CONSEQUENCES

OF
MISALIGNMENT
OF
KILN
CONDITION OF PERFECT ALIGNMENT
OF KILN
 MISALIGNMENT OF KILN
• The kiln is said to be misaligned, if any of the center
of the kiln at any of the supports is outside the
envelope of 3 mm diameter.
• The centers of the kiln may be out of alignment in
horizontal plane, vertical plane or both.
• In case the kiln is misaligned in both horizontal and
vertical plane at the same time, which is usually the
case, the centers may fall outside the envelope of 3
mm in one of the quadrants of the kiln at that
particular section.
MISALIGNMENT OF KILN IN
HORIZONTAL PLANE
MISALIGNMENT OF KILN IN VERTICAL
PLANE
 INCREASE IN HEIGHT OF THE CENTER OF
THE TYRE WITH THE CHANGE IN
TEMPERATURE IN OPERATING CONDITION
EFFECT OF TEMPERATURE ON THE HEIGHT OF
THE KILN CENTER AND EXPANSION OF KILN
EFFECT OF TEMPERATURE ON THE HEIGHT OF THE KILN
CENTER AND EXPANSION OF KILN IN CASE OF WORN
OUT ROLLER
EFFECT OF TEMPERATURE AND EXECESSIVE SKEW OF THE
ROLLER ON THE HEIGHT OF THE KILN CENTER AND
EXPANSION OF KILN
 TEMPERATURE PROFILE OF KILN SHELL, TYRE AND
SUPPORT ROLLERS OF A 2200TPD PRECALCINER KILN

176 248
 COMPARISON OF DIAMETERS OF TYRES AND SUPPORT ROLLERS IN OPERATING
(HOT) CONDITION AFTER MANY YEARS OF OPERATION WITH THE DIAMETERS AT
THE TIME ERECTION OF A 2200TPD PRECALCINER KILN
DEFORMATION OF KILN AXIS IN
HORIZONTAL PLANE
DEFORMATION OF KILN AXIS IN
VERTICAL PLANE
EVALUATION OF SINKING OF PIER
FOUNDATIONS
FACTORS RESPONSIBLE FOR MISALIGNMENT
OF KILN - 1

• Wear of chair pads and retainer bands.

• Excessive skew of the support rollers.
• Effect of temperature changes.
• Incorrect root clearance between girth gear
and pinion
• Change in inclination of support roller
assembly
FACTORS RESPONSIBLE FOR MISALIGNMENT
OF KILN - 2

• Settlement of piers
• Wear of support rollers.
• Wear of tyres.
• Wear of girth gear and pinion
• Cracks/damages to the pier foundations.
INDICATORS OF MISALIGNMENT OF KILN
 CONSEQUENCES OF MISALIGNMENT - 1
• Excessive stress on the shell
• Excessive stress on the roller shaft
• Excessive load on the drive unit
• Wear of chair pads and retainer bands.
• Wear of support rollers
• Cracks or breakage of roller shaft
• Bearings of rollers running hot or failure of bearings
• Wear of tyres
• Wear on girth gear and pinion.
 CONSEQUENCES OF MISALIGNMENT - 2
• Incorrect root clearance between girth gear and
pinion.
• Damage or breaking of gear or pinion tooth(s).
• Excessive vibrations in the whole kiln system.
• Cracks or damage to the pier foundations.
• Cracks on the shell.
• Premature deformation of the shell
• Failure to brick lining
• Damage to the seals.
 
CAUSES AND EFFECTS OF MISALIGNMENT OF
ROTARY KILN
 RESULTS OF NEGLECT OF ALIGNMENT
CHECKS

• Operation of the kiln is less than optimum.

• Higher wear rate of various components.
• High operating and maintenance costs.
• Lower availability of the kiln.
• Frequent interruptions due to unforeseen
stoppages of the kiln.