
9.2 Maintenance work during a stoppage .................................................... 9-6
9.2.2 Prior to any maintenance work ............................................................. 9-14
9.2.3 Table of maintenance work (Stoppage) ............................................... 9-15
9.2.4 After any maintenance work ................................................................. 9-15
10 Troubleshooting ................................................................................. 10-1
10.1 Safety instructions ................................................................................ 10-1
10.2 List of possible faults ............................................................................ 10-1
10.3 Recommissioning after fault elimination ............................................... 10-2
11 Spare parts .......................................................................................... 11-1
11.1 Suggestions for enquiries and orders of spare parts ........................... 11-1
12 Disassembly and disposal ................................................................ 12-1
12.1 Safety instructions ................................................................................ 12-1
12.2 Before disassembly .............................................................................. 12-1
12.3 Disposal ................................................................................................ 12-2
12.3.1 Safety instructions ................................................................................ 12-2
13 Appendix ............................................................................................. 13-1
13.1 Technical drawings ............................................................................... 13-1
13.2 Measurement records .......................................................................... 13-1
13.3 Subsuppliers' documentation ............................................................... 13-1
en-KN.CPT.003.G General information
Rotary kiln 1-1
1 General information
1.1 Information regarding this operating manual
This operating manual enables the user to operate the machine safely and
efficiently. The operating manual is an integral part of the machine and has to be
kept in the direct vicinity of the machine so that it is accessible for the personnel
at any time.
Before commencing any work, the personnel must have read and understood this
operating manual. Compliance with all safety instructions and other instructions
given in this operating manual on actions to be taken is the fundamental
prerequisite for safe working.
The figures contained in this operating manual serve for general illustration and
may deviate from the actual design.
1.2 Additionally applicable documents

In addition to this operating manual, the documents in the overall documentation
also apply. Be absolutely sure to comply with the instructions contained therein –
especially the safety instructions. The additionally applicable documents can be
found in the sections Appendix and Technical data.
1.3 Limitation on liability

thyssenkrupp Industrial Solutions explicitly excludes all liability and warranty
claims, particularly if damage or operational malfunctions originate from the
following:
● Disregarding of the information and/or instructions in the documentation
● Any use other than the intended use
● Maloperation
● Insufficient maintenance or non-observance of maintenance intervals
● Use of consumables (in particular lubricants) not expressly approved by the
manufacturer for the machine in question
● Use of spare parts not expressly approved by the manufacturer for the
machine in question
● Conversions and modifications not approved by thyssenkrupp Industrial
Solutions.
The conditions for liability and warranty stipulated in the contract between the
customer and thyssenkrupp Industrial Solutions shall apply.
1.4 Copyright
thyssenkrupp Industrial Solutions reserves all utilization rights in connection with
this operating manual. Without the written consent of thyssenkrupp Industrial
Solutions, this operating manual may neither be reproduced, nor be made
available to third parties, nor be used in any unauthorised manner.
1.5 Warranty provisions

The warranty provisions are contained in the contract.
General information en-KN.CPT.003.G
1-2 Rotary kiln
1.6 Symbol explanation
Safety instructions
DANGER
This combination of symbol and signal word indicates an immediately

dangerous situation which leads to death or severe injuries if it is not
avoided.
WARNING
This combination of symbol and signal word indicates a possibly

dangerous situation which may lead to death or severe injuries if it is not
avoided.
CAUTION

dangerous situation which may lead to slight or minor injuries if it is not
avoided.
NOTICE

dangerous situation which may lead to damage to property and
environmental damage if it is not avoided.
en-KN.CPT.003.G General information
Rotary kiln 1-3
Safety signs
A safety sign is a sign making a general safety statement through a combination
of a specific colour and a geometric form, and making a special safety statement
when a graphical symbol is added to the above combination.
Mandatory sign
A safety sign that stipulates a certain behaviour.
Prohibition sign
A safety sign that prohibits a certain behaviour.
Warning sign
A safety sign that warns of a specific danger.
Note
This symbol highlights useful tips and recommendations, as well as information

for efficient and trouble-free operation.
This symbol may also include a reference to additionally applicable documents.
General information en-KN.CPT.003.G
1-4 Rotary kiln
Distinctions used
In these instructions, the following symbols and means of emphasis are used for
indicating instructions on actions to be taken, lists, references and other elements:
Distinction Explanation
Italics Indicates references to other sections,

additionally applicable documents, foreign-
language terms and button texts
Step 1, 2, 3...: Indicates instructions on actions to be taken
● Indicates lists and list entries or instructions on

actions to be taken, without a specified
sequence
en-KN.CPT.003.G Safety
Rotary kiln 2-1
2 Safety
2.1 Intended use
The intended use comprises:
● Formation of the combustion space rotating in the longitudinal axis. The said
combustion space is for the burning of powdery, small-sized or sludgy feed
material
The rotary kiln is not a machine that is ready for use.
The rotary kiln is intended for use in conjunction with other components to form a
rotary kiln plant.
The rotary kiln may only be used if the requirements specified in the section
Technical data are complied with.
The intended use also includes compliance with all instructions in this operating
manual. Any use other than for the specified intended use shall be deemed
misuse.
2.2 Reasonably foreseeable misuse

The reasonably foreseeable misuse of this machine includes:
● Operation of the rotary kiln with unsuitable parameters
● Use of the rotary kiln by unauthorised personnel who have not received
special instruction
● Missing protection devices
● Use of unsuitable means of access to the machine
● Neglecting to wear the personal protective equipment
Any use other than the intended use is forbidden. thyssenkrupp Industrial
Solutions is not responsible for damage resulting from any use other than the
intended use. This risk shall be borne exclusively by the plant owner.
2.3 Limits of the machine
Time limits
The rotary kiln is designed for a five-year service life, provided that maintenance
work is carried out as stipulated. However, based on product-monitoring results, a
longer service life has been observed with proper performance of maintenance
and a general overhaul on expiry of the specified period of use, including
replacement of all safety components.
Spatial boundaries
The rotary kiln begins at the rotary kiln inlet (2.9) and ends after the kiln hood
(11.0).
Safety en-KN.CPT.003.G
2-2 Rotary kiln
2.4 Obligation of the owner
Owner
The owner is any individual or corporate body who operates the machine for
trade or commercial purposes or makes it available to a third party for
utilisation/application and who, during operation of the plant, bears the legal
product responsibility for the protection of the user, the personnel or third parties.
Fundamental principles
The machine is used for commercial purposes. The owner of the machine is
therefore subject to statutory regulations on occupational safety. Any safety
checks before or during operation depend on the relevant national regulations.
The owner is responsible for the performance and recording of such safety
checks.
In addition to the safety instructions contained in this operating manual, the
regulations on safety, accident prevention and environmental protection
applicable to the range of application of the machine must be complied with. The
following applies:
● The machine is part of an overall plant. The owner has to ensure that the
structural and organisational protective measures applicable to the plant at its
place of installation are implemented and adhered to.
● The owner must incorporate the machine into the safety concept of the overall
plant.
● The owner must seek to obtain all relevant information on the applicable
occupational safety regulations and perform a risk assessment to identify
additional hazards resulting from the special working conditions at the place of
installation of the machine or from installation in the overall plant. The owner
must implement the results of the risk assessment in operating instructions for
the machine.
● The owner is obliged to regularly instruct the personnel. A written record of
this instruction must be kept.
● During the entire operating time of the machine, the owner is responsible for
ensuring that the operating instructions that he/she prepares conform to the
current status of the rules and standards, and for adapting them if necessary.
● The owner is responsible for clearly defining and determining responsibilities
related to assembly, first commissioning, supervision, maintenance, cleaning
and fault elimination.
● The owner shall ensure that all employees who work with the machine have
read and understood this operating manual.
● The owner is responsible for regularly instructing the personnel and informing
on potential hazards arising from the machine and from the overall plant.
● The owner shall provide personnel with the required protective clothing and
equipment in complete and perfectly intact condition.
● The owner may not carry out any technical modifications to the machine.
Rotary kiln 2-3
Overall plant
● The machine is part of an overall plant. The owner has to ensure that the
structural and organisational protective measures applicable to the overall
plant at its place of installation are implemented and adhered to.
● The owner is responsible for informing the personnel working at the machine
on potential hazards arising from the overall plant, and for regularly instructing
the said personnel.
Condition of perfect technical serviceability

The owner is responsible for keeping the machine in a condition of perfect
technical serviceability at all times. The following applies:
● The owner has to ensure that the maintenance intervals specified in this
operating manual are adhered to.
● The owner has to check regularly whether all safety devices are complete and
in proper working order.
2.5 Obligation of the personnel

The personnel must always wear the necessary protective clothing such as safety
shoes, tough top clothes, protective gloves and a safety helmet.
2-4 Rotary kiln
2.6 Qualifications of the personnel
WARNING
Insufficient qualification of personnel

If unqualified personnel perform work on the machine or are within the
danger area of the machine, this gives rise to hazards that may result in
severe injuries and significant damage to property.
I. Keep unqualified personnel away from the danger area.
II. Only permit qualified personnel to perform work.
WARNING
Unauthorised persons in the danger and working areas

All persons who do not possess the qualifications described in the
operating manual are not familiar with the hazards in the working area.
There is a danger of severe injuries or death for these persons.
I. Keep unauthorised persons away from the danger and working
areas.
II. Interrupt work as long as unauthorised persons are present in the
danger and working areas.
III. If in doubt, speak to the persons concerned and instruct them to
leave the danger and working areas.
Assembly personnel
The assembly personnel are the persons charged with the task of assembling the
delivered machine. The assigned personnel must be qualified to carry out the
assembly work.
The assembly personnel must be able to perform the assigned work and to
recognise and prevent possible hazards independently due to their professional
training, knowledge and experience as well as their knowledge of the relevant
standards and regulations.
Commissioning personnel
The commissioning personnel are the persons charged with the task of
commissioning the delivered machine. The assigned commissioning personnel
must be qualified to carry out the commissioning work.
The commissioning personnel must be able to perform the assigned work and to
Rotary kiln 2-5
Operating personnel
The operating personnel are the persons charged by the owner of the plant with
the task of operating the delivered machine. The owner of the plant has to ensure
that the assigned operating personnel are qualified to carry out the operating
work.
The operating personnel must be able to perform the assigned work and to
Maintenance personnel
The maintenance personnel are the persons charged by the owner of the plant
with the task of maintaining the delivered machine. The owner of the plant has to
ensure that the assigned maintenance personnel are qualified to carry out the
maintenance work.
The maintenance personnel must be able to perform the assigned work and to
Qualified electrician
The qualified electrician is the person charged by the owner of the plant with the
task of performing work on the electrical equipment. The qualified electrician has
received professional training in his/her special field of activity and is familiar with
the relevant standards and regulations. The qualified electrician must fulfil the
applicable statutory provisions governing the prevention of accidents.
The qualified electrician must be able to perform the assigned work on electrical
equipment and to recognise and prevent possible hazards independently due to
his/her professional training, knowledge and experience as well as his/her
knowledge of the relevant standards and regulations.
Qualified hydraulics specialist

The hydraulics specialist is the person charged by the owner of the plant with the
task of performing work on the hydraulic equipment. The hydraulics specialist has
received professional training in his/her area of responsibilities and is familiar with
the relevant standards and regulations.
The hydraulics specialist must fulfil the applicable statutory provisions governing
the prevention of accidents. The hydraulics specialist must be able to perform the
assigned work on hydraulic equipment and to recognise and prevent possible
hazards independently due to his/her professional training, knowledge and
experience as well as his/her knowledge of the relevant standards and
regulations.
2-6 Rotary kiln
Qualified pneumatics specialist

The qualified pneumatics specialist is the person charged by the owner of the
plant with the task of performing work on pneumatic equipment. The qualified
pneumatics specialist has received professional training in his/her area of
responsibilities and is familiar with the relevant standards and regulations.
The qualified pneumatics specialist must fulfil the applicable statutory provisions
governing the prevention of accidents. The qualified pneumatics specialist must
be able to perform the assigned work on pneumatic equipment and to recognise
and prevent possible hazards independently due to his/her professional training,
knowledge and experience as well as his/her knowledge of the relevant
Rotary kiln 2-7
2.7 Safety and monitoring equipment
WARNING
Defective safety and monitoring equipment

Defective or deactivated safety and monitoring equipment may result in
bodily injuries and machine damage. This could lead to severe or even
fatal injuries.
I. At regular intervals and whenever work has been performed on the
machine, check whether all safety and monitoring devices are
installed properly and are functioning correctly.
II. Never deactivate or bypass any safety and monitoring devices.
III. Make sure that the safety and monitoring equipment is always easily
accessible.
Be sure to comply with the instructions concerning the extent and the location of
the safety and monitoring devices, in the contractually agreed documents
relating to the electrical equipment, for example:
● Location of electrical devices
● List of measuring points
● List of digital sensors
2.7.1 Safety devices to be retrofitted
WARNING
Unsecured or unmarked hazardous points

Dangerous situations and injuries may arise due to unsecured or
unmarked hazardous points in the working area.
I. Mark hazardous points with appropriate safety signs.
II. Shut off access to hazardous points during operation.
The rotary kiln is intended for use within an overall plant. Before the plant is
commissioned, the owner has to ensure the following:
Securing against restarting

The owner must implement measures to enable the machine to be secured
against restarting during maintenance work.
2-8 Rotary kiln
Guards
The rotary kiln is intended for use within a plant. Before the rotary kiln is put into
operation, install the following guards and integrate them into the safety chain of
the plant control system:
● Protective grating in the operating range of the individual subassemblies of
the rotary kiln, or locked or monitored access points and marking of danger
areas by means of suitable safety signs. Access to entrapment points,
trapping points and pinch points must only be possible when the rotary kiln is
stopped.
Integration into an EMERGENCY STOP concept

Before the machine is put into operation, install the EMERGENCY STOP devices
and integrate them into the safety chain of the plant control system.
Connect the EMERGENCY STOP devices such that dangerous situations for
persons and property are excluded in the case of a failure of the power supply or
activation of the power supply following a failure.
The EMERGENCY STOP devices always have to be freely accessible.
2.8 Personal protective equipment

Personal protective equipment serves to protect the personnel against hazards
that can impair their safety and health at work.
The personnel must wear the required personal protective equipment during
different kinds of work at and on the machine. Make absolutely sure that you put
on personal protective equipment before commencing the respective work.
Always be sure to comply with the notices regarding personal protective
equipment that are posted in the working area.
The personal protective equipment that has to be worn during special work is
described separately in the respective sections of this operating manual.
Rotary kiln 2-9
2.8.1 Personal protective equipment for all work
Safety helmet
A safety helmet protects against falling objects, swinging loads and impact with
static objects.
Safety shoes
Safety shoes protect against slipping and against injuries due to falling objects.
The use of safety shoes that are not in proper condition is forbidden. Safety
shoes are not in proper condition if, for instance, they have worn-out treads,
uncovered toe caps or seams that have come apart.
Safety goggles
Tightly-fitting safety goggles protect the eyes from airborne particles and liquid
splashes, dust, chemical splashes, dazzling light, sparks, metal splinters and
dangerous vapours. Dispose of and replace safety goggles that have scratched
or unclear lenses.
Protective clothing
Protective clothing means tight-fitting work clothes with low tear strength, tight
sleeves and without any protruding parts. Protective clothing mainly protects
against being entangled by moving machine parts and against skin contact with
materials and substances.
Protective gloves
Protective gloves protect against abrasions, cuts, skin cracks, punctures,
chemical burns or heat burns, infections and crushing.
2-10 Rotary kiln
2.8.2 Personal protective equipment for special work
Fall protection system

Fall protection systems protect the user against falls, by either preventing or
arresting a free fall. A fall protection system consists of at least one body-holding
device and an attachment system that can be connected to a reliable anchorage.
Heat-resistant protective clothing

Heat-resistant protective clothing protects against thermal radiation. Heat-
resistant protective clothing comprises a safety helmet with visor, a heat-resistant
jacket, heat-resistant trousers, protective gloves and safety boots.
Welding mask
Welding masks protect the face against radiation, heat and sparks during welding
work.
Dust mask
Depending on their design, dust masks protect against the inhalation of watery or
oily aerosols and particles
Safety goggles with UV-protection filter

Safety goggles with UV-protection filter protect the eyes against dazzling light.
Dispose of and replace safety goggles that have scratched or unclear lenses.
Rotary kiln 2-11
2.9 Fundamental hazards
2.9.1 Overview of residual risks

The following tables list the residual risks, together with the hazard sources:
Mechanical hazards
Hazard Source of hazard
Crushing Entire rotary kiln
Moving and rotating components of the rotary

kiln shell (1.0)
Inlet seal of the rotary kiln inlet (2.0)
Tyres (3.0) and supporting roller stations (4.0)
Axial positioning system of the rotary kiln (5.1)

or rotary kiln axial thrust system (5.2)
Girth gear and pinion drive (6.0)
Rotary kiln drive (9.0)
Outlet seal of the rotary kiln outlet (10.0)
Pulling-in, trapping or entanglement Entire rotary kiln
Moving and rotating components of the rotary

kiln shell (1.0)
Inlet seal of the rotary kiln inlet (2.0)
Tyres (3.0) and supporting roller stations (4.0)

Outlet seal of the rotary kiln outlet (10.0)
Slipping, tripping or falling Working area of the rotary kiln
Uncovered wires and cables
Uneven floor in the interior of the rotary kiln
Working at great heights
Escaping lubricants
2-12 Rotary kiln
Falling or ejected objects Suspended loads and moving components

during transportation, assembly, maintenance
and disassembly
Transportation of all components of the rotary

kiln
Loss of stability Rotary kiln inlet (2.0)
Supporting roller station (4.0)

Rotary kiln outlet (10.0)
Components of the rotary kiln
Breakage during operation Components of the rotary kiln
Missing, damaged or loose fastening devices
Corrosion
Uncontrolled movement Pneumatic equipment
Hydraulic equipment
Shifting of moving parts Pneumatic equipment
Hydraulic equipment
Ingress of pressurised media Hydraulic oil escaping from the hydraulic

equipment
Compressed air escaping from the pneumatic

equipment
Electrical hazards
Electric shock Live components
Electrical equipment
Damaged cables
Components that have become live due to

faults
Rotary kiln 2-13
Thermal hazards
Burns Hot surfaces anywhere on the rotary kiln
Hot gases escaping from the rotary kiln, and

hot gases in the interior of the rotary kiln
Hot material escaping from the rotary kiln, and

hot material in the interior of the rotary kiln
Frostbite Cold surfaces
Dehydration Hot work environment
Discomfort Hot work environment
Injuries as a result of radiation from sources of Hot work environment

heat
Heat stroke Hot work environment
Scalding Hot hydraulic oil during a lubricant change
Hazards generated by noise
Hearing loss High noise level during work on the pneumatic

equipment
2-14 Rotary kiln
Hazards generated by materials and substances
Explosion Wrong filling of hydraulic accumulators
Breathing difficulties, suffocation Escaping dusts and gases in the working area
of the rotary kiln
Gases and dusts in the interior of the rotary

kiln
Low oxygen concentration in the interior
Carbon monoxide in the interior of the rotary

kiln
Other hazards generated by materials and Escaping gases, dusts and escaping material
substances
Continuing flow of material and a high level of

dust generation when working in the interior
Consumables: fuel, greases, oils, cleaning

agents, nut-locking agents and sealing
compound
Escaping lubricants
Poisoning Gases in the interior of the rotary kiln
Fire Introduction of easily flammable materials
Hazards in connection with the environment in which the machine is used
Slipping, falling Usage of the machine outdoors

Rotary kiln 2-15
Other hazards
Problems as a result of human error Improper handling of the machine
Modifications to the machine
Illegible lettering and safety signs
Inadequate lighting
Wrong spare parts
Non-observance of the documentation
Accidental shutting-in of persons
Improper assembly
Radiation from sources of heat Hot environment of the rotary kiln
Loss of direct visibility of the working area Kiln inlet housing and rotary kiln inlet (2.0) with
inlet seal
Kiln hood (11.0) and rotary kiln outlet (10.0)

with outlet seal
Rotary kiln axial thrust system (5.0)
Supporting roller stations (4.0)
Other hazardous events Improper disposal
2.9.2 Mechanical hazards
WARNING
Moving components
If you reach past moving components, parts of your body may be pulled in
and crushed or severed.
I. Operate the machine only with properly mounted protection devices.
II. Only open protection devices, inspection covers, service covers or
inspection doors when the machine is switched off.
2-16 Rotary kiln
WARNING

There is a risk of falling when working at great heights. This could lead to
life-threatening injuries.
I. Wear personal protective equipment.
II. Use a fall protection system if necessary.
III. Before performing any work, make absolutely sure that the rotary
kiln has swung to a complete stop in its centre of gravity position
and then secure it by means of the holding brake.
IV. Use working platforms when working on high-level components.
V. If ladders or working platforms are used, make absolutely sure that
they have a secure footing.
WARNING
Lack of stability
Lack of stability of the foundations, the rotary kiln inlet and the supporting
roller stations may result in displacement of the components. This could
cause severe injuries.
I. Regularly inspect the foundations and supporting roller stations for
damage and changes in position.
II. Use suitable fastening devices. Replace any missing fastening
devices and firmly attach any loose fastening devices.
III. Regularly inspect the rotary kiln inlet and the rotary kiln outlet for
damage and corrosion.
IV. Repair any damaged areas in the anti-corrosion coating.
V. Only use the rotary kiln inlet and the rotary kiln outlet if the
mountings are undamaged.
WARNING
Falling components
In the outside area of the machine, components could fall down and cause
severe injuries.
II. Before entering the working area, inspect the machine for loose
components.
Rotary kiln 2-17
WARNING
Component breakage
Damaged, corroded or loose components may break and cause severe
injuries.
II. Before each use, inspect the machine for damage and corrosion.
III. Use suitable fastening devices. Replace any missing fastening
IV. Repair any damaged areas of the anti-corrosion coating.
WARNING
Pneumatic energy
Pneumatically operated components may move unexpectedly due to
stored residual energy. This could lead to severe injuries.
I. Only permit qualified pneumatics specialists to perform work on
pneumatic systems.
II. Never alter pressure settings to exceed the maximum values.
WARNING
Escaping compressed air

If malfunctions or leaks occur, or after the pneumatic system is switched
off, compressed air may escape. This could lead to severe injuries.
pneumatic systems.
WARNING
Protruding components
There is an impact and trip hazard at protruding components.
II. Mark protruding edges with warning tape.
2-18 Rotary kiln
CAUTION
Uncovered wires or cables

If wires or cables are not covered, they represent a trip and fall hazard.
II. Fasten or cover any uncovered wires and cables.
III. Mark trip hazards with warning tape.
2.9.3 Electrical hazards
DANGER
Electric current
There are live components in and at the machine. In the following cases,
there is danger of death due to electric shock:
● Contact with live parts of the electrical equipment (such as sensor
system, switch boxes and control cabinets)
● Contact with arcs
● Short circuit
I. Only permit qualified electricians to perform work on the electrical
equipment.
II. Before beginning any work, disconnect all poles of the machine
from the electricity supply network and secure the machine against
restarting.
III. Wear personal protective equipment for work on energised electrical
systems when performing work on electrical equipment or devices.
IV. Use suitable tools when performing work on electrical equipment or
devices.
V. Only in exceptional cases should fault localisation be carried out on
the energised machine.
VI. Observe the safety rules.
VII. Never bypass fuses or put them out of operation. When replacing
fuses, observe the correct rated current.
VIII. Keep all live parts dry.
IX. Repair or replace damaged insulation immediately.
X. Operate the machine only if all the protection devices have been
properly mounted.
Rotary kiln 2-19
DANGER
Electric current
The machine contains live parts. During thunderstorms, contact with
electrically conductive components means danger of death due to electric
shock.
I. Make sure that a lightning protection system has been installed.
II. Do not stay at the machine during a thunderstorm.
2.9.4 Thermal hazards
WARNING
Hot surfaces
Components in contact with the material may heat up during operation, as
may bearings and motors. Skin contact with hot surfaces may cause
severe burns.
Always wear personal protective equipment and heat-resistant protective
clothing when working in the vicinity of hot surfaces.
WARNING
Hot work environment

Staying in an area with a high ambient temperature presents the following
risks:
● Burns
● Heat stroke
● Dehydration
● Nausea
I. Wear personal protective equipment and heat-resistant protective
clothing.
II. Take regular breaks outside the area of high ambient temperature.
III. Drink enough fluids.
IV. If possible, provide additional cooling by fans.
WARNING
Cold surfaces
Touching cold surfaces may cause sensation of pain, numbness or local
skin frostbites.
Wear cold-resistant protective clothing and safety gloves if the ambient
temperature is below 0 °C.
2-20 Rotary kiln
2.9.5 Hazards generated by materials and substances
WARNING
Easily flammable substances

Easily flammable substances, liquids or gases may catch fire and lead to
severe injuries or death.
I. In case of fire, stop all work immediately. Leave the danger area until
the all-clear is given and alert the fire brigade.
II. Never smoke within the danger area or in the immediate vicinity. The
use of open flame, fire and ignition sources of any kind is
prohibited.
III. Keep suitable extinguishing agents (fire blanket, fire extinguisher) at
hand.
IV. Immediately report any suspect substances, liquids or gases to the
person in charge.
WARNING
Contact with pyroprocessed material

Contact with pyroprocessed material or residues thereof may cause skin
irritation and allergic reactions.
I. Clean the contaminated parts of the body.
II. Change out of dirty clothing.
WARNING
Escaping lubricants
Lubricant may escape at the machine. Contact with lubricants may cause
health damage or lead to injuries due to slipping.
II. Operate the machine only if all the protection devices have been
properly mounted.
III. Avoid any skin contact. If skin contact has occurred, wash the skin
thoroughly.
IV. Avoid any contact with eyes. If eye contact has occurred, thoroughly
rinse the eyes with large amounts of water and, if necessary, consult
a doctor.
V. Immediately remove any lubricants that have escaped.
VI. If necessary, mark the danger areas and cordon them off.
Rotary kiln 2-21
WARNING
Lubricants spurting out

Lubricants may spurt out under high pressure. Contact with lubricants
may cause injuries.
I. Make sure that lubrication piping is laid properly.
II. Regularly inspect the lubricators for damage, and regularly service
them.
CAUTION
Escaping dusts and gases

Dusts and gases may escape through leaky points of the machine. The
inhalation of dusts and gases may cause breathing difficulties and
suffocation. Contact with eyes may cause irritation or injury.
Wear personal protective equipment and a dust mask.
CAUTION
Improper handling of consumables

Consumables such as greases, oils and cleaning agents may contain toxic
substances. If such consumables are released into the natural
environment, they may harm humans, animals and plants.
I. Ensure that the environment is not polluted when consumables are
stored, used or disposed of.
II. When handling consumables, be sure to comply with the applicable
national regulations for the protection of the environment.
2.9.6 Hazards in connection with the environment in which the machine is used
CAUTION
Weather/Slippery ground
If the machine is used outdoors, there is a slip or fall hazard due to rain,
ice or snow. This could lead to minor injuries.
II. Always keep the working area around the machine clean.
III. Remove snow and ice.
2-22 Rotary kiln
2.9.7 Other hazards
WARNING
Improper handling of the machine

Mistakes in handling the machine may result in personal injury.
I. Keep safety signs at the machine legible.
II. Only operate the machine in full compliance with regulations.
III. Operate the machine only if all the protection devices have been
properly mounted.
IV. If safety-relevant changes occur at the machine or in its operating
behaviour, shut it down immediately.
WARNING
Modifications to the machine

Modifications to the machine may result in severe injuries.
I. Never carry out any conversions or make any modifications to the
machine without having first obtained the written consent of the
manufacturer.
II. Carry out separate hazard assessments for conversions or
components subsequently incorporated.
WARNING
Illegible lettering and safety signs

Illegible safety signs, or illegible or erroneous lettering on displays and
control elements, may cause errors and incorrect operation. This could
lead to severe injuries.
I. Mount the displays and control elements such that they can be
easily reached.
II. Keep all displays, control elements and safety signs clean and
legible.
III. Immediately replace faulty marking and lettering.
IV. Immediately replace damaged or defective displays, control
elements or safety signs.
Rotary kiln 2-23
WARNING
Inadequate lighting
Faulty, dirty or missing lighting may give rise to dangerous situations.
This could lead to severe injuries.
I. At the place of installation, illuminate the machine so as to provide
the required lighting conditions.
II. Only operate the machine if the lighting is in proper working order
and is adequate.
WARNING
Loss of direct visibility of the working area

Loss of direct visibility of the working area, and unsecured or unmarked
danger areas in the working area, may lead to dangerous situations and
injuries.
I. Secure the access to the danger area by installing protective grating
and locked or monitored access points.
II. Mark the danger areas with appropriate safety signs.
III. Shut off access to danger areas during operation.
IV. Make absolutely sure that safe access is ensured for the specialist
personnel for the entire duration of the maintenance work.
CAUTION
Wrong spare parts

Wrong or defective spare parts may have a negative effect on safety, and
may lead to damage, malfunctions or complete failure of the machine. This
could lead to severe injuries.
Only use the manufacturer's original spare parts or spare parts that have
been approved by the manufacturer.
2-24 Rotary kiln
2.10 Safety signs at the machine
WARNING
Illegible safety signs

Illegible safety signs may cause errors and incorrect operation, and may
result in severe injuries.
I. Keep all safety signs clean and legible.
II. Immediately replace damaged safety signs.
All safety signs at the machine must always be complete and easily legible.
The following safety signs are located in the operating range of the machine.
They refer to the direct vicinity of the sign's location.
Be sure to comply with the instructions in the drawing (see page 13-1, Technical
drawings) regarding the position of the safety signs.
2.10.1 Mandatory signs at the machine
Wear eye protection
Use opaque eye protection
Use foot protection
Wear a mask.
Rotary kiln 2-25
2.10.2 Warning signs at the machine
Risk of falling
Warning of high voltage
Warning of hot surface
Warning of hand injuries
Warning of counter-rotating rollers

en-KN.CPT.003.G Technical data
Rotary kiln 3-1
3 Technical data
Type of construction
2-support kiln with friction roller drive Yes/No
3-support kiln with girth gear and Yes/No

pinion drive
General data
Year of manufacture
Rotational speed of the rotary kiln rpm
Slope of the rotary kiln %
Ambient conditions
Location
Height above mean sea level m
Ambient temperature °C
Relative humidity %
Dimensions
Nominal diameter of the rotary kiln mm
Length of the rotary kiln mm
Rotary kiln shell (1.0)

See operating manual No.
Rotary kiln inlet (2.0) with inlet seal

Rotary kiln outlet (10.0) with outlet seal

Tyre (3.0) with tyre fastening system

Supporting roller stations (4.0)

Technical data en-KN.CPT.003.G
3-2 Rotary kiln

Rotary kiln axial thrust system (5.2)



Kiln hood (11.0)

en-KN.CPT.003.G Components and description of functioning
Rotary kiln 4-1
4 Components and description of functioning

4.1 Components
Some details of the drawings in this operating manual may not be identical to
the drawings of the actually delivered machine.
● The following versions of the rotary kiln are possible:

● 2-support rotary kiln with friction roller drive
● 2-support rotary kiln or 3-support rotary kiln with girth gear and pinion drive
Components and description of functioning en-KN.CPT.003.G
4-2 Rotary kiln
Fig. 1: Versions of the rotary kiln

Rotary kiln 4-3
No. Denomination Description
V 2-support rotary kiln with (see figure 2, page 4-4, 2-support rotary kiln with friction
friction roller drive roller drive)
W 3-support rotary kiln with (see figure 3, page 4-6, 3-support rotary kiln with girth gear
girth gear and pinion drive and pinion drive)
4-4 Rotary kiln
4.1.1 2-support rotary kiln with friction roller drive
Fig. 2: 2-support rotary kiln with friction roller drive

Rotary kiln 4-5
1.0 Rotary kiln shell
2.0 Rotary kiln inlet With inlet seal
3.0 Tyres With tyre fastening system
4.0 Supporting roller stations
5.1 Axial positioning system of With thruster and limiting thruster

the rotary kiln
9.0 Rotary kiln drive
10.0 Rotary kiln outlet With outlet seal and outlet cooling system
11.0 Kiln hood
12.0 Shell-cooling Optional
13.0 Tertiary air supply Optional
14.0 Measuring device Optional
I Station I
II Station II
4-6 Rotary kiln
4.1.2 3-support rotary kiln with girth gear and pinion drive
Fig. 3: 3-support rotary kiln with girth gear and pinion drive
Rotary kiln 4-7
1.0 Rotary kiln shell
2.0 Rotary kiln inlet With inlet seal
3.0 Tyres With tyre fastening system
4.0 Supporting roller stations
5.2 Rotary kiln axial thrust With thruster and limiting thruster
system
6.0 Girth gear and pinion drive
7.0 Girth gear protection cover
8.0 Lubricator For girth gear and pinion drive
9.0 Rotary kiln drive
10.0 Rotary kiln outlet With outlet seal (and outlet cooling system)
11.0 Kiln hood
12.0 Shell-cooling Optional
13.0 Tertiary air supply Optional
14.0 Measuring device Optional
I Station I
II Station II
III Station III

4-8 Rotary kiln
4.2 Description of functioning

The rotary kiln is designed for burning powdery, small-sized or sludgy feed
material.
For this purpose, a special rotary kiln burner is installed in the kiln hood (11.0) at
the rotary kiln outlet (10.0).
Due to the slope and rotation of the rotary kiln, the material fed in at the rotary kiln
inlet (2.0) is conducted to the rotary kiln outlet (10.0). The downstream kiln hood
(11.0) serves as an airlock and as a connection to the subsequent unit.
In order to protect the rotary kiln shell (1.0) and the components attached to it, as
well as to prevent excessive heat losses, the rotary kiln is equipped with a special
refractory lining.
The rotary kiln shell (1.0) consists of individual sections that are welded in the
workshop or at site, depending on size and transportability, and is provided with a
refractory lining!
The plate thicknesses meet the calculated stresses in the respective areas.
The material quality is selected in accordance with the temperature stresses to be
expected.
The rotary kiln is supported on the tyres (3.0) and supporting roller stations (4.0).
The rotary kiln can be driven by the girth gear and pinion drive or by the friction
roller drive.
The kiln hood (11.0) at the outlet end of the rotary kiln is the transition to the
downstream units. It has openings providing access to the rotary kiln and
passage for the rotary kiln burner.
Seals at the rotary kiln inlet (2.0) and the rotary kiln outlet (10.0) prevent the
inleakage of false air.
Girth gear and pinion drive

The driving torque is transmitted from the rotary kiln drive (9.0) via the girth gear
and pinion drive (6.0) to the rotary kiln shell (1.0). The girth gear and pinion drive
(6.0) is protected against external influences by a girth gear protection cover (7.0)
and provided with a lubricator (8.0).
In the case of a rotary kiln with girth gear and pinion drive, the kiln shell is moved
with the aid of a rotary kiln axial thrust system (5.2) in axial direction.
Friction roller drive

The driving torque is transmitted from the rotary kiln drive (9.0) directly via the
supporting rollers of the supporting roller stations (4.0) to the tyre (3.0) and to the
rotary kiln shell (1.0).
In the case of a rotary kiln with friction roller drive, the rotary kiln shell is not
axially moved; it is axially positioned with the aid of the axial positioning system of
the rotary kiln (5.1).
en-KN.CPT.003.G Transportation, storage and assembly
Rotary kiln 5-1
5 Transportation, storage and assembly

5.1 Transportation
5.1.1 Safety instructions
WARNING
Suspended loads
During lifting operations, loads might swing out or fall down. This could
lead to life-threatening injuries.
II. Only use approved lifting accessories with sufficient load-bearing
capacity.
III. Do not use damaged, cracked or chafed lifting accessories.
IV. Do not attach lifting accessories to sharp edges, and do not knot or
twist them.
V. Only move loads under supervision.
VI. Never work below or in the swivelling range of suspended loads.
VII. Set down the load before leaving the place of work.
WARNING
Loads swinging out

If a load with an eccentric centre of gravity is not properly attached, it may
swing out unexpectedly. This could lead to severe injuries or damage to
property.
I. When lifting a load, prevent it from swinging out.
II. If necessary, adjust the length of the slings.
WARNING
Falling or toppling loads

Loads may have an eccentric centre of gravity. If the load is not attached
correctly, it might tip or fall. This could lead to severe injuries or damage
to property.
I. Pay attention to marks and instructions concerning the centre of
gravity.
II. If you use a crane to move the load, attach the crane hook such that
it is located directly above the centre of gravity of the load.
III. Lift the load carefully and observe whether it tips or not. If
necessary, adjust the attachment.
Transportation, storage and assembly en-KN.CPT.003.G
5-2 Rotary kiln
NOTICE
Improper transportation
If items of freight are not transported properly, they may fall down or tip
over, causing damage to components.
I. Handle the items of freight carefully when unloading them upon
delivery and transporting them on site, and observe the symbols
and instructions on the packaging of the freight items.
II. Only use the specified fastening points.
III. Do not remove packaging until shortly before assembly.
5.1.2 Identifying the transport units

The machine may be divided into several transport units. Transport units may
contain one or more loose part.
Each transport unit can be identified by a marking and the supplied packing list.
Each loose part can be identified by an applied label and the supplied packing list.
Markings on the transport units

All transport units have a waterproof marking with the following details:
● Customer data
● Order data
● Point of delivery
● Port at point of delivery
● Weight (net/gross)
● Number of the transport unit
● Safety symbol according to the HPE [German Federal Association for wooden
packaging, pallets and export packaging] international packaging directive
Packing list
In addition to the dispatch note, the consignee receives for each delivery a
packing list indicating the contents of each transport unit. The packing list states
all of the loose part items, with the following details:
● Order number
● Packing list number
● Plant Order Code (POC)
● Quantity delivered
● Loose part designation
● Customer equipment code
● Loose part number
● Number of the transport unit
● Total weight of the transport unit
● Dimensions
Rotary kiln 5-3
Loose part label

For identification purposes, each loose part is provided with a label containing the
following details:
● Order number
● Code word
● Plant Order Code (POC)
● Loose part designation
● Designation of the plant section
● Drawing or parts list number, with item details
● Quantity ordered
● Quantity delivered
● Loose part number
5.1.3 Checking the transport units

Check the packaging for damage immediately upon receipt of the delivery. In the
case of externally visible transport damage, proceed as follows:
● Do not accept the delivery, or only accept it with reservation.
● Record the extent of the damage on the shipping documents or on the
delivery note of the carrier.
● Initiate a complaint.
5.1.4 Packaging
The individual transport units were packed according to the expected transport
conditions and the expected storage conditions at the place of installation.
The packaging is intended to protect the individual components until assembly
from transport damage, corrosion and other damage. Do not destroy the
packaging and do not remove it until assembly begins.
5.1.5 Transporting the transport units

Transport the transport units under the following conditions:
● Be sure to observe the safety symbols and instructions on the transport units.
● Cranes and fork-lift trucks must be designed for the weight of the transport
units.
● Handle the transport units carefully when unloading them, when they are
delivered and when transporting them on site.
● Transport the transport units using suitable lifting machinery.
● Only use the specified fastening points.
● Do not remove packaging until assembly begins.
● Before transporting, remove the piping and oil pumps on gear units, and close
all pipe sockets and openings with weather-proof and impact-proof sealing
covers to prevent the ingress of foreign matter.
5-4 Rotary kiln
5.2 Storage
NOTICE
Improper storage
Improper storage may lead to impairment of material properties and to
damage of components.
I. When they arrive at the site, inspect all components for transport
damage.
II. During storage, protect against moisture, soiling and damage.
III. Be sure to comply with the storage instructions of thyssenkrupp
Industrial Solutions and the subsuppliers.
IV. In the case of long-term storage, be sure to comply with the special
instructions of thyssenkrupp Industrial Solutions and the
subsuppliers. If necessary, request additional information.
5.2.2 Storage of transport units

Store the transport units under the following conditions:
● Protect against moisture, soiling and damage.
● Protect against direct sunlight.
● Protect against sub-zero temperatures.
● Avoid mechanical jolting.
● Do not expose to aggressive media.
● Store only on a level storage surface.
● Set up escape and evacuation routes, and keep them clear.
● Stack and secure all transport units in such a way that they do not slip, fall or
collapse.
● Stack and secure cylindrical materials in such a way that they do not slip away
from each other or tip over.
● Keep storage areas free from materials that constitute an increased trip
hazard or a fire hazard.
● If a transport unit is stored for more than 3 months, regularly check the
general condition of all parts and of the packaging. If required, replace or
renew the preservation.
Rotary kiln 5-5
5.2.3 Storage conditions and long-term storage
Component Storage Maintenance in the Preservation

conditions case of long-term
storage
Material for the refractory Be sure to comply with the instructions in the separate subsupplier's
lining documentation.
Site assembly material, ● Store in dry

tools, electrodes conditions
All individual parts for ● Store in dry

bolted connections conditions
Measurement and control ● Store in

devices closed
rooms
● Store in dry
conditions
Machine frames, ● Store under ● Exterior paint coat

supporting structures, a roof
welded components
Structural steelwork ● Store under ● Exterior paint coat

components a roof
Rotary kiln shell (1.0) See separate operating manual
Rotary kiln inlet (2.0) with

See separate operating manual
inlet seal
Rotary kiln outlet (10.0)

with outlet seal
Tyre (3.0) with tyre

fastening system
Supporting roller stations

(4.0)
Axial positioning system

of the rotary kiln (5.1),
rotary kiln axial thrust
system (5.2)
Girth gear and pinion

drive (6.0)
Rotary kiln drive (9.0) See separate operating manual
Kiln hood (11.0) See separate operating manual

5-6 Rotary kiln
5.3 Assembly
The following assembly description only provides an overview of the work to be

performed and does not detail the individual steps for assembling the machine.
Changes in the planning of the plant during the processing of the contract may
lead to deviations from this assembly description.
To ensure correct performance of the work, only assign it to personnel that have
received special training for the tasks to be performed.
It is a prerequisite for our warranty and essential for correct assembly that
assembly supervision and assembly inspection are performed by specialists
from thyssenkrupp Industrial Solutions.
WARNING
Improper assembly
Improper assembly may lead to severe injuries or death.
I. Be sure to comply with the assembly instructions in the technical
documentation.
II. Ensure that there is adequate space to perform the assembly work.
III. Keep the assembly area clean and tidy! Components or tools that
are loosely lying on top of each other or lying around on the floor
are potential causes of accidents.
IV. Assemble the components properly.
V. Make sure that there are no unauthorised persons in the working
area.
WARNING
Unauthorised connection of electrical power

Unauthorised connection of electrical power during assembly may cause
severe injuries or death of the persons in the working area and the danger
area.
Before commencing any work, disconnect the power supply and secure it
against restarting.
Rotary kiln 5-7
WARNING
Structural failure or falling components.

Platforms and supporting structures may collapse. Insufficiently secured
components may fall down during assembly and cause severe injuries or
even death.
I. Never use platforms and their supporting structures as auxiliary
mounting supports or as storage areas for heavy components.
II. Secure the components until stability is ensured.
WARNING
Lack of stability
Lack of stability may result in the machine tipping over. This could lead to
severe injuries.
I. Make sure that the foundation is level and designed such that it can
support the machine load.
II. Use suitable fastening devices. Replace any missing fastening
III. After assembling the machine, make absolutely sure that it is in a
stable position and then carry out a test run.
WARNING
Welding or cutting
During welding or cutting work, the heat, smoke, gases, radiation and
spatters may cause injuries.
Wear personal protective equipment and a welding mask.
WARNING
Rotating machine
The machine may rotate accidentally due to the unbalance mass of the
components already installed. This could lead to life-threatening injuries
due to falling components, or cause persons to fall down inside the
machine.
I. Let the machine swing to a complete stop before commencing any
work.
II. Use a safety cable to secure the machine against accidental rotation.
III. If ladders or working platforms are used, make absolutely sure that
IV. Wear personal protective equipment and use a fall protection
system.
5-8 Rotary kiln
WARNING
Vibrations
Vibrations may occur at the machine. These vibrations may be caused by
the work process or by damage, and may be transmitted via the floor
under the machine. Vibrations may cause health damage.
I. Set up the working platform such that no vibrations can be
transmitted from the machine to the personnel.
II. After assembly, check all fastening elements for tight fitting.
CAUTION
Sharp-edged components
Sharp-edged components may cause cuts if handled improperly.
II. Handle open, sharp-edged components with the utmost care.
CAUTION
Nut-locking agents and sealing compound

Contact with nut-locking agents may cause sensitisation or eczemas.
Contact with sealing compound may cause skin irritation and allergic
reactions. Inhalation of vapours may result in dizziness and drowsiness.
I. Be sure to comply with the manufacturer's safety data sheet.
II. Wear personal protective equipment.
III. Never inhale vapours. Always ensure that the workplace is
sufficiently ventilated.
IV. Avoid any skin contact. If skin contact has occurred, wash the skin
thoroughly.
V. Avoid any contact with eyes. If eye contact has occurred, thoroughly
a doctor.
Rotary kiln 5-9
NOTICE
Welding current
Moving connecting points, measuring devices or sliding surfaces could be
damaged.
I. Always directly connect the welding current return lead to the part
being welded.
II. Never conduct the welding current through plain or antifriction
bearings, other moving connecting elements or measuring devices.
NOTICE
Improperly installed pressure piping

Improperly installed pressure piping may suffer damage. If any pressure
piping is damaged, a jet of fluid may spurt out under high pressure.
I. Do not subject hose piping to tensile loads or twisting.
II. Do not kink the hose piping or lead it over edges.
III. Observe the minimum bending radii for piping.
5-10 Rotary kiln
5.3.2 Tightening torques for bolts with standard thread
WARNING
Incorrect tightening torques

If bolts are tightened to an incorrect tightening torque, components may
come loose. This could lead to severe injuries and damage to property.
I. Be sure to always comply with the relevant directives and design
criteria for bolted connections.
II. Never exceed the maximum permissible tightening torque.
III. Regularly check the tightening torques.
If not stated otherwise in the drawings, the following specifications apply:

● The specified values are applicable to as-new bolts in accordance with DIN
EN.
● Threads and contact surfaces must be cleaned and lightly oiled (do not use
molybdenum disulphide lubricants).
Bolt thread Tightening torque (Nm)
Strength class 4.6 Strength class 5.6 Strength class 8.8
M12 25 30 70
M16 55 75 180
M20 110 140 360
M24 180 250 620
M30 370 490 1240
M36 840 1120 2160
M42 1250 1560 3430
M48 1890 2360 5190
M56 3020 3780 8310
M64 4510 5640 12410

Rotary kiln 5-11
5.3.3 Preparing for assembly

Before assembly, make sure that the following prerequisites are fulfilled:
Check Correct
The place of installation is dimensioned to enable safe access to the place of

assembly and for performing maintenance and repair work in the future.
The place of installation and the access paths are sufficiently illuminated.
All danger areas, such as floor openings or steps, that are located at the place of
installation or at the access points to the place of installation, have been marked
and secured.
The access paths are free of objects.
The foundation has an adequate load-bearing capacity and is level.
The foundation has the anchor holes required for mounting the machine.
Steel plates sized 200 x 200 mm are anchored in the foundation, and bear the
permanently chiselled-in elevation data determined by means of a levelling
instrument or a rubber tube level.
The level of, for example, 1000 mm above the zero datum line is marked on the
rotary kiln foundations.
Lifting machinery and industrial trucks with a sufficient lifting capacity are available
for the transportation of the transport units and for assembly of the plant.
5-12 Rotary kiln
Fig. 4: Marking of the elevation reference point
No. Denomination
A Datum mark
B Steel plate
C Anchorage
D Concrete
E Drilled hole for nailed connection to the formwork

Rotary kiln 5-13
5.4 Mounting the rotary kiln with girth gear and pinion drive
Required personnel
● Assembly personnel
Required consumables
● Welding electrodes
● Gas, oxygen
Necessary personal protective equipment
● Personal protective equipment for all work (see page 2-9)
● Welding mask
Be sure to comply with the instructions in the assembly drawing, regarding

mounting of the rotary kiln (see page 13-1, Technical drawings).
Step 1: Make the relevant marks:

1.1 Mark the benchmark on the foundations.
1.2 Mark the longitudinal kiln axis on the foundations.
1.3 Inscribe an axis parallel to the longitudinal kiln axis and lateral axes on the
foundation.
1.4 Make a written record of all marks.
Step 2: Mount the baseplates:
2.1 Mount and align the baseplates.
2.2 Secure the baseplates against displacement and then grout them in.
2.3 Prepare a written report.
Step 3: Apply graphite grease to the bearing contact areas of the supporting rollers.
Step 4: Install the pre-assembled supporting rollers (including bearings) and
thrusters, and prepare a written report.
See separate operating manual.
Step 5: Mount the rotary kiln axial thrust system (5.2).
Step 6: Fill up the bearing housings with oil (see page 6-1).
Step 7: Fit and position the tyres (3.0) on the tyre-bearing shell sections and secure
them against displacement.
Step 8: Pre-assemble the tyre fastening system.
5-14 Rotary kiln
Step 9: Mount the kiln sections and the tyre-bearing shell sections:
9.1 Begin at the kiln inlet.
The assembly sequence may vary due to local conditions.
9.2 Exactly align the kiln shell sections in relation to each other.
If necessary, the kiln shell bracing element can be removed at one side of the
joints during the aligning work.
Step 10: Pre-assemble the girth gear with pinion:

Also see separate operating manual.
10.1 Roughly align the girth gear and pinion and temporarily secure with
auxiliary assembly devices.
10.2 Clean the tooth flanks.
10.3 Apply lubricant.
Step 11: Clean the contact surfaces of the tyres (3.0) and the supporting rollers.
Step 12: Check the rotary kiln shell (1.0):
12.1 Carry out a concentricity check of the rotary kiln shell (1.0) in the area of
the welds.
Prepare a written report.
12.2 Check the tyres (3.0) for axial runout.
12.3 Realign the tyre-bearing shell sections of the rotary kiln shell (1.0), if
necessary.
Step 13: Weld the circumferential welds at the rotary kiln shell (1.0).
Step 14: Check the rotary kiln welds in accordance with the instructions of
thyssenkrupp Industrial Solutions.
Step 15: Check the concentricity of the rotary kiln shell (1.0).
Step 16: Precisely align the tyres (3.0) with regard to axial runout.
Step 17: Finish the assembly of the tyre fastening system:
17.1 Weld the tyre fastening system.
17.2 Check the welds in accordance with the instructions of thyssenkrupp
Industrial Solutions.
Step 18: Precisely align the girth gear:
18.1 Pretension the girth gear fastening systems according to the drawing (see
the section Appendix).
18.2 Weld the girth gear fastening system.
18.3 Remove the auxiliary assembly devices (with plates for pretensioning).
18.4 Measure the girth gear.
Rotary kiln 5-15
Step 19: Precisely align and grout the kiln girth gear and pinion and the gear unit
group.
Step 20: Mount the protection devices (girth gear protection cover (7.0), heat shields,
protective grating etc.).
Step 21: Assemble the kiln inlet and outlet seals and the kiln outlet cooling system.
Step 22: Install the lubricator (8.0) for the girth gear and pinion drive (6.0), the
supporting roller bearing cooling system, the hydraulic system (if
necessary) etc. and check for proper functioning.
Step 23: Install the kiln refractory lining:
23.1 Carry out checks prior to the refractory lining work (see page 5-18, Checks
before installing the refractory lining).
5-16 Rotary kiln
5.5 Mounting the rotary kiln with friction roller drive

Required personnel
● Assembly personnel
Required consumables
● Welding electrodes
● Gas, oxygen
● Welding mask
Be sure to comply with the instructions in the assembly drawing, regarding

mounting of the rotary kiln (see page 13-1, Technical drawings).
Step 1: Make the relevant marks:

1.1 Mark the benchmark on the foundations.
1.2 Mark the longitudinal kiln axis on the foundations.
1.3 Inscribe an axis parallel to the longitudinal kiln axis and lateral axes on the
foundation.
1.4 Make a written record of all marks.
Step 2: Mount the baseplates:
2.1 Mount and align the baseplates.
2.2 Secure the baseplates against displacement and then grout them in.
2.3 Prepare a written report.
Step 3: Apply graphite grease to the bearing contact areas of the supporting rollers.
Step 4: Install the pre-assembled supporting rollers (including bearings), drives
and thrusters, and prepare a written report.
Step 5: Mount the axial positioning system of the rotary kiln (5.1).
Step 6: Fill up the bearing housings with oil (see page 6-1).
Step 7: Fit and position the tyres (3.0) on the tyre-bearing shell sections and secure
them against displacement.
Step 8: Pre-assemble the tyre fastening system.
Step 9: Mount the kiln sections and the tyre-bearing shell sections:
9.1 Begin at the kiln inlet.
The assembly sequence may vary due to local conditions.

Rotary kiln 5-17
9.2 Exactly align the kiln shell sections in relation to each other.
If necessary, the kiln shell bracing element can be removed at one side of the
joints during the aligning work.
Step 10: Check the rotary kiln shell (1.0):

10.1 Carry out a concentricity check of the rotary kiln shell (1.0) in the area of
the welds.
10.2 Check the tyres (3.0) for axial runout.
10.3 Realign the tyre-bearing shell sections of the rotary kiln shell (1.0), if
necessary.
Step 11: Weld the circumferential welds at the rotary kiln shell (1.0).
Step 12: Check the rotary kiln welds in accordance with the instructions of
thyssenkrupp Industrial Solutions.
Step 13: Check the concentricity of the rotary kiln shell (1.0).
Step 14: Precisely align the tyres (3.0) with regard to axial runout.
Step 15: Finish the assembly of the tyre fastening system:
15.1 Weld the tyre fastening system.
15.2 Check the welds in accordance with the instructions of thyssenkrupp
Step 16: Precisely align and grout the roller drives.
Step 17: Mount the protection devices (heat shields, protective grating etc.).
Step 18: Assemble the kiln inlet and outlet seals and the kiln outlet cooling system.
Step 19: Install the supporting roller bearing cooling system, the hydraulic system (if
necessary) etc. and check for proper functioning.
Step 20: Install the kiln refractory lining:
20.1 Carry out checks prior to the refractory lining work (see page 5-18, Checks
before installing the refractory lining).
5-18 Rotary kiln
5.6 Checks before installing the refractory lining

Prior to installing the refractory lining, check the machine in accordance with the
following list.
Check Correct
There are no assembly scaffolds, transport stiffeners and auxiliary assembly devices
in/on the rotary kiln shell.
All auxiliary assembly devices that were welded onto the inside of the rotary kiln shell
have been removed, and the weld points have been ground level without any
notches.
The circumferential assembly weld is free from cracks.
The edge misalignment and the weld cap of the assembly weld seam on the inner
surface are not more than 4 mm.
The outlet segments of the rotary kiln outlet (10.0) have been properly fastened and
secured
en-KN.CPT.003.G Lubrication
Rotary kiln 6-1
6 Lubrication
The table of lubricants with the lubricant reference numbers is contained in this
folder or at the start of the overall documentation. Each lubricant has a unique
reference number to which the lubrication instructions in this section relate. The
table of lubricants comprises the full listing of all manufacturers and products
that have been approved for this machine. It is the responsibility of the lubricant
supplier to select appropriate lubricants corresponding to the lubricant reference
numbers. thyssenkrupp Industrial Solutions accepts no liability for the
correctness of this data. If you wish to use a lubricant that is not listed in the
table of lubricants, you have to obtain approval for this from thyssenkrupp
6.1 Safety instructions
WARNING
Contact with lubricants

Contact with lubricants may cause allergic reactions and skin irritation.
thoroughly.
a doctor.
CAUTION
Improper handling of lubricants

Lubricants such as greases and oils may contain toxic substances. If
lubricants are released into the natural environment, they may harm
humans, animals and plants.
I. Ensure that the environment is not polluted when lubricants are
II. Be sure to comply with the applicable national regulations for the
protection of the environment when handling lubricants.
Lubrication en-KN.CPT.003.G
6-2 Rotary kiln
6.2 Lubrication chart
Lubrication points Quantity (L, kg) Lubrication intervals (weeks)

per lubrication
point
No. Qty. Designation Lubricant Initial Topping Topping up First Further

ref. no. filling up change changes
1 1 Rotary kiln inlet (2.0) with inlet See separate operating manual. For the number of the operating
seal manual, see the section Technical data (see page 3-1)
[1]
2 1 Tyres (3.0) See separate operating manual. For the number of the operating
manual, see the section Technical data (see page 3-1)
[1]
3 1 Supporting roller stations (4.0) See separate operating manual. For the number of the operating
[1]
4 1 Axial positioning system of the See separate operating manual. For the number of the operating
rotary kiln (5.1), rotary kiln axial manual, see the section Technical data (see page 3-1)
thrust system (5.2)
[1]
5 1 Girth gear and pinion drive (6.0) See separate operating manual. For the number of the operating
[1]
6 Rotary kiln outlet (10.0) with See separate operating manual. For the number of the operating
outlet seal manual, see the section Technical data (see page 3-1)
7 1 Rotary kiln drive (9.0) See separate operating manual. For the number of the operating
[1]
8 1 Shell-cooling (12.0) (optional) See the subsupplier's documentation.
[2]
9 1 Tertiary air supply (13.0) See the subsupplier's documentation.

(optional)
[2]
Explanation of the numerals in square brackets
[1] See separate operating manual. For the number of the operating manual, see the section Technical data (see
page 3-1)
[2] See the subsupplier's documentation.

en-KN.CPT.003.G Commissioning
Rotary kiln 7-1
7 Commissioning
It is a prerequisite for our warranty that the commissioning is carried out in the
presence of specialists from thyssenkrupp Industrial Solutions and in
accordance with their instructions.
WARNING
Improper commissioning
Improper commissioning may lead to severe injuries and may cause
damage to property.
I. Make sure that all assembly work has been carried out and
completed in accordance with the specifications and instructions
given in the technical documentation.
II. Make sure that the test run has been carried out and completed in
accordance with the specifications and instructions given in the
technical documentation.
III. Make absolutely sure that nobody is inside the danger area.
IV. Do not start first commissioning until the safety of the complete
plant has been ensured.
WARNING
Moving components
I. Operate the machine only if all the protection devices have been
properly mounted.
II. Only open protection devices, inspection covers, service covers and
III. If adjustment work is necessary, switch off the machine and secure
it against restarting.
IV. Pay attention to the after-running time. Do not open any protection
devices, inspection covers, service covers or inspection doors until
all components have come to a complete standstill.
V. After any adjustment work, mount all protection devices. Close the
inspection covers, service covers and inspection doors properly.
Commissioning en-KN.CPT.003.G
7-2 Rotary kiln
WARNING
Hot surfaces
severe burns.
I. Always wear personal protective equipment and heat-resistant
protective clothing when working in the vicinity of hot surfaces.
II. If adjustment work is necessary, switch off the machine and secure
it against restarting.
III. Before carrying out any adjustment work, allow the surfaces of the
machine to cool down to ambient temperature.
WARNING
Jet of fluid under pressure

In the case of hydraulic system components or damaged pressure piping,
a jet of fluid may spurt out under high pressure. Contact with the jet of
fluid may lead to severe or even fatal injuries.
I. In the event of an escaping jet of fluid, immediately press the
EMERGENCY STOP button. If necessary, take further measures to
reduce the pressure and to stop the jet of fluid.
III. Only allow qualified hydraulics specialists to carry out work on the
hydraulic system.
IV. Observe the maintenance intervals for hydraulic components and
pressure piping.
V. Regularly check pressure piping for tightness and proper surface
condition.
VI. Never touch a jet of fluid.
VII. Carefully take up any leaked fluids and dispose of them properly.
VIII. Replace any damaged pressure piping or components.
Rotary kiln 7-3
WARNING
Escaping jet of hot fluid

If hydraulic components burst or if pressure piping burst, a jet of hot fluid
may spurt out. Contact with the jet of hot fluid may lead to severe
scalding.
III. Observe the maintenance intervals for hydraulic components and
pressure piping.
IV. Never touch a jet of fluid.
V. Carefully take up any leaked fluids and dispose of them properly.
VI. Repair or replace any damaged or faulty components.
WARNING

risks:
● Burns
● Heat stroke
● Dehydration
● Nausea
clothing.
CAUTION
Escaping dusts
Dusts may escape through leaky points of the machine. The inhalation of
dusts may cause breathing difficulties and suffocation. Contact with eyes
may cause irritation or injury.
II. Do not remain in the danger area when the rotary kiln is being
heated up.
7-4 Rotary kiln
7.2 Checking the safety and monitoring equipment

Required personnel
● Commissioning personnel
WARNING
Defective safety and monitoring equipment

Defective or deactivated safety and monitoring equipment may result in
bodily injuries and machine damage. This could lead to severe or even
fatal injuries.
I. At regular intervals and whenever work has been performed on the
machine, check whether all safety and monitoring devices are
installed properly and are functioning correctly.
II. Never deactivate or bypass any safety and monitoring devices.
III. Make sure that the safety and monitoring equipment is always easily
accessible.
Step 1: Check all safety and monitoring equipment for proper functioning.
Step 2: If defects occur, eliminate them. Only continue with the commissioning
when the defects have been eliminated.
7.3 Basic settings

Required personnel
Commissioning personnel
Perform initial settings in accordance with the separate operating manuals for the
individual subassemblies of the rotary kiln.
For the numbers of the operating manuals, see the section Technical data (see
page 3-1).
Rotary kiln 7-5
7.4 Checks prior to commissioning

Prior to commissioning, check the machine in accordance with the following
checklist.
Check Correct
The checks have been performed in accordance with the checklists in the separate
operating manuals for the individual subassemblies.
page 3-1).
All transporting devices, transport stiffeners and auxiliary assembly devices have
been removed.
The machine is undamaged.
All bolts have been tightened to the required tightening torques.
The seals of the inspection covers and service covers have been inserted. All
inspection covers and service covers are securely closed.
All components have been connected correctly.
All lubrication points have been filled with lubricants.
All monitoring devices are connected and are in proper working order. The correct
switching values have been set properly.
All required protection devices have been installed.
All electrical components have been wired correctly and are in proper working order.
The operating voltage matches the data on the nameplate.
The safety interlocks are correct.
All safety signs are mounted and are easily legible. Be sure to comply with the
instructions in the drawing Hazardous points and sign location regarding location of
the safety signs (see page 13-1).
All tools have been removed from the machine and from the working area.
There are no persons in the vicinity of the machine.
The centre axis of the rotary kiln has been aligned correctly (as far as possible in cold
condition).
The rotary kiln measurement record has been made for the actual condition.
The refractory lining has been installed in accordance with the supplier's instructions.
All auxiliary assembly devices welded onto the outer shell have been removed, and
the welds have been ground level without any notches.
The design-specific radial space between the rotating rotary kiln shell (1.0) and the
static subassemblies (rotary kiln inlet (2.0)/kiln hood (11.0)) is maintained during the
entire rotation.
7-6 Rotary kiln
7.5 Commissioning
Required personnel
● Commissioning personnel
● Commissioning personnel from thyssenkrupp Industrial Solutions
● Heat-resistant protective clothing
Be sure to perform the commissioning in conformity with the process functional

diagram.
Carry out the commissioning of the individual subassemblies in accordance with the
separate operating manuals.
page 3-1).
en-KN.CPT.003.G Operation
Rotary kiln 8-1
8 Operation
The machine operates fully automatically. It is not necessary to carry out
operator control actions at the machine while it is in operation. The operating
personnel operate and monitor the machine via the master control system.
WARNING
Improper operation
Improper operation may lead to severe injuries and damage to property.
I. Operate the machine only if all the protection devices have been
properly mounted.
II. Before starting the machine, make absolutely sure that nobody is
inside the danger area.
III. Never switch off or bypass any safety devices during operation.
8.2 Operation with main drive

Required personnel
● Operating personnel
Start the rotary kiln in accordance with the section Operation, in the separate operating
manual for the rotary kiln drive.
page 3-1).
8.3 Operation with the auxiliary drive

Required personnel
page 3-1).
Operation en-KN.CPT.003.G
8-2 Rotary kiln
8.4 Maintenance operation

Required personnel
● Maintenance personnel
page 3-1).
en-KN.CPT.003.G Maintenance
Rotary kiln 9-1
9 Maintenance
9.1 Maintenance work during operation
WARNING
Moving components
I. Operate the machine only with properly mounted protection devices.
II. Only open protection devices, inspection covers, service covers or
WARNING
Hot surfaces
severe burns.
Always wear personal protective equipment and heat-resistant protective
clothing when working in the vicinity of hot surfaces.
WARNING

risks:
● Burns
● Heat stroke
● Dehydration
● Nausea
clothing.
Maintenance en-KN.CPT.003.G
9-2 Rotary kiln
WARNING

I. Wear personal protective equipment and use a fall protection
system.
II. Do not remove protection devices.
WARNING

hydraulic system.
pressure piping.
V. Regularly check pressure piping for tightness and proper surface
condition.
VI. Never touch a jet of fluid.
VII. Carefully take up any leaked fluids and dispose of them properly.
VIII. Replace any damaged pressure piping or components.
Rotary kiln 9-3
WARNING
Escaping jet of hot fluid

If hydraulic components burst or if pressure piping burst, a jet of hot fluid
may spurt out. Contact with the jet of hot fluid may lead to severe
scalding.
III. Observe the maintenance intervals for hydraulic components and
pressure piping.
IV. Never touch a jet of fluid.
V. Carefully take up any leaked fluids and dispose of them properly.
VI. Repair or replace any damaged or faulty components.
WARNING
Pneumatic energy
pneumatic systems.
WARNING
Rotating fan blades

If you reach past rotating fan blades, parts of your body may be pulled in
I. During operation, do not reach past or work on rotating
components.
II. Do not open any guards or maintenance covers during operation.
CAUTION
Escaping dusts and gases

Dusts and gases may escape through leaky points of the machine. The
inhalation of dusts and gases may cause breathing difficulties and
suffocation. Contact with eyes may cause irritation or injury.
Wear personal protective equipment and a dust mask.
9-4 Rotary kiln
CAUTION
Strong light of the burner flame

Observation of the flame through inspection holes may lead to eye
injuries.
Wear personal protective equipment and suitable safety goggles with a
protective filter.
NOTICE
Cracks in the rotary kiln shell

The rotary kiln shell is subjected to alternating bending stresses, as is
inherent in the type of construction. This constantly increases the crack
progression speed due to the notch effect at the crack ends, while the
remaining cross-section decreases at the same time. If there are incipient
cracks or other cracks in the rotary kiln shell, the rotary kiln shell may be
destroyed.
I. If cracks appear in the rotary kiln shell, turn the rotary kiln until it
has cooled down, and then shut it down.
II. Repair the cracks or replace the shell section.
9.1.2 Prior to any maintenance work

Be sure to do the following prior to any maintenance work during operation:
● Only permit authorised and instructed maintenance personnel to perform any
work.
● Ensure that there is adequate space to perform the work.
● Keep the work area clean and tidy. Components or tools that are loosely lying
on top of each other or lying around on the floor are potential causes of
accidents.
● Put up a warning sign: Attention – Maintenance work
Rotary kiln 9-5
9.1.3 Table of maintenance work (Operation)

The following sections describe the maintenance work required for optimal and
trouble-free operation of the plant. If increased wear is detected during regular
checks, shorten the required maintenance intervals to suit the actual signs of
wear.
No. Work to be performed Frequency Qualification Remarks
of personnel
1 Service individual In accordance In accordance ● For the

subassemblies of the rotary kiln with the section with the section numbers of the
during operation "Maintenance "Maintenance operating
work during work during manuals, see
operation", in operation", in the section
the separate the separate Technical data
operating operating (see page 3-1).
manuals for the manuals for the
subassemblies. subassemblies.
2 Check the rotary kiln alignment Every 2 years Specialists ● In order to

from correct
thyssenkrupp foundation
Industrial settlements and
Solutions tilting in good
time.
● In the case of
large
settlements
(tilting), we
recommend
carrying out
readjustments
at shorter
intervals of
time.
● Depending on
the kiln
geometry, even
station
settlements of 5
mm can cause
stress increases
of up to 30% in
the kiln shell.
9.1.4 After any maintenance work

Be sure to do the following after any maintenance work during operation:
● Remove all tools, auxiliary devices, measuring devices, etc. from the machine.
● Mount all protection devices.
● Check all joints and connections for leaks.
● Make absolutely sure that nobody is inside the danger area of the rotary kiln.
9-6 Rotary kiln
9.2 Maintenance work during a stoppage
DANGER
Electric current
There are live components in and at the machine. Contact with live parts
means immediate danger of death due to electric shock.
I. Only permit qualified electricians to perform work on the electrical
equipment.
II. Before beginning any work, disconnect all poles of the machine
from the electricity supply network and secure it against restarting.
DANGER
Contact with material in the interior

When working in the interior of the rotary kiln, contact with material may
cause damage to health. The potential hazard depends on the material that
has been fed in.
I. Wear personal protective equipment and a protective filter mask.
II. Avoid contact with material.
III. Following contact with harmful material, clean the affected parts of
the body and change out of dirty clothing.
IV. Remount all protection devices when the work has been completed.
WARNING
Moving components
I. Before commencing any work, switch off the machine and secure it
against restarting.
II. Pay attention to the after-running time. Do not open any protection
devices, inspection covers, service covers or inspection doors until
all components have come to a complete standstill.
III. After performing any work, mount all protection devices. Close the
inspection covers, service covers and inspection doors properly.
Rotary kiln 9-7
WARNING
Rotating fan blades

If you reach past rotating fan blades, parts of your body may be pulled in
I. Before commencing any work, disconnect all poles of the cooling air
fan from the electricity supply network and secure it against
restarting for the entire duration of the work.
II. Pay attention to the after-running time. Before you open any guards
or maintenance covers, make sure that all components have come
to a complete standstill.
III. After finishing the maintenance work, make absolutely sure that
nobody is inside the danger area of the plant.
IV. Remount all protection devices.
WARNING
Unexpectedly moving flap vane plate

Your fingers or hands may be crushed or severed if you reach into the
machine.
II. Shut down the plant section in which the machine is located and
secure the said plant section against restarting.
III. Do not remove protection devices until the plant section in which
the machine is located has been shut down and secured against
restarting.
IV. Before reaching into the machine, secure the flap vane plate against
unintended movement.
WARNING
Closing and opening the suspension door and the inspection door
Limbs may be crushed when the suspension door and the inspection door
are closed or opened.
II. Never reach into the danger area.
III. Do not stand in the swing range of the suspension door or the
inspection door.
9-8 Rotary kiln
WARNING
Opening the suspension door and the inspection door

When opening the suspension door or the inspection door, there is a risk
of falling. This could lead to life-threatening injuries.
I. Secure the danger area.
III. Use a fall protection system.
WARNING

I. Wear personal protective equipment and use a fall protection
system.
II. Do not remove protection devices.
WARNING
Hot surfaces
severe burns.
I. Always wear personal protective equipment and heat-resistant
protective clothing when working in the vicinity of hot surfaces.
II. Before commencing any work, switch off the machine and secure it
against restarting. Allow surfaces to cool down to ambient
temperature.
Rotary kiln 9-9
WARNING

hydraulic system.
pressure piping. Regularly check pressure piping for tightness and
proper surface condition.
V. Never touch a jet of fluid.
VI. Carefully take up any leaked fluid and dispose of it properly.
VII. Replace any damaged pressure piping or components.
WARNING
Carbon monoxide
There may be a high concentration of carbon monoxide in the interior of
the machine. The inhalation of large amounts of carbon monoxide may
cause acute poisoning.
I. Check the concentration of carbon monoxide before entering the
interior.
II. Enter the interior only if the concentration of carbon monoxide is not
harmful.
III. Constantly supply fresh air when work is being carried out in the
interior of the machine, and keep the inhaled air free from carbon
monoxide.
IV. Never use pure oxygen for ventilation of the interior.
V. Wear self-contained breathing apparatus if necessary, and monitor
the oxygen concentration.
VI. If signs of poisoning occur, carry out first aid measures and arrange
for immediate medical treatment.
9-10 Rotary kiln
WARNING
High noise level

The noise level in the working area may cause hearing loss.
I. Wear hearing protectors.
II. Measure noise emission on-site and introduce further protective
measures as required.
III. Do not spend more time than necessary in the working area.
IV. Take breaks at regular intervals and leave the working area.
WARNING
Hot hydraulic oil

Hydraulic oil can reach high temperatures during operation. Contact with
hot hydraulic oil may lead to severe scalding.
II. Before draining hydraulic oil and changing the oil, allow the
hydraulic oil to cool down.
WARNING
Hot gases and dusts in the interior

The interior of the machine heats up during operation. Entering the hot
interior may cause burns and, if hot gases are inhaled, damage to the
respiratory tracts.
II. Before commencing any work, switch off the machine and secure it
against restarting. Allow the interior to cool down.
III. Directly after the machine has been shut down, you may only enter
the interior wearing a self-contained breathing apparatus.
IV. Sufficiently purge the interior with fresh air. Never use pure oxygen
for ventilation of the interior.
V. Before entering the interior without self-contained breathing
apparatus, make absolutely sure that no more hot gases can reach
the working area.
Rotary kiln 9-11
WARNING
Hot material in the interior

There is hot material in the interior. Contact with hot material may cause
burns.
II. Before entering the interior, always put on heat-resistant protective
clothing, ankle-high safety boots and a dust mask.
III. Do not enter the interior until the rotary kiln has cooled down to
ambient temperature.
WARNING
Falling incrustations or falling parts of the refractory lining

In the interior, adhering incrustations or parts of the refractory lining may
come loose, fall down and cause injuries. There is also a danger of being
buried alive.
II. Eliminate incrustations and loose parts of the refractory lining in the
ceiling zone first, before entering the interior.
III. Before entering the interior, suitably cover such material as is
present.
WARNING
Uncovered compressed-air hoses

During cleaning work, there is a trip hazard due to uncovered
compressed-air hoses.
Wear personal protective equipment.
WARNING
Pneumatic energy
II. Only permit qualified pneumatics specialists to perform work on
pneumatic components.
III. Never alter pressure settings to exceed the maximum values.
IV. Before carrying out any work, switch off and completely
depressurise the pneumatic components. Discharge the residual
energy and check that the pneumatic components are
depressurised.
9-12 Rotary kiln
WARNING
Escaping compressed air

If malfunctions or leaks occur, or after the pneumatic components are
switched off, compressed air may escape. This could lead to severe
injuries.
II. Only permit qualified pneumatics specialists to perform work on
pneumatic components.
III. Never alter pressure settings to exceed the maximum values.
IV. Before carrying out any work, switch off and completely
depressurise the pneumatic components. Discharge the residual
energy and check that the pneumatic components are
depressurised.
V. If any leaks occur, immediately switch the pneumatic components
off, and repair or replace any damaged or faulty components.
WARNING
Preloaded springs
Preloaded springs in frictional dampers and in the angling device could
become detached and whip back. This could lead to injuries.
Before commencing any work at frictional dampers or at the angling
device, relieve the springs.
WARNING
Tensioned steel cable

If components are replaced in the vicinity of the counterweight, reaction
forces may lead to uncontrolled movements. This could lead to severe
injuries.
Before beginning any work, relieve the steel cable in the vicinity of the
counterweight.
Rotary kiln 9-13
WARNING
Escaping lubricants
Lubricant may escape at the machine. Contact with lubricants may cause
health damage or lead to injuries due to slipping.
II. Operate the machine only if all the protection devices have been
properly mounted.
III. Avoid any skin contact. If skin contact has occurred, wash the skin
thoroughly.
IV. Avoid any contact with eyes. If eye contact has occurred, thoroughly
a doctor.
V. Immediately remove any lubricants that have escaped.
VI. If necessary, mark the danger areas and cordon them off.
WARNING
Easily flammable substances

Easily flammable substances, liquids or gases may catch fire and lead to
severe injuries or death.
I. In case of fire, stop all work immediately. Leave the danger area until
the all-clear is given and alert the fire brigade.
II. Never smoke within the danger area or in the immediate vicinity. The
use of open flame, fire and ignition sources of any kind is
prohibited.
III. Keep suitable extinguishing agents (fire blanket, fire extinguisher) at
hand.
IV. Immediately report any suspect substances, liquids or gases to the
person in charge.
WARNING
Closing and opening the suspension door and the inspection door
Limbs may be crushed when the suspension door and the inspection door
are closed or opened.
II. Never reach into the danger area.
III. Do not stand in the swing range of the suspension door or the
inspection door.
9-14 Rotary kiln
CAUTION
Floor unevenness
Floor unevenness in the interior of the machine is a slip and trip hazard
and may lead to injuries.
II. Cover uneven floor areas with suitable covering material.
NOTICE
Condensate in the filter

If the ambient temperature is below 0 °C, the condensate in the filter
freezes and can thus damage the filter.
Drain condensate from the filter at regular intervals.
9.2.2 Prior to any maintenance work

Be sure to do the following prior to any maintenance work during a stoppage:
● Put up a warning sign stating that maintenance work is in progress.
● Keep the work area clean and tidy. Components or tools that are loosely lying
on top of each other or lying around on the floor are potential causes of
accidents.
● Shut down the rotary kiln in accordance with the owner's instructions and
secure it against restarting.
● Make absolutely sure that the rotary kiln has swung to a complete stop in its
centre of gravity position. Then fix it in position by means of the holding brake
of the rotary kiln drive and secure it against restarting.
● Stop the material feed and secure it against restarting.
● Allow the rotary kiln to cool down.
● Depressurise all pressurised components and bleed them.
Rotary kiln 9-15
9.2.3 Table of maintenance work (Stoppage)

The following sections describe the maintenance work required for optimal and
trouble-free operation of the plant. If increased wear is detected during regular
checks, shorten the required maintenance intervals to suit the actual signs of
wear.
No. Work to be performed Frequency Qualification Remarks
of personnel
1 Service individual subassemblies In accordance In accordance ● For the

of the rotary kiln during a with the section with the section numbers of the
stoppage "Maintenance "Maintenance operating
work during a work during manuals, see
stoppage", in operation", in the section
the separate the separate Technical data
operating operating (see page 3-1).
manual for the manuals for the
subassemblies. subassemblies.
9.2.4 After any maintenance work

Be sure to do the following after any maintenance work during a stoppage:
● After any maintenance work, carry out the checks stipulated in the section
Checks prior to commissioning (see page 7-5, Checks prior to commissioning).
● Remove all tools, auxiliary devices, measuring devices etc. from the machine.
● Mount all protection devices.
● Ensure that all inspection covers, service covers and inspection doors are
closed.
● Check all joints and connections for leaks.
● After carrying out work which changes the position of the centre axis of the
rotary kiln, e.g. replacement of supporting roller stations (4.0), replacement of
shell sections of the rotary kiln shell (1.0), be sure to check the centre axis of
the rotary kiln by means of a suitable measuring process, and realign it.
● Make absolutely sure that nobody remains in the interior of the rotary kiln.
● Release the holding brake of the rotary kiln drive.
en-KN.CPT.003.G Troubleshooting
Rotary kiln 10-1
10 Troubleshooting
WARNING
Improper troubleshooting
Improper performance of fault-elimination work may lead to severe injuries
and damage to property.
I. Before commencing the work, ensure that there is adequate space
to carry it out.
II. Keep the work area clean and tidy. Components or tools that are
loosely lying on top of each other or lying around on the floor are
potential causes of accidents.
III. If components have been removed, make sure that assembly is
carried out properly. Remount all fastening elements and be sure to
comply with the specified tightening torques.
IV. Perform and complete fault-elimination work in accordance with the
instructions in the technical documentation.
V. If, for the purpose of eliminating faults, work has to be performed in
the danger area, switch off the machine and secure it against
restarting.
VI. Never deactivate protection devices during operation.
VII. Depending on the type of fault, only permit appropriately qualified
personnel to perform fault elimination.
10.2 List of possible faults
Tables with detailed information about other faults, their causes and their
elimination are contained in the separate operating manuals for the individual
subassemblies. For the numbers of the operating manuals, see the section
Technical data (see page 3-1).
As a rule, troubleshooting is limited to mechanical faults.
Observe the additional information about faults, their causes and their
elimination, in the subsuppliers' documentation.
Troubleshooting en-KN.CPT.003.G
10-2 Rotary kiln
10.3 Recommissioning after fault elimination

After the fault has been eliminated, carry out the following steps:
1. Remove all tools from the machine.
2. Make absolutely sure that nobody is inside the danger area.
3. Close all components previously opened.
4. Ensure that all safety devices are fitted and in proper working order.
5. Reset the EMERGENCY OFF devices as necessary.
6. Acknowledge the fault message at the control system.
7. After any maintenance work, carry out the checks stipulated in the section
Checks prior to commissioning (see page 7-5).
en-KN.CPT.003.G Spare parts
Rotary kiln 11-1
11 Spare parts
11.1 Suggestions for enquiries and orders of spare parts
To enquire about or order spare parts, proceed as follows:

● Copy the title page and the page with the table.
● Complete the Quantity and Unit columns.
● In the Enquiry or Order column, mark the applicable spare parts with a cross.
● Send title page and the table to the spare parts department of thyssenkrupp
● If the table refers to several machines, please state the Plant Order Code
(POC).
Spare parts can be enquired about and ordered via the Professional Spare
Parts Navigator (PSPN), the electronic spare parts catalogue from thyssenkrupp
Tables with detailed information about spare parts are contained in the separate
operating manuals for the individual subassemblies. For the numbers of the
operating manuals, see the section Technical data (see page 3-1).
en-KN.CPT.003.G Disassembly and disposal
Rotary kiln 12-1
12 Disassembly and disposal

WARNING
Improper disassembly
Improper disassembly may result in the machine tipping over, or may
cause components to fall down. This could lead to severe injuries.
I. Make absolutely sure that suitable lifting machinery is employed for
securing the components against falling.
II. Use one hoist to secure the mounted components and a further
hoist to move the components that are to be dismounted.
III. Only remove the lifting machinery when the components have been
safely dismounted with all the specified fastening devices.
WARNING
Suspended loads
During lifting operations, loads might swing out or fall down. This could
lead to life-threatening injuries.
II. Only use approved lifting accessories with sufficient load-bearing
capacity.
III. Do not use damaged, cracked or chafed lifting accessories.
IV. Do not attach lifting accessories to sharp edges, and do not knot or
twist them.
V. Only move loads under supervision.
VI. Never work below or in the swivelling range of suspended loads.
VII. Set down the load before leaving the place of work.
12.2 Before disassembly

Be sure to do the following before disassembly:
● Keep the place of work clean and tidy. Components or tools that are loosely
lying on top of each other or lying around on the floor are potential causes of
accidents.
● Stop the material feed and wait until there is no longer any material in the
machine.
● Switch off the machine and secure it against restarting.
● Allow the machine to cool down to ambient temperature.
● Close the shut-off devices.
Disassembly and disposal en-KN.CPT.003.G
12-2 Rotary kiln
12.3 Disposal
Contract a specialist company to dispose of the machine. Ensure that disposal

is carried out in accordance with local conditions and statutory provisions.
WARNING
Contact with lubricants

Contact with lubricants may cause allergic reactions and skin irritation.
thoroughly.
a doctor.
CAUTION
Improper handling of lubricants

Lubricants such as greases and oils may contain toxic substances. If
lubricants are released into the natural environment, they may harm
humans, animals and plants.
I. Ensure that the environment is not polluted when lubricants are
II. Be sure to comply with the applicable national regulations for the
protection of the environment when handling lubricants.
en-KN.CPT.003.G Appendix
Rotary kiln 13-1
13 Appendix
13.1 Technical drawings
For drawing numbers, please refer to the table of contents of this folder.
Designation Drawing number
Assembly drawing
Hazardous points and sign location
13.2 Measurement records
Measurement records are contained in the separate operating manuals. For

numbers of the operating manuals, see the section Technical data (see page 3-
1).
13.3 Subsuppliers' documentation
Designation Subsupplier
Shell-cooling (12.0)
Tertiary air supply (13.0)

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Operating manual

Plant Order Code (POC)

1 General information ............................................................................. 1-1

5.3.1 Safety instructions .................................................................................. 5-6

1.2 Additionally applicable documents

1.3 Limitation on liability

1.5 Warranty provisions

1.6 Symbol explanation

This combination of symbol and signal word indicates an immediately

This combination of symbol and signal word indicates a possibly

This combination of symbol and signal word indicates a possibly

This combination of symbol and signal word indicates a possibly

A safety sign that stipulates a certain behaviour.

A safety sign that prohibits a certain behaviour.

A safety sign that warns of a specific danger.

This symbol highlights useful tips and recommendations, as well as information

Italics Indicates references to other sections,

Step 1, 2, 3...: Indicates instructions on actions to be taken

● Indicates lists and list entries or instructions on

2.2 Reasonably foreseeable misuse

2.3 Limits of the machine

2.4 Obligation of the owner

Condition of perfect technical serviceability

2.5 Obligation of the personnel

2.6 Qualifications of the personnel

Insufficient qualification of personnel

Unauthorised persons in the danger and working areas

Qualified hydraulics specialist

Qualified pneumatics specialist

2.7 Safety and monitoring equipment

Defective safety and monitoring equipment

2.7.1 Safety devices to be retrofitted

Unsecured or unmarked hazardous points

Securing against restarting

Integration into an EMERGENCY STOP concept

2.8 Personal protective equipment

2.8.1 Personal protective equipment for all work

2.8.2 Personal protective equipment for special work

Fall protection system

Heat-resistant protective clothing

Safety goggles with UV-protection filter

2.9 Fundamental hazards

2.9.1 Overview of residual risks

Hazard Source of hazard

Crushing Entire rotary kiln

Moving and rotating components of the rotary

Inlet seal of the rotary kiln inlet (2.0)

Tyres (3.0) and supporting roller stations (4.0)

Axial positioning system of the rotary kiln (5.1)

Girth gear and pinion drive (6.0)

Rotary kiln drive (9.0)

Outlet seal of the rotary kiln outlet (10.0)

Pulling-in, trapping or entanglement Entire rotary kiln

Moving and rotating components of the rotary

Inlet seal of the rotary kiln inlet (2.0)

Tyres (3.0) and supporting roller stations (4.0)

Axial positioning system of the rotary kiln (5.1)

Girth gear and pinion drive (6.0)

Rotary kiln drive (9.0)

Outlet seal of the rotary kiln outlet (10.0)

Slipping, tripping or falling Working area of the rotary kiln

Uncovered wires and cables

Uneven floor in the interior of the rotary kiln