Kiln Support Roller
Kiln support rollers are essential components in industrial kiln systems. They provide support and guidance to the kiln shell, allowing it to rotate smoothly and maintain stability during operation.
- Material: Cast steel ZG55, ZG42CrMO
- Certificate: ISO9001:2015, ISO14001:2015, OHSAS 18001:2007
- Heat Treatment: Normalized, Normalized and Tempered, Quench and Tempered, 2 sets of heat treatment furnaces (max 18m*7m*4m)
support roller for rotary kiln description
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The primary function of kiln support rollers is to bear the weight of the kiln shell and distribute it evenly along the support points.
They provide a stable platform for the kiln to rotate, allowing for efficient and continuous operation.
Kiln support rollers also help to minimize axial thrust and ensure proper alignment of the kiln shell.
Design and Construction
Kiln support rollers are typically cylindrical in shape and consist of a central shaft or spindle with support rings or tires mounted around it.
The support rings have a slightly conical shape to facilitate proper alignment and prevent unwanted movement.
They are usually made from high-quality alloy steels or cast iron, selected for their strength, durability, and heat resistance.
Alignment and Adjustment
Proper alignment of kiln support rollers is crucial for smooth kiln operation.
Misalignment can lead to increased friction, uneven load distribution, and premature wear of components.
Kiln support rollers are designed to allow for adjustment and alignment through the use of shims, spacers, and precise mounting mechanisms.
Regular monitoring and adjustment of kiln support rollers help to maintain optimal alignment and minimize issues.
Heat Resistance
Kiln support rollers are subjected to high temperatures, especially in industries like cement and lime production.
Therefore, they need to withstand thermal stress and maintain their structural integrity under these extreme conditions.
The materials and heat treatment processes used in the construction of kiln support rollers enhance their heat resistance and prevent deformation or failure.
kiln support roller material
Kiln support rollers are typically made from high-quality alloy steels or cast iron, chosen for their strength, durability, and heat resistance.
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Here is a brief overview of these materials:
- Alloy Steels: Alloy steels are commonly used for kiln support rollers due to their excellent mechanical properties and resistance to high temperatures. These steels are typically alloyed with elements such as chromium, nickel, and molybdenum to enhance their strength, hardness, and heat resistance. The specific alloy composition depends on the desired properties and operating conditions of the kiln.
- Cast Iron: Cast iron is another material frequently used for kiln support rollers. It offers good strength, high wear resistance, and excellent heat dissipation properties. Different types of cast iron, such as gray iron and ductile iron, may be employed depending on the specific requirements of the kiln system. Cast iron support rollers are often chosen for their durability and ability to withstand heavy loads and continuous rotation.
Both alloy sheets of steel and cast iron undergo heat treatment processes to improve their material properties.
Common heat treatment methods include quenching and tempering, which involve controlled heating and cooling cycles to enhance strength, hardness, and resistance to wear and thermal stress.
The selection of kiln support roller material depends on factors such as kiln temperature, load capacity, operational conditions, and specific requirements of the kiln system.
The chosen material must possess sufficient strength, wear resistance, and thermal stability to withstand the harsh and demanding environment of the kiln.
AGICO CEMENT Kiln Support Roller Advantages
High-Quality Materials
AGICO CEMENT kiln support rollers are crafted using carefully selected high-quality alloy steels or cast iron. These materials exhibit excellent strength, durability, and heat resistance, ensuring reliable performance in demanding kiln environments.
Precision Manufacturing
AGICO CEMENT employs advanced CNC machining technology to ensure precise shaping and refinement of kiln support roller components. This precision manufacturing process guarantees accurate dimensions, smooth surfaces, and optimal alignment, resulting in reliable and efficient kiln operation.
Rigorous Quality Control
AGICO CEMENT places great emphasis on quality control throughout the manufacturing process. Their kiln support rollers undergo comprehensive inspections, including dimensional checks, non-destructive testing, and visual inspections. This commitment to quality ensures that each support roller meets stringent standards and performs reliably in industrial kilns.
Customization Options
AGICO CEMENT understands that kiln support roller requirements can vary across different industries and applications. To cater to diverse needs, they offer customization options for dimensions, load capacity, material selection, and surface coatings. This flexibility allows customers to obtain kiln support rollers tailored to their specific kiln systems and operational requirements.
Robust Performance
AGICO CEMENT kiln support rollers are designed to withstand heavy loads, high temperatures, and continuous rotation. Their robust construction and heat treatment processes enhance strength, hardness, and resistance to wear and thermal stress, enabling them to endure challenging kiln conditions with minimal maintenance requirements.
Expert Technical Support
AGICO CEMENT provides comprehensive technical support to its customers, assisting with design considerations, installation guidance, and maintenance recommendations. Their team of experts possesses extensive knowledge and experience in kiln support systems, ensuring that customers receive reliable and practical solutions for their kiln operations.
Cost-Effectiveness
Kiln support rollers offer a combination of high quality and cost-effectiveness. By utilizing efficient manufacturing processes and optimizing material usage, AGICO strives to provide competitive pricing without compromising on performance or durability.
Proven Track Record
AGICO CEMENT has a proven track record in supplying kiln support rollers to various industries, including cement production, lime kilns, and other high-temperature applications. Their products have gained trust and recognition from customers worldwide, reinforcing their reputation as a reliable manufacturer in the kiln support roller market.
AGICO CEMENT has rich production experience, high-quality kiln support roller for sale at ex-factory prices, and complete certification, welcome to consult!
AGICO CEMENT Kiln Support Roller Parameters
Item | Introduction |
Material | Cast steel ZG55, ZG42CrMO |
Test | Chemical composition, mechanical property, dimensional check, UT, MT, PT, etc. |
Certificate | ISO9001:2015, ISO14001:2015, OHSAS 18001:2007 |
Heat Treatment | Normalized, Normalized and Tempered, Quench and Tempered, 2 sets of heat treatment furnaces (max 18m*7m*4m). |
Molding Pit | The deepest molding pit is 45m*16.1m*(-6.0m), the largest casting pit is 87m*16.1m*(-3.5m) |
Kiln Support Roller Manufacturing Process
The manufacturing process of kiln support rollers involves several steps to ensure their quality and functionality.
Here is a detailed overview of the process:
The manufacturing process begins with the design and engineering phase.
Skilled engineers analyze the requirements and specifications of the kiln support roller, considering factors such as load capacity, dimensions, material selection, and alignment requirements.
They create detailed technical drawings and 3D models to guide the manufacturing process.
Kiln support rollers are typically made from high-quality alloy steels or cast iron, chosen for their strength, durability, and heat resistance.
The specific material selection depends on factors like kiln temperature, load capacity, and environmental conditions.
The selected materials are then prepared for the manufacturing process.
This may involve cutting the raw materials into appropriate sizes and shapes, removing impurities, and performing heat treatments like annealing or quenching to enhance the material’s properties.
Machining operations are carried out to shape and refine the kiln support roller components.
Computer Numerical Control (CNC) machines are commonly used to ensure precision and consistency.
The machining process includes operations like turning, milling, drilling, and grinding to achieve the desired dimensions and surface finish.
Kiln support rollers undergo heat treatment processes to improve their strength, hardness, and resistance to wear and thermal stress.
Common heat treatment methods include quenching and tempering, which involve controlled heating and cooling cycles to achieve the desired material properties.
To enhance the performance and longevity of kiln support rollers, they may undergo surface coating processes.
This can include applying protective coatings like ceramic or metallic coatings to increase wear resistance, reduce friction, and minimize corrosion.
Throughout the manufacturing process, rigorous quality control measures are implemented to ensure the kiln support rollers meet the required standards.
This includes dimensional inspections, non-destructive testing methods such as ultrasonic or magnetic particle testing, and visual inspections to identify any defects or imperfections.
Once the kiln support rollers are manufactured and pass quality control checks, they are assembled into the kiln support system.
Skilled technicians carefully align and install the support rollers, ensuring proper fit and functionality within the kiln structure.
After installation, the kiln support rollers undergo thorough testing to verify their performance and functionality.
This can include load testing, rotational testing, and monitoring of temperature and vibration levels.
Any necessary adjustments or fine-tuning are made to optimize the kiln support system’s operation.
Kiln support rollers require regular maintenance and inspection to ensure their continued performance and longevity.
This includes lubrication, periodic alignment checks, and monitoring for signs of wear or damage.
Timely maintenance and inspections help prevent issues and extend the lifespan of the kiln support rollers.
How To Replace The Kiln Support Roller?
Replacing a kiln support roller involves several steps to ensure proper installation and alignment.
Here is a general guide on how to replace a kiln support roller:
Preparation
Ensure that the kiln is shut down and cooled to a safe temperature. Gather all the necessary tools and equipment, including a crane or lifting device, wrenches, measuring tools, lubricants, and any specific components required for the replacement. Put on appropriate personal protective equipment (PPE) such as gloves and safety goggles.
Removal of the Old Support Roller
Locate the support roller that needs replacement and identify its mounting points. Securely attach the lifting device to the kiln shell or other suitable attachment points. Gradually and carefully lift the kiln shell to relieve the weight on the support roller. Remove any bolts, fasteners, or retaining rings that secure the support roller in place. Slowly lower the kiln shell to remove the old support roller from its position. Take note of the position and orientation of any shims, spacers, or other components that were used with the old support roller.
Cleaning and Inspection
Thoroughly clean the mounting area, removing any debris, dust, or residue. Inspect the mounting surface and surrounding components for any signs of wear, damage, or misalignment. Address any issues before proceeding with the installation.
Installation of the New Support Roller
Position the new support roller at the correct location, aligning it with the mounting points on the kiln. Apply an appropriate lubricant or grease to the mounting surfaces to facilitate installation and rotation. If required, place shims, spacers, or other components in the appropriate positions based on the notes taken during the removal process. Gradually and carefully lift the kiln shell using the lifting device, ensuring that the weight is evenly distributed. Align the support roller with its corresponding trunnion or bearing, taking care to achieve proper alignment and clearance. Securely attach the support roller using bolts, fasteners, or retaining rings, following the manufacturer's specifications for torque and tightening sequence.
Alignment and Adjustment
Once the support roller is installed, carefully lower the kiln shell, allowing the weight to rest on the new support roller. Check the alignment of the kiln shell and support roller using appropriate measuring tools such as a straight edge, laser alignment system, or dial indicators. Make any necessary adjustments to ensure proper alignment, taking into account factors such as roller slope, axial thrust, and kiln shell runout.
Testing and Commissioning
Conduct thorough testing of the kiln support roller and surrounding components, including rotational tests, temperature monitoring, and vibration analysis. Verify that the kiln operates smoothly and without any abnormal vibrations or noises. Monitor the kiln's performance during the initial operation to ensure the new support roller functions properly.
It’s important to note that the above steps provide a general outline, and the specific procedure may vary depending on the kiln design, manufacturer guidelines, and other factors.
It is recommended to consult the kiln manufacturer’s instructions and seek assistance from qualified professionals to ensure a safe and accurate replacement of the kiln support roller.