Rotary Kiln Alignment Methods - A Comparative Study, 2008 Engineering, Pulping and Environmental Conference

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In recent years the cement and lime industries have seen production levels soar higher in the worldwide market than at any point in recent history. As a result, individual plants feel pressure not only to maintain current production levels but increase the overall efficiency of equipment to achieve the maximum amount of equipment reliability. In this article we will look at the importance of predictive maintenance on the rotary kiln, an important piece of production equipment at the plant site. To better assist cement producers in determining the operational performance of the kiln, an attempt will be made to provide the reader with a comparative approach to kiln alignment.

Why is kiln alignment so important? Quite simply, being a massive rotating piece of mechanical equipment with multiple support stations, the kiln’s operation is directly influenced by its alignment accuracy. A kiln is not any different than a large fan, a turbine or a grinding mill with the exception that it is much larger and the rotational speed is much slower. However, the kiln is sloped and the static and dynamic loads as a result of size, refractory and product are extensive. In addition to this, the operating temperature of the kiln and resultant thermal expansion makes the alignment of the kiln unique unto itself. So unlike high-speed like turbines, fans and mills, a misalignment condition in a kiln is not often immediately noticeable until the damage is extensive; such as refractory failure, hot bearings and major component failures.