Installation,Operation and Maintenance

Instructions of
Φ6.1×42m Rotary Kiln

CITIC Heavy Industries Co., Ltd.

2015.2

1
 Introduction

The Installation and Operation Instructions is designed for the rotary kiln to produce
oxide pellets. The pellet kiln has two support points, and the kiln temperature can be improved
through coal injection (or oil injection, etc.) at the the kiln head. The dried materials shall be
placed into the tilted kiln through the kiln tail, after a certain time of oxidizing calcination,
and finally discharged from the kiln head to the cooling device for cooling.
This manual specifies the necessary conditions and required procedures when on-site
installation and commissioning of the rotary kiln, and it can be used by the personnel for on-
site installation and commissioning, the owners and the workers for commissioning from the
ancillary factory.
The manual is the general instruction for installation and operation of the pellet kiln, if
any content of this manual is inconsistent with the requirements of the drawing, the drawing
shall prevail.
If any error or omissions found in this manual, users can make proper adjustment
according to the actual on-site condition for this manual can only be used for reference.
This manual is prepared by Liu Xingan, checked by Wang Wenyu, and translated
cooperatively by the Information Department.

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 Content

1. Rotary kiln installation............................................................................................................1

2. Installation description............................................................................................................4
3. Installation preparation........................................................................................................... 6
4. Supporting device installation...............................................................................................22
5. Tyre and shell installation..................................................................................................... 31
6. Girth ring installation .......................................................................................................... 39
7. Transmission devices .......................................................................................................... 41
8. Components for inlet and outlet of kiln, and the bricklaying................................................43
9. Test run of rotary kiln............................................................................................................44
10. Operation and maintenance.................................................................................................46
11 Epilogue............................................................................................................................... 60

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1. Rotary kiln installation
1.1 General description of rotary kiln
1.1.1 Working principle
Rotary kiln is the key plant for pellet production.
The raw pellet material preheated by the chain grate shall be fed to the kiln shell
from the kiln tail (high end). As the tilted kiln shell is slowly rotated, making the
materials rotated along the circumferential direction and moved axially from high end
to low end. After a period of oxidizing calcination, the pellet clinker will be
discharged from the kiln head (low-end) into the circular cooler for cooling.
Fuels (coal powder or combustible gases) are injected from the burner at the kiln
head, burned in the kiln; the heat emitted increases the kiln temperature, and the
pellets are calcined to clinkers. The hot air formed during the oxidizing calcination
will enter into the kiln rear system (chain grate and the dust collector), which would be
discharged into the atmosphere through the chimney after treatment.
1) Sealing cover at kiln head
It is used for the connection of rotary kiln and the circular cooler, lined with
refractory inside. The oxide pellets in the sealing cover of rotary kiln are fed through
the stationary screen to the feed hopper of circular cooler. There is the hot air return
port on the cover and connected to the hot air duct. The cover is mainly of welding
structure. There are the coal injector, observation hole and access door fixed on the
cover.
2) Sealing device at kiln head and tail
Realize the effective sealing between the rotated rotary kiln body and the fixed
kiln tail and head hoods.
3) Stationary screen
Used to screen the bulk materials from the pellets in the kiln, and ensure the
uniformity of the material particle sizes entering the circular cooler, and guarantee the
cooling effect and normal operation of the equipment. This device is located at the kiln

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head sealing cover where the clinkers are discharged, with the main body of water-
cooled casting structure and the heat resistant and anti-wear sieve plate on the upper
part.
4) The shell
The shell is the main part of the kiln, rolled by thick steel plate and welded with
the replaceable protective irons respectively at the kiln head and tail, which are the
casting structures. The kiln shell is tilted and mounted on two support rollers, with two
rectangular tyres along the longitudinal direction of the kiln shell. The tyres help to
carry the weight of shell, materials, liner and all the other rotary parts, and transfer the
weights to the supporting devices. The shell is used to support the lined refractory, get
the materials to turn over, and complete the pellets oxidizing calcination. The pellet
kiln is a kind of rotatory furnace with a larger diameter, shorter length. In order to
improve the working conditions of opening protective iron and sealing device, the air
duct is fixed at the kiln tail for partially forced cooling.
5) Supporting device
The supporting device is an important part of the rotary kiln, which carries the
total weight of the kiln shell, and has the function of adjusting the kiln shell. There are
two supports of the rotary kiln, and rolling bearings for the supporting rollers. The
support rollers are large castings. The support roller is meshing with the tyre mounted
on the shell to ensure the rotary motion of the shell. The supporting device is
composed of the support roller bearing pack, the welded bearing seat and other
components. The correct allocation of supporting points makes the design of each
supporting device more reasonable, and ensures the safe and stable running of the
rotary kiln.
6) Transmission unit
It is used to drive the rotation of the shell. Since the power is required to be large,
multi-point transmission is adopted, with four hydraulic motors and the auxiliary
hydraulic system to make the kiln shell rotated. The large girth gear is attached with
the shell by the tangent spring plate to transmit the torque. The connection between the

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girth gear and the shell by the spring plate, and the coupling attachments of girth gear
on the kiln shell could leave enough space for heat dissipation between the ring gear
and kiln shell, and can reduce the kiln shell bending or deformation and others, which
will affect the accuracy of meshing; they also play the role of shock absorption and
cushioning, which help extend the life of the kiln lining. The sealing hood is designed
for the girth gear, and heat shield for the hydraulic motor.
7) The hydraulic thrust roller device is mainly composed of the thrust roller,
thrust roller shaft, bearing body, guiding shaft, rolling bearings, travel switch and so
on. The hydraulic thrust roller device carries the sliding force of the whole kiln. And
through the hydraulic thrust roller device, the kiln body can be driven to move
upwards, pushing the tyre and kiln shell to move together back and forth on the
support roller along the kiln center direction at a certain speed and stroke, which helps
to make the wears of tyre and support roller uniform in the full width so as to prolong
the service life.
8) Sealing cover at kiln tail
It is used for the connection of rotary kiln and chain grate, equipped with
refractory lining inside. The pellets dried by chain grate are fed to the rotary kiln
through the feeding chutes fixed inside the kiln head hood. There is the flange on the
cover to connect with the chain grate cover. There are the bulk material reclaimed
point, and bulk discharge opening at the lower part. The cover is mainly of welded
structure with the observation hole and access door on it.
9) Structural cooling device
It is used for the forced cooling of kiln head and tail to realize the uniform
cooling by cold air through the nozzles evenly distributed in circumferential direction.
10) Hydraulic system of transmission
It is used for the oil supplying of hydraulic motor for its operation. There are the
spare pump and auxiliary pump to get the soft start and meet the requirements of slow
rotation.
11) Intelligent lubrication system

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 It is used for the grease lubrication of rotary kiln (support, thrust roller, pinion
bearing) and spraying lubricant of girth gear.
In addition, there are installation tools, anchor bolts and other parts to facilitate
the installation of the rotary kiln, make the rotary kiln a complete system operated
independently, and ensure the smooth and safe operation.

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2. Installation description
Thank you very much for your trust and confidence in the rotary kiln from CITIC.
With high reliability and serviceability, easy observation, inspection and maintenance,
this equipment is improved to be stable and reliable when running. We aim to help you
gain more earnings from our equipments, and wish you could read this manual
carefully before installation and operation. This manual will contribute to easy
assembly, installation and knowing well about its structural features especially for the
personnel involved installation, operation and maintenance, which does good to the
rotatory kiln in the aspects of maintenance and operation after repeated reading it.
For the modern technology and business become more specialized, the duty of
installation is different from others; it lasts for the whole process of the project. The
most commonly used rule is taking measures but no guarantee. Reinspection and
guarantee of the completed work quality will pave the way for the further installation .
Considerable design and accurate judgment are necessary to avoid the future
troubles especially during the primary run of the rotary kiln. Although it is impossible
to foresee everything bad, this manual attempts to describe the installation procedures
of the rotary kiln and aims to avoid the hidden troubles.
This manual includes the flowing information:
The precautions for supporting foundation, bearing, thrust roller unit,
transmission foundation, and driving system; Besides,requirements for lubrication and
foundation and other related information involved with installation and maintenance.
Although this manual includes the installation information for the common type
of rotary kilns, some special situation is different. The main difference is in the drive,
for example: motor, coupling, clutch and reducer. These variable factors usually have
the special specifications. In some situation, the adjusting tolerance for the bought-in
parts are specified by the supplier of the parts (such as: reducer or motor).

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3. Installation preparation
3.1 Compile the construction technical documents
Make the relevant personals familiar with the drawing and relevant technical
document and know the structure of the equipment and purpose of design, specify
each technical requirement, compile the construction organization plan, installation
plan and construction safety measures etc. and appoint principal to take in charge of
the installation work for the whole equipment. The unit of rotary kiln is large, the parts
of it are many, and the requirement for installation is high. The installation unit should
confirm the installation sequence and method in terms of self-condition& facilities
and requirement of schedule. Usually, the installation sequence for each part is as
follows:
3.1.1 Installation engineer
The qualified and experienced engineer for rotary kiln should be accompanied
with in the installation field.
3.1.2 Foundation
The proper foundation should be equipped with. Please see the detailed relevant
requirements in the alignment and foundation drawing of the rotary kiln. The central
line of the foundation and datum mark point should be marked on the foundation.
3.1.3 Supporting device
Install and align the foundation of supporting device.
3.1.4 Assemblies of the supporting roller and the thrust roller.
Assemble and align the supporting roller and thrust roller on the foundation of the
supporting device. At this time, pour the foundation of the supporting device.
3.1.5 Installation of the tyre and shell
Mount the tyre and shell on the supporting device of the kiln.
3.1.6 Installation of the large geared ring
Mount the large geared ring on the shell and align the geared ring roughly. Please
see some installation drawings relevant to drive and geared ring.

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3.1.7 Installation of the driving device
Install the drive foundation and align the drive parts roughly. It is necessary to
align the large geared ring and driving device roughly, which can use auxiliary motor
to turn the rotary kiln to align the shell and tyre subtly.
3.1.8 Alignment of the shell
After the fine alignment of the shell, welding the section of the shell, carry out
the final alignment and make the record.
3.1.9 Alignment of the tyre
Align the tyre ad weld the stopper.
3.1.10 Align the large geared ring
Make the final alignment for the large geared ring
3.11.11 Alignment of the driving device
3.
Make the final alignment for the stand of the driving device. Pour the foundation
of the driving device, meanwhile; remove the reinforced plate, which is used for
transportation.
3.11.12 Auxiliary parts
3.
Engineer in field should check the sealing on the inlet and outlet, feeding housing,
discharging housing and housing for the kiln outlet, baffle plate etc., and make sure
that whether the installation procedure of these parts are included in the installation
outline or not.
3.2 Storage and inspection of the equipment in field
3. 2.1 Equipment inspection in field
3.2.1
When the equipment reaches the field, it is necessary to inspect carefully to make
sure if the goods are missed or damaged, each item should be inspected in accordance
with packing list. If the goods are found missed or damaged, please inform our field
freight agent or our company as soon as possible.
When taking the supporting parts, which is made of machined surface, off from
the bolster and clamp in transportation, the contact surface should be checked and
coated with protective layer if necessary.

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3. 2.2 Field maintenance for the equipment
3.2.2
Machining surface can be protected by half-dry varnish film and corrosion
prevention treatment has been done. Overseas products can be from America; Tectyl
506 or Veto 342; Domestic products are also available. Asphalt hard film antirust paint
or asphalt transparent film antirust paint.
Among them, some products must be stored in the room; the storage time should
not too long. The overseas products can be from America: Tectyl 511M or Rust Veto
4212；Domestic products are also available:907 antirust grease or 201 antirust oil.
Paint coating surface must use the similar paint, which is suitable for the finish
coat. The surface without painting should be protected so as to avoid contacting the
parts directly.
3. 2.3 Storage of the parts
3.2.3
The field storing place should be with high topography and good drainage,
without hydrocele and loblolly. The stored parts should be placed and covered well so
as to avoid hydrocele, which can make the parts rusted.
Mechanical parts should be placed on the wood stand, wood block or rail, which
are off the flour and separated with the construction field so as to avoid damaging the
parts. Shell and section on the can not be placed on the quadrate bolster but placed on
the stand which is transported by ship. When the shell is adjusted on the straight
bolster, the depression will be formed on the surface of the shell.
The equipment with machined-tooled surface must be covered with canvas or
rain cloth and placed on the reliable field.
The stored parts should be checked regularly to see if there is rust, especially in
the supporting position. The damaged parts must be cleaned up and carried out the
protective treatment if necessary. The regular inspection is according to the climate
condition.
The assembly machine-tooled piece, motor and electric equipment or package
piece in bulk or in paper box, such as: small castings, bolt, nut, welding bar, refractory
material etc., should be stored in the room. The area for storage in room should be dry,

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it is better to equipped with the heating condition.
3.2.4 Size check of the main parts
3. 2.4.1 Check of the foundation
3.2.4.1
1) Check if the foundation is deformed; measure the clearance between the holes of
anchor bolt of the foundation and the height size of the foundation practically, then to make
a good record. Please see the appendix 1 as the reference.
2) Check up the vertical central line and the horizontal central line of the foundation.
3. 2.4.2 Check of the shell
3.2.4.2
1) Diameter check: especially to check the two ends on each section of the shell,
check recording list. (Please see appendix table 3-2 as the reference.). The roundness
tolerance inside the shell should not be over ±6mm; and that for the shell under the tyre
and under the girth gear not over ±2mm; the roundness should be adjusted if this limit
is exceeded. But it is forbidden to adopt the hot-working method. The circumferential
length tolerance is not more than ± 6mm; the flatness tolerance of shell end face is not
more than ± 1.2mm; the verticality between the end face and center line of shell is not
more than ± 1.5mm; the concentricity tolerance of adjacent shell centerline is not more
than ± 1.5 mm.
2) Please see the circumference of the round in check recording list. (See in
appendix table 3-2).
The radial deviation of adjacent shell inner circle should not be more than ± 3mm.
3) The local part of the shell should not be deformed, especially in the position of
interface. For the local deformation, the hot-working or cold-working method can be
adopted for reparation, but the heating time should not be more than two.
4) Check the following dimension for the shell of kiln.
a) The length of the shell;
b) The dimension from the position of the central line of the tyre to the interface
edge of the shell. the tolerance of the length should be less than ±0.025 ％ of the
length.

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3. 2.4.3 Check the clearance (S) between the internal diameter of the tyre and the
3.2.4.3
external diameter of the shell base plate, and check up the dimension of the internal
diameter marked with steel seal on the tyre. Check recording list: (Please see appendix
table 3).
scribe((the content in 3.3 is only for reference
3.3 Foundation acceptance and scribe reference))
Before installing the equipment, the foundation of equipment should be accepted
in comparison with the civil drawing, installation drawing and the actual dimension of
the equipment so as to confirm if there exist problems in the foundation of the
equipment, therefore, the foundation problem can be dealt with ahead to ensure the
quality and schedule of the installation.
3. 3.1 The work for accepting the foundation of the equipment includes the following
3.3.1
items:
The foundation shall be made of the concrete with the strength not less than
20MPa; not until the concrete has reached 80% of the design strength, any operation
on the foundation is not allowed. The acceptance of equipment foundation includes:
a) Check the central line supplied by the civil unit, and check if the point of the
datum mark is correct or not;
b) Check the boundary dimension, dimension of datum mark, physical dimension
of the basic hole and dimension of mutual position in comparison with the equipment
drawing and the flow sheet;
c) Hold the acceptance data and records, and the deviation checklist for each part
of the equipment foundation conforms to the specified requirements.
3. 3.2 Submit the base for installing the equipment; the following requirements should
3.3.2
be obtained:
a) The basic surface should be made rough in order to make two grouts combined
well.
b) All remaining formworks and concrete bar exposed from the concrete etc.
should be removed; the sliver, dirty things and hydrocele in the installation field of the
equipment and hole of foundation should be cleaned up.

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3. 3.3 Modification of dimension of the general drawing
3.3.3
Since the errors of dimension are unavoidable in the process of the machine
manufacture and the civil construction, especially such as the shell with tens of meters and
more than 100 meters in length, composed of many sections, the accumulative error in
length is unavoidable. Therefore, according to dimension of each big section, each tyre
and supporting device, which are measured actually, the theoretical installation dimension
for the general drawing should be modified after calculation and to form a new installation
general drawing so as to be as the basis for installation.
3. 3.3.1 According to the above length measured actually for each big section of the shell,
3.3.3.1
axial space between each thrust roller tyre, the lengths of the kiln outlet and kiln inlet in
the general drawing should be modified. When carrying out the modification, it must be
noticed that the gap on clearance of the shell should not be added. In addition to this, when
installing the equipment, if the ambient temperature is more or less than 20℃, the swell
increment should take the infection of temperature into consideration.
ΔL=L×(T－T0)×α
In the equation: ΔL is the increased or reduced swell increment when the ambient
temperature accounts to T
T0：ambient temperature T0=20℃
L： axial space between two tyres
α：linear expansion coefficient of the steel α=12×10-6/℃
3. 3.3.2 Measure actually and calculate some dimensions related to each tyre and
3.3.3.2
supporting device.
3. 3.3.3 According to the known real data in 3.3.1 and 3.3.2, calculate the horizontal space
3.3.3.3
of relevant testing points and difference of datum mark relative to reference point in the
general drawing.
3.3.4 Check up the dimension of the kiln foundation
Check up the dimension of the kiln foundation according to the modified drawing,
especially for the central distance of the foundation. When there is unconformity, the
following measures should be adopted:
After modification, if the deviation for dimension between the two supporting
devices and central distance of corresponding two foundations is less than 5mm, it is

11
unnecessary to take the measures; when deviation is 5～10mm, it can be adjusted by
lengthening or shortening the axial distance of the tyre. If the requirements can not be
satisfied or when the deviation is more than 10mm, in addition to adjust the gap on the
junction interface of shell segment, position of the whole supporting device should be
adjusted when installing the supporting device, the axial gap dimension for each
supporting device on the drawing should be modified again in accordance with actual
dimension of the shell, which has been adjusted, and calculate its horizontal clearance
dimension and datum mark difference of the reference point, then to be as the final
installation drawing.
3.3.5 Installations of the sign of datum mark
In order to make the checkback of possible depression or inclination of the
foundation, the reference plate supplied with equipment should be embedded ahead on
the position with 1m upper from the floor when pouring the plane of reference, four
blocks of reference plate should be embedded for each foundation, whose position
should close to the four edge angles of the foundation and placed on the corresponding
position with each other. The height of the sign is better to be 1000mm, horizontal line
and vertical line with the same datum mark should be scribed on the plate when
carrying out the installation. Then weld the reference iron on the plate and make the
upper edge of the reference iron close to the reference layout liner.
The topper surface of reference bolt head on each foundation should be on the
same datum mark by filing and turning the face of the bolt head of datum mark as
much as possible. If the difference of sedimentation for each foundation is too much
and such requirement can not be met, the lowest limit is to make the four surfaces
reference bolt head on each foundation has the same datum mark, then fill the
heights(h) of the datum mark and bolt head into the table indicated in appendix 7 for
review. These values of datum mark can be a relative datum height value, which is
based on reference point of permanent mark in factory zone and whose deviation
should be less than 0.5mm. After finishing the whole installation of the kiln (including
bricking), the final check-up for the datum mark should be carried out, then fill the

12
form and give it to the manufacturer. The manufacturer can check the changes of these
datum marks regularly or if necessary. It is easy to obtain the sedimentation or
inclination for each foundation by simple calculation so as to be used in the alignment
of the kiln.
3.3.6 Foundation scribing
3.3.6.1 Scribing the longitudinal central line
According to the requirements in flowsheet, through theodolite or sending out the
wire hammer by drawing steel wire (be careful to avoid the affect of wind power), fix
on two base points on outlet of kiln and inlet of kin respectively, measure the
longitudinal central line of each foundation on the surface of foundation. The central
point should be made by punch on the pre-embedded longitudinal central marking
plate. The deviation should be less than ±0.5mm; sign should be made well around the
punching hole.
3.3.6.2 Scrib ing the horizontal central line
Scribing
According to the revised final installation general drawing, take the foundation
pier as the datum. first, scribe the horizontal central line of the supporting roller group
and then fix the horizontal clearance for each foundation on the horizontal reference
line, then scribe the horizontal central line on upper surface of the corresponding
foundation pier according to the above. Each horizontal central line should be punched
with the central point on the pre-embedded horizontal central marking plate. Deviation
of the central distance for two adjacent foundations should be less than±1.5mm
3.3.6.3 Scribe the longitudinal and horizontal central lines of the pinion and other
driving devices.
When measuring the above horizontal distance, I-grade steel tape should be used
and tightened by spring balance with 5 ～ 8N/m tension. The deviation, which is
caused by affect of temperature, should be corrected accurately.

3.3.7 Sizing blocks and its collocation

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 Before the foundation of the equipment is ready, the size, number of group and
stacking place should be fixed on according to the shape and size of the foundation,
the diameter of anchor bolt, as well as the weight of the equipment.
1) The following equation can be used to calculate the area of the sizing block
when the drawing has not identified the area and distribution of the sizing block
A=C×100×（Q1+Q2）/ R
In equation: A: the area of the sizing block（mm2）
C: safety factor: 1.5～3 is usually adopted, 2.3 is recommended for calculation.
Q1: the load, which is caused by the weight of the equipment adding on this
sizing block group(N),that is, the vertical load given in the general drawing of the kiln
×150%。
Q2: The pressure (N) distributed on this sizing block after because of tightening
the anchor bolt (the permissible tensile strength of the anchor bolt can be adopted.)
R: compression strength （N/cm2 ）of the foundation, cement sand pier or the
concrete of floor surface. (The foundation or the concrete of floor surface can adopt
the design label of concrete, the cement sand pier can adopt the compression strength
of the cement mortar, the compression strength of the concrete can adopt 150 ～
200kg/cm2.）
2) The sizing block should be placed in accordance with the following
requirement:

a) one group of sizing blocks should be placed on the two sides of each anchor
bolt, the rest of sizing blocks are placed on the position of ribbing plate, the space
between the adjacent two groups sizing block should be less than 1000mm；

14
 b) The place where to be placed with sizing block should be relief grinding, the
contact of sizing block and concrete should be homogeneous and closed;
c) The levelness of the upper surface of sizing block is 0.2mm/m；
d) The total height of the sizing block should be less than 30mm；
e) Each group of sizing blocks should be less than 4 blocks, the thickest one
should be placed on the lower position, the thinnest one should be placed in the
medium position, then these blocks should be firmed by point welding after finishing
the spotting.
f) The flat sizing block protrudes the foundation 10～40mm, the oblique sizing
block protrudes the foundation 10～50mm.
3) The sizing blocks should contact closely with each other, so do the sizing
block and the foundation. The contact area should not be less than 70% of the contact
surface. The sizing block and the foundation should not be loose; the length of the
sizing block group protruding the base surface of the foundation of equipment should
exceed the hole of anchor bolt.
4) Before the second grout for the equipment, all of the sizing block should be
firmed by electro welding. (Except for the cast-iron sizing block)
5) The sand pier sizing block should be used in order to ensure the installation
quality of the equipment. The method for manufacturing cement sand pier sizing block
is as follows:

According to the distribution position of the sizing block, the foundation surface
should be roughed and flushed by the water;
The mixed cement mortar should be added with one layer, and added with
another layer with hammer tamping, usually the three layers is proper until the water
comes out;
The finished flat sizing block should be tamped into the sand pier; the surface of
the flat sizing block usually should be 5 mm higher than the surface of the sand pier,
the sand piling height is about 60～80mm (Fig.7);
The datum mark and the levelness of the cement sand pier sizing block should be
measured on the flat sizing block of the steel plate, the deviation of the datum mark
should less than 0.5mm, the levelness should be 0.2mm/m;
Adventitia-off and refinishing of the cement sand pier;

15
Maintenance with water, the equipment can be installed after protecting for 48 hours
when the ambient temperature is above 20℃, when air temperature is a little low, the
maintenance period should be prolonged, when carrying out construction in winter,
heat insulating measure should be adopted;
Place the sand pier flat sizing block directly on the oblique sizing block, total
thickness of the two oblique blocks is 30～50mm.
3.4 The lifting and the handling of the equipment
3.4.1 Before the construction, all lifting and handling tools, such as: steel cable and
pulley, should be inspected and checked calculation, after been confirmed reliability,
they can be used.
3.4.2 When using the various lifting and handling tools, the following regulations
should be observed:
a) When operating the lifting machine, the safety operational rules and relevant
construction safety regulations should be observed;
b) All of the lifting tools should be used strictly.
3.4.3 The following items should be noticed when transporting, lifting the equipment:
a) The special person should be appointed to guide, when lifting and transporting
the heavy equipment, lifting personnel with much experience and high-level skill can
be appointed to guild the construction;
b) When transporting the equipment, the unloading field, the situation of roads for
transportation, the installation position, direction of the equipment, as well as the
transporting sequence should be known well ahead in order to avoid doing work over
again.
The horizontal transportation of the parts should keep balance, it is forbidden to
be inverted or upright at random.
The cylindrical parts, such as: segment of the kiln, tyre and supporting roller, must be
fixed on the tie frame reliably, then underside supported with rolling bar, dragged by
whim, being dragged forward on the floor or rolling bar is not allowed.
c) When lifting the equipment, it must be lifted according to the lifting position
marked when leaving factory. If there is no obvious sign, the median point should be
found ahead to confirm the forced position, the lifting hook or slinger screws on the
some parts, such as: reducer cover, bearing housing; as well as the lifting holes on the
end of gear shaft and the supporting roller shaft are just used to lift themselves, it is not
allowed to lift the whole assembly parts, these above related aspects should be noticed;

16
 d) Hoisting rope can not be contacted with the machined surface or corner angle
directly, it also be padded with the board, rubber to avoid the machined surface being
damaged and cutting the hoisting rope;
e) When the weight of the lifted equipment is approaching the permissive lifting
capability of the lifting machine, test-lifting should be carried out before lifting, the
lifted objects and the machine should be examined to see carefully if there is change
abnormally; after confirming the safety and correctness, object cab is lifted.
Please see the weight of each heavy part in the installation specification of this
equipment;
f) When lifting with more than two steel cables, each of steel cable should be
stressed equably, the included angle formed with steel cable and pendulum wire
should be less than 30°;
g) When the hoister is lifting near the transmitting line, the closest distance
between machine, equipment and the transmitting line should be comply with the
provisions stipulated in the following table.
Distances between machines, equipmentAnd the transmitting line
Voltage of the transmitting line (KV) ＜0.4 3～10 35～110 ≥220

Closest distance (m) 1.5 2 4 6

h) When lifting the equipment by two set of hoister, the permissive load of the
hoister should be used as a reference of 20% reduction of the rated load.
3.3.4 In order to install and spotting the large geared ring and the shell of kiln, the shell
of kiln need turning, steel cable can be wound on the shell of kiln, then dragged with
winding engine or winch. When selecting the diameter of the steel cable, the safety
factor should be more than 2. The steel cable should be lead out through the pulley,
which is hung on the hoister or chevron crane boom, because the friction of the
supporting roller shaft and the bending moment acting on the shell is minimum when
pulling force is upward. When welding the shell, it is better to install the plate kiln
temporarily by using the driving device, which is very useful in the equality of speed
and shortening the working time when welding the interface of the shell.

17
 Appendix Table 3-1: Dimension checking list for each part of foundation of equipment
(only for reference)

Unit: mm

Base Clearance of the anchor bolt hole Base height

Remark
No.
l1 l2 l3 l4 l5 l6 l7 l8 l9 l10 l11 l12 h1 h2 h3 h4

installation Representative
Date
unit of the unit

Construction Representative Date

unit of the unit

18
 Appendix Table 3-2: checking and recording list for the two match diameter and the
peripheral length (only for reference)

unit：mm
Specification
Measured diameter Calculated value
requirements
Difference
Interface Differen rema
Difference of of the Difference
number ce of rk
D1 D2 D3 D4 the diameter interface of the
circumfe
Dmax-Dmin circumfere diameters
rence
nce
1’
1
1”
2’
2
2”
3’
3
3”
4’
4
4”
5’
5
5”
6’
6
6”
7’
7
7”
8’
8
8”
9’
9
9”

Installation Representative
Date
unit of the unit

Construction Representative Date

unit of the unit

19
 Appendix Table 3-3 ： Clearance between the internal diameter of tyre and external

diameter of the base plate of kiln shell (S)

Unit: mm
Measured
Examined and
clearance
measured data steel
value
seal
The The requirements
Filing value
internal external of the design deviation remarks
No. of the
diameter diameter drawing
S=d-D tyre
of the of the shell
d0
tyre baseplate
d D
Ⅰ

Representative
Installation unit Date
of the unit

Representative Date
Construction unit
of the unit

Remarks: 1. the internal diameter of tyre should be measured at least 4 places on the
circumference, and get the average value.

2. The external diameter of the shell baseplate should be measured at least 3 places within the
width of tyre. Its circumference can be measured by I-grade steel tape ， and then add 2 mm to

20
calculate its external diameter appreciatively, the pulling force of the steel tape is about 200N when
measuring.

21
 Appendix Table 3-4 Dimension inspection recording sheet for each part of the
foundation for the equipment
Unit: mm
Inspection record Remarks
Error I Span II Span
Item
allowance
Initial Observed Error Initial Observed Error
data data data data
External
dimension of the ±30
foundation
Longitudinal
Coordinate center line ±20
position of
the
foundation Horizontal
±20
center line
Height mark of the top
surface of the foundation 0～-20

Distance between centre

lines 1

Height mark of the basic

point relative to the height
mark of the zero point in ±3
the workshop
Mutual
centre ±10
Foundation positions
hole Depth 0～+20
Verticality 5/1000
Pre-buried Height mark
0～+10
foundation of the top
bolt Center
±2
distance
Height mark
0～+10
Center
Pre-buried ±5
position
steel plate Levelness 1/1000
parallelism 10/1000
Civil construction Representative
organization
Date

Construction unit Representative Date

Installation unit Representative Date

Note: The span in the table should be calculated from the outlet to the inlet.

22
Appendix Table 3-5 Recording sheet for the height mark on the top surface of the
height mark bolt head and the height of the bolt head

Unit：mm
1 2 3 4
Foundation
Height h Height h Height h Height h
Ⅰ
Ⅱ

Installation Represent
Date
unit ative
Construction Represent
Date
unit ative

23
4. Installation of the supporting device
Whether the centre line of the rotary kiln shell can stay straight during the
operation depends firstly on the installation of the supporting device, therefore, to
which high attention should be paid.
Select the supporting rollers with the similar taper as a group before installing,
measure the tyre taper and match the supporting roller group of great taper with the
tyre of great taper. The large side of each supporting roller group should have the same
orientation, and opposite to the large side of the tyre.
4.1 Alignment of the base frame
4.1.1 Longitudinal and horizontal alignment of the base frame
(a) Use the theodolite or steel wire, wire weight and straight rule to make the
longitudinal centre line marked on the top surface of the base frame coincide with the
longitudinal centre line of the foundation. The offset should not be more than ±0.5mm.
(b) There are two methods to determine that the horizontal centre line on the top
surface of the base frame coincides with the horizontal centre line on the foundation:
Method A:
Firstly calculate the distance S between the horizontal centre line of the
foundation and the projection line on the foundation by the horizontal centre line on
the top surface of the base frame on the basis of distance h between the top surface of
the base frame and foundation surface as well as the kiln inclination indicated by angle
α. Use the straight ruler and wire weight to align according to the above. See the
following figure a.
Method B:
Put the flat steel with two machined sides on the foundation and then align the
inclination of the top surfaces of both flat steel and base frame by use of taper gauge
and level gauge in compliance with the inclination of the kiln. Finally put the right
angle ruler on it to confirm that the horizontal centre line on the top surface of the base
frame coincides with the horizontal centre line on the foundation. See the following

24
figure b.
Whichever method is used, the offset of two horizontal centre lines should not
exceed ±0.5mm:
S=h×tga

When i=4.25%: tga=0.042538.

Horizontal alignment of base frame of supporting device

1. Straightedge 2. Horizontal centre line on the top surface of the base frame
3. Wire weight 4. Horizontal centre line on the foundation
5. Right angle ruler 6. Flat steel
alignment))
4.1.2 Mutual alignment of the base frames (Overall alignment
The base frames should meet the following requirements:
a) The allowable deviation of the centre lines for two adjacent base frames should
not be more than 1.5mm.
b) The allowable deviation of the height marks for two adjacent base frames
should not be more than 0.5mm.
c) Take measures to ensure the base frames are installed parallel to each other and
vertical to the centre line of the shell, and the permissible error is 0.1mm/m.
Specific alignment method is as follows:
1) Elevation difference
2) Firstly use the foundation pier of the supporting device with thrust roller as the
reference point to compare the elevations of the kin inlet and outlet and then align
according to the elevation difference on the final corrected general drawing.
3) The elevation difference can be aligned by means of theodolite or level gauge.
But attention should be paid to the fact that the measuring point should be located on

25
the horizontal centre line of the top surface of the base frame of the supporting device
and the measuring points on the base frames should be in a straight line coinciding
with or parallel to the longitudinal centerline.
4) Horizontal leveling: Horizontally level the base frame of the supporting device
by adjusting sizing block. Horizontally level the base frame at 4 to 6 symmetrical
places of top surface of the base frame by means of the level gauge of 0.02/1000. The
deviation should not be more than 0.05mm/m.
5) Longitudinal inclination adjustment: By adjusting the sizing block, make the
longitudinal inclination of the top surface of the base frame meet the design
requirement. The allowable deviation of the inclination for the machined surface of the
base frame should be within 0.05mm/m. The sizing block should be adjusted
horizontally and symmetrically to ensure the ready horizontal level. The inspection of
the longitudinal inclination should be carried out by use of level gauge for horizontal
alignment. Put the slope gauge under the level gauge.
6) Comprehensively level and recheck the horizontal level again. In case of any
deviation, adjust again. Repeat the above two steps until the horizontal level and
longitudinal inclination are up to standard.
4.2 Installation of the bearing units for the supporting roller
4.2.1 General description for the structure of the supporting roller bearing unit
Due to the heavy bearing load of the rotary kiln, the pellet rotary kiln usually
adopts the supporting roller rolling bearing unit. The unit is composed by supporting
roller, roller shaft, rolling bearing, and base frame, etc.
4.2.2 Alignment of supporting roller bearing units on the base frame
1) Maker sure that the longitudinal centerlines marked on the surface of the base
frame coincides with that on the foundation, and the deviation is within ± 0.5mm.
2) The allowable deviation of the centrelines between two adjacent base frames is
not greater than 1.5mm, and that of the elevation between two adjacent base frames is
not greater than 0.5mm. Refer to Table 4-1for the record form.
3) The axial centre lines of four bearing blocks of the supporting rollers should be

26
parallel to the longitudinal center lines of the base frames of the supporting devices. In
the meanwhile, ensure that the distance between the axial centre line and the
longitudinal center line should be in compliance with the dimension on the revised
general drawing with the deviation within ±0.5mm. The horizontal centre line of the
supporting roller should coincide with the horizontal centre line of the base frame with
the deviation within ±0.5mm. The inclination deviation of the supporting roller shall
be within 0.1mm/m. The line connecting the two centre points on the top surfaces of
two supporting rollers of the same supporting station should be horizontal in the
transverse direction with the deviation within 0.05mm/m. Take Table 4-2 as the
reference for the record list.
4) The deviation of the dimension L of the horizontal center-to-center spacing
between the rollers with the adjacent stages is within ± 1.5mm, the relative difference
of L1 and L2 is not greater than 1mm, and the difference of the diagonal a & b is not
more than 3mm. Refer to Table 4-3 for the record form.
Install the supporting device, adjust the rollers to keep parallel, and then make the
lead wire-rolling test on the lines of contact to ensure over 90% of the line contact ratio;
the lead wire should be rectangular after rolling.
4.5 Installation of hydraulic thrust roller
4.5.1 General instruction for the structure of the hydraulic thrust roller device
The structure of the hydraulic thrust roller device is composed by cylinder, lever,
thrust roller and shaft, guide roller, rolling bearing and support, etc. The pressure oil of
the hydraulic station for the thrust roller enters into the cylinder to push forward the
piston rod in the cylinder in order to drive the thrust roller then the whole rotary kiln
shell moving upwards. When the shell moving to some distance, that is high-limit
position, the high-limit switch is touched, so that the valve in the hydraulic oil station
commutates and the motor of the oil pump stops. The oil in the cylinder flows to the oil
reservoir under the function of the kiln gravity. The kiln and supporting roller move
downwards slowly. When moving to the lower-limit position, touching the lower-limit
switch, so that the valve commutates and the motor of the oil pump starts. And then the

27
pressure oil slowly into the cylinder and the thrust roller drives the kiln shell moving
upwards. In this way the shell moves up and down within the specific stroke
constantly and repeatedly.
1. Cylinder 2. Lever 3. Pin shaft
4. Trust roller 5. Guide roller 6. Base frame

Structural sketch of the hydraulic thrust roller

4.5.2 Things should be paid attention to when installing the hydraulic thrust roller
device
The installing position of the hydraulic thrust roller device should be in
compliance with the regulations on the design drawing. The thrust roller should be
tightly contact the tyre. The axis of the conical hydraulic thrust roller device should be
on the longitudinal center line of the base frame of the supporting device for the thrust
roller. In order to ensure not to deviate to the wrong direction, the thrust roller can be
offset 2~3mm relative to the longitudinal center line of the shell for the kiln when
adjusting. Therefore the thrust roller is on the side of rotating downwards of the shell
for the kiln.
The hydraulic thrust roller and the tyre shall contact well. After installation the
linear contact ratio between the conical surface and the tyre shall be more than 75%.
After installing the hydraulic thrust roller device, rotate the thrust roller manually
for inspecting. There should not be fasten, tighten and blocked. In the meanwhile,
push the thrust roller manually. The thrust roller can slip on the two axles without
blocked.
Install the limit switches for the thrust roller after assembling and adjusting the
hydraulic thrust roller. The zero position of the hydraulic thrust roller should be the
position for the center line of the thrust roller when the center line of the tyre of the

28
driving device coinciding with the center line of the supporting roller.
4.5.3 Installation for the oil pump station of the thrust roller
Owing to the different specification of the rotary kiln, different size of the
hydraulic thrust roller, different oil pump station of the thrust roller, for the detail
installation see the installing instructions attached with each oil pump station.
4.5.4 Installation of the foundation bolts
Installation of the foundation bolts shall meet the following requirements:
1) to reserve 2-4 pitches after tightening the nuts;
2) to make sure that the nuts and pads as well as the pads and the equipment are
well- contacted;
3) to keep the mounting surface vertical to the bolts which are forbidden to touch
the inner wall of the foundation hole;
4) to keep the fasteners clean and apply oil on the screw thread to avoid rust.

29
 Appendix Table 4-1: Record form for installation of the base frame of the support
device
Allowable Measured
Inspection items Remarks
deviation (mm) value

The deviation of the

≤±0.5
base frame longitudinal centerlines

deviation of Stage 1 The deviation of the

≤±0.5
with the horizontal centerlines

foundation The deviation of the

≤±0.5
centerlines base frame longitudinal centerlines

of Stage 2 The deviation of the

≤±0.5
horizontal centerlines

The allowable deviation

Stage 1 ≤1.5
Relative of the centerlines
and Stage
deviation The allowable deviation
2 ≤0.5
of the elevations

Installation unit Representative Date

Construction unit Representative Date

30
 Appendix Table 4-2: Record form for installation of the kiln supporting device

spacing spacing between top surface

slope
between the the horizontal levelness of
deviation of thrust
supporting centerlines of the the same
Name of items the ring Remarks
roller axis and supporting roller stage
supporting clearance
the base frame and the base supporting
roller
centerlines frame centerlines roller

Allowable deviation ≤0.5mm ≤0.5mm ≤0.1mm/m ≤0.05mm/m

supporting
Stage 1
roller1
supporting
supporting
device
roller2

supporting
Stage 2
roller1
supporting
supporting
device
roller2

Installation unit Representative Date

Construction unit Representative Date

31
 Appendix Table 4-3: Record form for installation of the bearing group of the
supporting roller

The diagram of the horizontal spacing between the roller groups of two adjacent
stages
1. supporting roller 2. base frame

Spacing deviation between the

longitudinal centerlines of the
Inspection items supporting rollers Remarks
Allowable Measured
deviation (mm) value
Spacing deviation between the
longitudinal centerlines of the L1 ≤±1.5
supporting rollers
Spacing deviation between the
longitudinal centerlines of the L2 ≤±1.5
supporting rollers
Stage 1 and
Spacing difference of the
Stage 2
centerlines of the supporting L1-L2 ≤1
rollers
Length difference of the
a-b ≤3
diagonal of supporting rollers
The height deviation of the
≤0.5
supporting rollers
Installation
Representative Date
unit
Construction
Representative Date
unit

32
9. Test run of the rotary kiln
After finishing the installation inspect the location, inclination and lubrication
condition of each part. After confirming that the requirements in drawing and technical
documents are met, the test run can be performed.

9.1 Preparation before test run

reparation
1) Check whether there is any change on foundation elevation, measure the
subsidence volume of kiln pier and make records;
2) Check whether tighten up the joint bolt in everywhere, especially for anchor
bolt, the joint bolt of roller bearing ,fixed bolt of catch wheel , girth gear counterpart
bolts, etc.;
3) Check the condition of thrust roller system
4) Check whether is there any obstruction of small tools and sundry, welding slag,
etc. in everywhere,especially for girth gear, pinion, the gap between the tyer and plate,
the gap between the tyer and roller. Where needs carefully check the clearance ;
5) Check the meshing condition of girth gear and pinion.
6) Check the sealing condition of preheater and cooler
7) Check whether all lubricating points add sufficient lubricant according to the
lube system.
8) Open the cooling water valve in everywhere, and make the water flow freely;
9.22 The test run of single unit
9.
9.2.1 Time of test run
1) Time of test run before bricklaying
The no load test run time for the hydraulic pump and fluid motor shall be more
than 2 hours (or according to the fluid motor manufacturer’s instruction).
The fluid motor driven equipment are respectively in slow speed, working speed
and maximum speed running for more than 24 hours (or according to the fluid motor
manufacturer’s requirement).
The operation should be smooth, and without any jam or loosening. Girth gear,
rotating deviation of kiln outlet and inlet should be within the error range. Each
rotation of the rotating parts should be continuous and uniform, and hydraulic limit
should be controlled precisely.
9.2.2 Operation requirements for the shell after bricklaying

33
 After bricklaying and drying kiln, requires a test run without material, the
operation needs more than four hours.
If the time between kiln heating/drying and bricklaying is too long, run 90°or
180°for the shell every 7days to avoid deforming of the shell. At this time, it is not
permitted to start the fluid motor to drive the kiln shell.
kiln heating/drying and running of the shell of kiln heating/drying is performed as
per the debug plan from the manufacturer.
9.2.3 Inspection during operation
1) Inspection during operation before bricklaying
Check the lubrication condition and temperature rise of each part, and the
temperature rise of rolling bearing should be no more than 25℃. Check for oil leakage.
And check the oil and water supply of the pulley bearing.
2) Check whether there is abnormal noise like vibration-impact on the driving
device, whether the mesh and contact of the bull gear and the pinion conform to the
requirements.
3) Check whether the contact of the tyre and the supporting roller is normal.
4) When test the hydraulic trust roller, check the up velocity and down velocity of
the kiln during the running of the kiln, adjust the up and down speed not more than 2-3
mm/h, to avoid the up and down slide velocity too fast the flank of girth gear and
pinion and the surface of supporting roller of the tyre be scraped.
5) Check whether the sealing devices on both ends of the shell are in good
condition, over-sized air leak clearance or noticeable wear are not permitted.
6) Check whether there is looseness on each attachment bolt.
9.2.4 Inspection during running after bricklaying
After bricklaying, the test run and kiln heating/drying are taken at the same time.
The following checks are required:
1) Check the lubrication condition and temperature rise of each part, and the
temperature rise of rolling bearing should be no more than 35℃. Check for oil leakage.
And check the oil and water supply of the pulley bearing.
2) Check whether there is abnormal noise like vibration-impact on the driving
device, whether the mesh and contact of the bull gear and the pinion conform to the
requirements.

34
 3) Take particular check in whether the supporting roller is adjusted correctly, and
whether the supporting roller and the surface of the tyre is uniform contact. One of the
checking methods for adjusting the supporting roller is galvanized wire inspection
method.
4) Other rules and inspection items are the same as the test run before bricklaying.
9.2.5 Inspection after a period of trial production
After a period of heat loading trial production, carefully observe the thermal
elongation of the shell. After stabilizing the position, adjust the limit again to mesh the
girth gear and pinion gear. Kiln body can move up and down in the range of ± 40mm.

35
10. Operation and maintenance
10.1 Preparatory work before start
10.1.1 To inspect following items before ignite the rotary kiln:
1) Inspect whether brick crevice of brick lining for each section is straight, crevice
meet the requirement of masonry; whole surface should be smooth, not allow have
step, masonry should be solid and brick lining not have damage or deformity.
2) Inspect whether the position of blanking slope is right, and the liner size on this
slope is right or smooth;
3) Inspect whether the contacting condition or surface for tyre and supporting roller
have crack, defect and clean the surface of supporting roller;
4) Inspect whether the position for tyre and supporting roller is right;
5) Inspect whether the tooth of gear is damage and the meshing condition of bull gear
and pinion in the drive unit;
6) Inspect whether the seal of seal installation is good;
7) Inspect whether have the condition of loose, crack and falling about match bolt and
each coupling bolt;
8) Inspect whether have crack on each welding seam of shell and have fracture or
sinkage on each foundation or not;
9) Inspect whether have enough oil in the bearing set of supporting roller, or have the
situation of oil leak, and lubricant is clean or not;
10) Inspect whether the lubricant has solidified in winter, provided that it has solidified
that required to heat, oil temperature should over 10℃ about oil solidification point;
11) Inspect whether water pipe, valve and joint of each cooling installation is damage,
water flow is unimpeded or not; whether have the situation of water leak or blockage,
water is enough or not;
12) Inspect whether the circuit of monitoring instrument is connected, the measuring
position is right or not; whether the measuring point component is excellent, the
arresting gear of rotary kiln and each switch is flexible and reliable;

36
13) Inspect whether the test run of accessory equipment is normal or not;
The worker who observing fire could send the contacting signal so that enter into
the procedure of igniting after confirm the treatment of all problems during inspection
is qualified and inspect no people in the kiln and accessory equipment.
10.1.2 Ignition
10.1.2
Please see the commissioning manual and process operation manual prepared by
the commissioning engineer for the detailed ignition procedure. Here only the
following is emphasized:
1) The procedure of igniting is linkage process which closely match with rotary
kiln, kiln end and kiln head system, moreover should prudently operate that take the
temperature of kiln end as control point. First of all we should care about safety, must
not look inside of kiln when fuel is not yet light enter into kiln, meanwhile can not
stand person in front of kiln head. We should pay attention to the correct fit of
ventilation system on kiln end. In the second place, we are strictly in terms of
commissioning routine decide when feed to the kiln and how much feeding we need,
match with kiln speed;
2) It should pay special attention to the heating/drying of new kiln and first
igniting, need operate strictly according to the heating-up curve of commissioning
scheme, the gradient of temperature rise can not be large and should have a certain
temperature retention time. It is necessary for equipment except the need of masonry;
at the time of heating-up, temperature rise of kiln shell will faster than tyre, if it can not
control well, the clearance will disappear between them, easily cause the phenomenon
of “constriction”, affect normal operating of kiln; at this time we must time the
variable situation of its clearance, adjust temperature rise and make the clearance to
2mm probably, meanwhile we should determine the time interval and angle of
dumping kiln according to the actual temperature curve;
3) The operated kiln stop run that has a same strict operation in accordance with
regulation as 2) when the kiln reignite. However, there are some different points that
have no stage of heating/drying kiln, time interval and angle of dumping kiln.

37
10.2 The operation of start and stop of kiln
10.2 .1 Start of kiln
10.2.1
The start of the kiln shall be performed according to the instructions of fluid
motor’s manufacturer.
10. 2.2 Stop of kiln
10.2.2
Sometimes we should have a short stop for inspecting and repairing as required
during the production; sometimes stop kiln for a long time and carry out maintenance.
We should reduce stopping the kiln, but it can not be avoided. No matter stopping the
kiln for a long or short time, get in touch with related production personnel before
stopping.
10. 2.2.1 Stop kiln for a long time
10.2.2.1
1) If anticipating time of stop kiln exceeds 4 hours, operate according to long-
term stopping procedure; at this moment we should notice that reduce feeding before
stopping, control kiln end temperature below normal index. Wait for the kiln end
temperature go on dropping, further reduce feeding until stop feeding into the kiln.
2) Pull out the burner when the kiln stop working; discharge part or all of the
material from inside the kiln in accordance with the maintenance condition.
3）Not immediately stopping the cooling water to the bearings of two supporting
rollers near the kiln head after the kiln stops; it can’t be closed until the kiln shell cools
down.
4) The kiln is hot when it just stops; if not rotating the kiln shell frequently and
regularly, on the one hand the center line of kiln is easy to bend; on the other hand, the
static friction between each tyre and supporting roller produces tensile stress on the
kiln shell during the cooling and shrinkage of hot kiln shell. Moreover, this stress
constantly increases until overcoming the friction between tyre and supporting roller,
which produces a relative replacement between tyre and supporting roller and releases
the internal stress of kiln shell. But before the internal tensile stress of kiln shell
overcomes the friction between the tyre and supporting roller, it will transmit to the
tyre with thrust roller and take effect on the thrust roller and foundation. Under this

38
situation, the axial force acting on the thrust roller is considerable, which is the total of
friction between each tyre and supporting roller except that on the support device of
thrust roller. Such a large axial force will be hazardous to the thrust roller and
construction foundation, if not regularly rotating hot kiln shell till it’s cooling down. In
the practical condition, there was the foundation of thrust roller device overturned or
horizontal crack on the civil foundation in some plants; all of these questions were
caused by improper operation of hot kiln stopping. Therefore, it is the most important
and precautious work to ensure that rotating hot kiln shell till cooling down according
to the specification when stopping the kiln for a long time, which is to ensure the
kiln center line not bending and no failure on the equipment and civil foundation.
After the kiln cools down, if stopping the kiln for a long time, the kiln shell
should be rotated 90° or 180° every seven days to avoid deforming and bending of kiln
center line.
10. 2.2.2 Stop kiln for a short time
10.2.2.2
1) If stopping the kiln for not more than 30 minutes, we should:
Stop feeding;
Stop adding fuel, but the fan should go on running for a while to cool the nozzle;
Slightly turn down the gate of exhausting system;
Rotate the kiln for half ring once every 10 minutes after stopping the kiln.
2) If stopping the kiln for more than 30 minutes, do as follows besides the above:
Lower the kiln temperature not too fast; close the fan at kiln end, stop exhausting;
Rotate the kiln and make inspection according to the regulation of long-term
stopping after the kiln stops.
3) Inspect the following items after stopping the kiln:
Whether part of water coolant has completely discharged;
The situation of each wearing surface, the clearance between shaft and bush, the
clearance of gear and pinion;
Whether there is loosening or damage on all the connecting bolts, especially that
for the girth gear, kiln shell and spring board, and if there is crack on the weld seam of

39
shell;
Whether the lubricant of oil site needs to be replaced, cleaned or replenished. If
necessary, drain off the oil, clean up, and replenish with new lubricant;
Whether it is necessary to adjust or replace the wearing parts for the thrust roller,
seal at kiln head and kiln end.
10.2.3 Requirement of the operation and the maintenance of hydraulic thrust
roller
There is the hydraulic thrust roller for the kiln, the installation of supporting roller
and tyre should be with the axis parallel, kiln shell gliding under its gravity. After it
comes to a certain position, start the hydraulic pump by the limit switch and push the
thrust roller by the pressure of hydraulic oil to realize the upward playing of kiln. At a
certain position trigger the limit switch, oil pump power off, reversing valve changing
direction, and the kiln shell glides again by its self weight.
Refer to the specification of thrust roller oil pump station for the specific
operation requirement, here only emphasize:
1) Strictly control the speed of up playing and gliding of the kiln, normally below
2 ～ 3mm/h. Otherwise, there is the danger of scratching the drive gear, supporting
roller and tyre because the kiln moves too fast;
2) Frequently observe the reading of manometer at oil pump station, control it
within the setting range;
3) Not allowed to start the oil pump when stopping the kiln or rotating the kiln by
using auxiliary drive; the position of thrust roller should meet the requirement of the
assembly drawing of the rotary kiln when stopping the kiln for a long time;
4) Strengthen maintenance for the oil pump station, establish strict work
responsibility system to ensure the safe operation of the equipment.

10.2.44 Inspection and maintenance

10.2.
10.2.4.11 Inspection during production
10.2.4.
1) Inspection of drive system
a) Drive system

40
 Inspect the running condition of the fluid motor, ensuring the electric current is in
the specified value; if the value suddenly increase, then we must ascertain reason and
deal with it in time;
Inspect whether have vibration, abnormal noise and smell;
Inspect whether the foundation bolts are loose;
Inspect whether operating is steady and meshing sound of gear is normal;
Inspect whether have vibration and oil leak;
Open the gear cover to inspect whether the gear has pitting corrosion and grit
wear according to requirement when stop kiln, if necessary.
b) Driving bull gear, pinion and bearing
Inspect whether the drive unit of gear run smoothly, have some knocking noise or
not;
Inspect the contacting spot of bull gear and pinion on gear surface, which is not
less than 40% along tooth depth and is not less than 50% along tooth length;
Radial and axial wobble of bull gear;
Whether the gear with oil is flexible, oil of tooth flank is enough, viscosity of oil is
suitable and have abnormal smoke or not;
Inspect whether the temperature rise of drive bearing is normal, seal installation is
effective, have oil leak and abnormal phenomenon or not;
Whether ground bolt of drive installation and other coupling bolt have loose, affect
vibration and wobble.
2) Inspection of tyre and supporting device
a) Inspect whether the clearance between tyre and backing plate is normal, there
is abnormal noise, baffle plate, pressure plate and reinforcing plate are effective and
welding seam cracks;
b) Inspect contacting situation and surface wear about tyre and supporting roller;
c) Inspect the jump of kiln shell, adjust supporting roller and control kiln shell
jumping in time. Each thrust direction should be identical for supporting roller. The
pressure supported by each supporting roller should be uniform; the identifying
method generally is see glossiness of contacting surface between tyre and supporting
roller. If contacting surface is shinny that forcing is greater, on the contrary forcing is
lesser;
d) Inspect whether water coolant in the spherical bush is running smoothly;

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 e) Inspect whether temperature rise of supporting roller bearing is normal;
f) Inspect whether rotation of thrust roller is flexible, or have shine, fluff or heat
and noise of bearing on the surface of thrust roller owing to forcing is too great.
g) Inspect whether ground bolt of supporting device have loose or crack;
h) Inspect whether foundation have vibration and local settlement.
3) Inspection of kiln shell
a) Inspect temperature variation on the surface of kiln shell, avoid the red kiln
accident of drop brick and provide the basis of where and when to replace firebrick.
Pay special attention to: the maximum temperature of kiln shell surface should not
exceed 400℃, otherwise it will cause a danger of crack because of a remarkable
reducing of intensity and rigidity for the steel plate of kiln shell;
b) Inspect whether the butt weld of kiln shell have crack or not;
c) Inspect whether kiln shell have serious wobble or not, whether the play of kiln
shell is steady.
4) Inspection of the protecting plate of kiln outlet and inlet hood
Check if there is the condition of loose, deformation and shedding at the
protecting plate of kiln outlet and inlet hood.
5) Inspection of sealing device for kiln inlet and outlet
a) Inspect whether parts of sealing device have serious wear and damage or not,
whether the coupling bolt have loose and fall off;
b) whether sealing component is complete and effective, the position of sealing
friction have a good contacting and have a serious air leak.
mainteenance
10.2.4.2 Matters needing attention during daily running and maint
1) Inspect drive system, support device and thrust roller system frequently (every
hour), abnormal situation such as noise, vibration or heat (if any) should be handled in
time;
2) Inspect whether the lubricating of all lubricating point is normal, inspect
whether oil is enough or not frequently in terms of lubricating system strictly;
3) Inspect supporting roller’s bearing temperature and its lubrication condition
every hour;
4) Ascertain clearance and wear according to rotating relative displacement
between tyre and backing plate. Check and record the clearance of tire and pad when
stop the kiln, and the gap value can not be too large or too small. The pad should be

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replaced at the time when the gap is too large or too small;
5) Observe the regularly up and down jumping condition of kiln shell (jumping
once per day);
6) Observe whether water from each cooling water outlet flow smoothly;
7) Observe the temperature of kiln shell frequently. During manufacturing and
operation, surface temperature of the shell should be controlled below 220 ℃, and
local temperature in short time must not exceed 240 ℃. Once the local temperature is
too high during the production, adjust production operations and take the necessary
measures to reduce the surface temperature of the shell to prevent accidents. Only
under the accidental situation, allow to reach 400℃. If continue operating without
treating when the temperature exceed 400℃, it means operation against rules;
8) During the operation of rotary kiln, must rotate in the direction according to
the installation requirement strictly. Rotate in the opposite direction IS not allowed
under any condition;
9) During the operation, the welding condition of guard at the spring plate and
shell, wheel down float stopper plate, etc. should be often checked to prevent sealing
off;
10) During running, pay attention to the contact condition of thrust roller and tire,
tire and roller station, girth gear and pinion gear. Adjust timely if they can’t contact
uniformly.
11) The service condition of rubber guard ring should be observed frequently
during running, phenomenon of deformed and dropped off are not allowed, and the
rubber guard ring should be replaced if there is any problem;
12) The rotary kiln should be retarded cooling when it is stopped and under
maintenance, and water cooling is not allowed;
13) Before rotating the kiln, confirm the cooling water and intelligent lubrication
system has been turned on and working normally. Confirm hydraulic system of fluid
motor and lubrication system of hydraulic thrust roller has been turned on and working
normally.
Make sure that the problems be handled properly according to nature of them,
pay attention to safety, the inspection of some items should be checked after stop kiln.
10.2.4.3 Inspection of uneven settlement of foundation

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 Rotary kiln is a device that is big and heavy. Kiln shell support is on many
independent foundations of kiln abutment, the settlement of foundation is inevitable.
But if excessive settlement or uneven sinkage on each kiln abutment appears, it will
affect the linearity of kiln directly, which make kiln to bend and deform and bring
harm to safe running. Meanwhile kiln outlet end of rotary kiln connects to cooler and
kiln outlet cover, kiln inlet end connects to preheater; the uneven sinkage of these
equipment and kiln abutment will bring harm to connecting parts and directly affect
seal effect of inlet and outlet end of the kiln. So it is necessary to inspect the
foundation settlement of these equipment.
1) Inspection of foundation settlement of kiln abutment
Level measuring point is the basis for settlement of kiln abutment, it has been set
on the side of each kiln abutment and has been measured and recorded when installing
equipment. Observe and measure the level of these points stage by stage from the
beginning of installing rotary kiln.
a) The foundation of kiln abutment may be have a maximum vertical settlement
of 15mm from equipment installing to test run. So we need to measure foundation
settlement before test run and adjust the position of supporting roller for support
device according to measuring result in order to make the center line of kiln shell
restore to design position;
b) Within 6 months at initial stage of running, the foundation of kiln abutment
still may have a maximum settlement of 5mm, so we should measure the foundation
settlement of kiln abutment frequently during this period;
c) After running 6 months, the foundation of kiln abutment still may have a
settlement of 1mm every year, so if necessary we should also measure the foundation
settlement.
2) Analysis and treatment of foundation settlement
It is hard to deal with tilt settlement for the equipment itself, so relative vertical
settlement for each kiln abutment is allowed but tilt settlement of foundation is not
allowed:
a) When vertical differential settlement of each kiln abutment is over 3mm, it is
necessary to adjust roller position of relative supporting device, but the included angle
between the center of two under rollers and center of tyre should be 60°±2°.

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 b) The differential settlement of kiln abutment of outlet and inlet cannot over
25mm, and the differential settlement of foundations for cooler or preheater which are
correspond to the kiln abutment also cannot access 25mm. If the settlement have
exceeded or affect the sealing, the related part must be treated until it is satisfactory.

10.2.4.4 Lubrication and cooling

Good lubrication for various lubricating parts is very important. Reasonable
lubrication can prolong service life of parts and reduce repairing fee, so we have to
consider lubrication as a very important mechanical part.
Pay attention to the following points for then lubrication and cooling:
1) Lubricating oil and grease should be used in accordance with specification.
Trial product must be used in accordance of the performance requirements of oil
quality.
2) When oil is leaking, measures should be taken immediately to prevent leakage,
oil leaked to the foundation should be cleared promptly to avoid foundation corrosion.
3) After a long time stop, the kiln can only be started according to the specific
starting requirement for long time stop condition.
10.2.5 Common failure and solution
When the failure appears in the process of operation, the treatment should be
different according to specific conditions. Major problems should be investigated,
analyzed and discussed among using unit , manufacturing unit and design unit.
10.2.5.1 The possible reason and phenomenon which cause failure of rotary kiln:
1) Lubricate for driving gear and supporting roller is not good, and the
temperature of bearing is too high;
2) Hydraulic thrust roller system failure;
3) Kiln jumping cannot access permissible range to damage the sealing of outlet
and inlet and cause the air leaking;
4) Poor contact of gear and pinion, supporting roller and tyre;
5) Driving system trouble;
6) If supporting roller displaces or the center line of supporting roller and rotary
kiln are not parallel, will cause inner force excess;
7) In interlocking condition, the system will start jump-stop protection

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 automatically as programmed control requirement. In unlocking condition, the
corresponding treatment should be:
Material feeding, fuel feeding for rotary kiln must be stopped at once. Kiln
ventilation air flow and cooling air flow of cooler should be decreased in order to
prevent too much cold air entering into rotary kiln and causing kiln coating falling
down, and to make rotary kiln in heat insulating condition;
Make drive system rotate the kiln in low speed, pay attention to the material
deposit at kiln inlet;
If can not solve the problem and cause a long time kiln stop, full system stop
should be considered.
10.2.5.2 Treatment for kiln jumping
From massive operational and test-run practices we can know that kiln jumping
exists in new mounting rotary kiln of the stages of ignition 、 drying and
commissioning. Some jump up and some jump down, all of these only depend on
installation and adjustment for kiln supporting roller. So when kiln jumping, must
adjust them in time, or sealing device of kiln outlet and inlet may be distorted, and
cause system leaking air seriously and more seriously is that the hydraulic thrust roller
will be damaged. The kiln jumping problem should be solved by experienced
mechanical engineer, it is not right to adjust it at random because it will bring many
technical problems which is not easy to recover.
10.2.5.
10.2.5.33 Analysis for the cause of common failure
The cause of common failure and the treatment are listed in the following table:
Common
Main cause Treatment method
failure
Red kiln shell The bad quality of rotary liner and its lay Using good quality refractory brick,
out or the over thin part didn’t change in stopping kiln to change new brick, and
time after corroded; all these result in the improve lay out quality. It is forbidden to
shell burned to be red. pressing repair.
The tyre and bedplate wear heavily, The clearance of tyre and bedplate which is
clearance is to large, and radial near burning zone should be rigid controlled.
deformation of rotary shell increase. When the clearance increase, bedplate must
be changed or pad be added.

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 The centerline of kiln shell is not straight. The centerline of rotary shell should be
corrected regularity.
The deformation of the kiln shell caused Stop red rotary shell, repair or change rotary
by overheating local, and surface of in- shell which deformed largely in time.
wall is uneven.
Kiln shell The rotary shell bending deflection is very Supporting roller should be adjusted in right
vibration large because it received unevenly heat, way.
and the supporting roller fall through.
Back lash between bull gear and pinion is The back lash between gear and pinion
too large or too small. should be adjusted.
Interface bolt for girth gear is loose or To fix or change bolt
dropped off.
The weld of spring lamination has cracked. To align it again and repair welding
Driving pinion is heavily worn , and To change pinion
stoop is appeared.
Foundation bolt is loose. To fix foundation bolt
Cracking on the Caused by vibration of rotary shell. To see the above description, and deal with
kiln shell them in right way.
Surface temperature is too high or kiln Weld up rotary shell and fix frozen.
shell is loss by burning of red kiln, so
strength and rigidity are weakened.
Push force on some part of supporting In order to reduce loading the supporting
roller is too large. roller should be adjusted in right way.
The quality of steel plate material for the insight flaw should be check through
rotary shell is not good or the quality of metal defect detector.
joint weld is not good.
Kiln shell is When the rotary stop suddenly, not run it Make mark on the turning of kiln, when kiln
crooked and for long time. pass to, it should stop for several minutes
deflected and make it recovery.
The position of supporting roller has Position of supporting roller should be
moved because of settlement of rotary adjusted correctly according to data
mound foundation. measured.

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 Supporting The stress on radial supporting roller is Adjust the load condition of supporting
roller bearing too large, making the friction between roller. Replace or add lubricating oil for the
has noise and axles and lining tile increase; oil film was bearing.
vibration. damaged.
Poor lubrication condition in the bearing Repair, clean and add new oil in time.
The bearing is radiated by the high High viscosity lubrication be swap-in
temperature of kiln shell section, make the temporarily, and heat insulation measures
viscosity of lubrication decrease and the should be increased.
thickness of oil film decrease.
In winter the temperature is low, so the Winter lubrication should be used in time;
viscosity of lubrication in bearing is a heater should be running; oil should be
little bit high, the fluidity is not good and heated in time.
oil starvation is indicated.
There are nap, The centerline of supporting roller is skew In order to increase contact face between
ratcheting, and heavily, contact is irregular and the supporting roller and tyre, the supporting
butcher cuts on pressure is increased on part. roller should be adjusted, and skewness
the contact face should be reduced.
between Radial stress of supporting roller is too Supporting roller should be adjusted to
supporting large. reduce load.
roller and tyre. Kiln jumping ability is bad. If the kiln is Scabble shoulder to maintain the flexibility
operating in a certain position for a long for up and down jumping of the kiln shell.
time, the supporting roller shall bring out
shoulder. Once the kiln jumping again, the
contacting face shall be damaged.
Sliding friction between tyre and Adjust supporting roller and make sure that
supporting is increased. the position of supporting roller is correct.
The baffle ring The over-size thrust on axial direction of Adjust supporting roller and reduce thrust.
for side face of supporting roller makes the friction
tyre has between tyre and its side baffle ring
undercuts, chips increased
and shedding.

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Inner face and Over-size stress to the supporting roller Adjust supporting roller to reduce load.
base plate is radial makes the turning or supporting Lubrication have to be filled to the place
seizure. roller and tyre abnormal; the friction between tyre and base plate.
between supporting roller and tyre is
increased.

The gap between inner surface of tyre and Adjust the clearance and clear the dirty
things in the gap.
base plate is too small, the temperature is
too high or powder-like waste, oil fouling,
and foreign and so on may be in the gap.
The over-size expansion capacity is Blow cooling air to the section which is
between tyre and base plate.
caused by red kiln shell.
The rigidity of caused by wear Change base plate or add shim.
kiln shell is
decreased
because the gap
between inner
face of tyre and
base plate is too
large.

Circular bead Axial slinger of kiln body is not good; the Flatten circular bead, and the flexibility of
running time is too long at one fixing kiln body should be kept.
appears on
place.
contact face of
The gap between tyre and thrust roller is Adjust the gap between thrust roller and tyre.
driving gear and
too small or too large.
pinion.
Driving bearing The kiln shell bended, and may cause Straighten shell of kiln
is swing and impact when gear and pinion run.
vibrating. The manufacturing errors of teeth of bull Repair teeth or exchange
gear and pinion.
Back lash of gear and pinion is not good. Adjust mesh clearance
The centerlines of pinion shaft and Correct centerline.
coupling are misalignment.

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 The fastening bolt of bearing or Fasten in time
foundation bolt is loose.
The rigidity of base pate is not enough. Strengthen base plate.
The current of Accretion formation in kiln The accretion formation should be handled.
motor increase.

Adjust supporting roller in improper way Adjust supporting roller and make sure that
can make the thrust of supporting roller be the direction of thrust is right.
out of line.
The lubrication for bearing of supporting Check lubricating and cooling unit and to
roller is not good. improve lubrication and strengthen
management.
The kiln body is bended. Turn the convex section or cantilever of
lilting part to upside, after stop in suitable
time, correcting shell according to its dead
weight.

Serious air The gap between sealing scale and cooling air Tighten them.
leakage of sealing shell is too large
device of kiln inlet Wear out or drop of sealing scale Replace the sealing scale.
and outlet

10.2.5.4 Overhaul
In process of running, the part of rotary kiln will be wore out, running degree of
reliability will be reduced, and even the output of it will be impacted, so all of these
should be recovered during troubleshooting. Troubleshooting can be divided into three
kinds according to working capacity: major repair, periodic repair and minor repair.
The repair planning should be made according to the service and maintenance
condition of rotary kiln in each factory. The maintenance should be done during rotary
stopping when lining of rotary kiln to be changed. Only the maintenance of driving
device should be done after brick work finished. But have to be done in short time.
The time for major repair is a little bit long, because all damage parts have to be
changed and the whole equipment(such as the segment of kiln shell changing; changes
for girth gear, tyre, supporting roller, thrust roller and sealing parts for kiln outlet and

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inlet and so on.) have to be checked and adjusted. In order to reduce maintenance time,
all parts need to be changed and tools to be needed have to be prepared in advance.
When wear extent of the main parts for rotary kiln reaching the following degree
or appear the following defects, in this situation, the above should be changed or
repaired:
1) When teeth thickness of driving gear has worn out 30% or 0.5 module, or the
damage for rim cannot be recovered.
2) When crack and local deformation appears on the segment of kiln shell
3) When found the section of tyre have worn out 10% (at this time, the stress and
rigidity should be checked and calculated.) or its surface have worn into cone-shaped,
polygon and other shape, and thorough crack occurring.
4) When the thickness of supporting roller worn 10% , rim of thrust roller worn
20%, or the surface of supporting roller worn into cone-shaped, polygon and other
shape, or through crack appear the rim of supporting roller and thrust roller. In this
situation, all these parts have to be changed or repaired.
10.2.5.
10.2.5.55 Safety notice
All maintenance work should be done when rotary kiln stopper and hanging with
“no-start” mark on motor switch.
1) During operation, repairing, checking, cleaning and so on with hand or tool is
not allowed inside the bearing, gearbox or drive gear guard. Dismount of any guarding
device is not allowed, such as coupling and so on.
2) The tools and parts which are used to repair cannot put on the rotary parts,
especially for supporting roller.
3) When look at fire, have to use fire looking glasses, naked eye is not allowed.
Turn off the view port after used.
4) Alerting signal must be given before the running of kiln; and make sure that no
person is in it and then start driving device of kiln.

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11.. Epilogue
11
Thanks again for selecting the product of CITIC Heavy Industries Co., Ltd.
Wish our product would create more value for you!

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