The rotary kiln girth gear is a large ring gear that is mounted on the outer surface of the rotary kiln shell. It is usually made of high-strength steel and is designed to withstand the stresses and loads associated with the rotation of the kiln. The girth gear is directly connected to the kiln's drive system, which includes a motor and other transmission component. As the motor turns the girth gear, it causes the rotary kiln to rotate, facilitating the movement of materials through the kiln for various thermal and chemical processes.
The rotary kiln girth gear is a large ring gear that is mounted on the outer surface of the rotary kiln shell. It is usually made of high-strength steel and is designed to withstand the stresses and loads associated with the rotation of the kiln. The girth gear is directly connected to the kiln's drive system, which includes a motor and other transmission component. As the motor turns the girth gear, it causes the rotary kiln to rotate, facilitating the movement of materials through the kiln for various thermal and chemical processes. Tongli, as a professional rotary kiln manufacturer, provides various types of rotary kiln girth gear with different specifications and materials. Tongli rotary kiln girth gear steel casting has a mature casting process and strong machining strength. Tongli steel casting is made of high-quality mild carbon steel and 304 stainless steel that is fresh out from our own fabrication workshop in which the quality of the raw material is strictly controlled.
A rotary kiln is a large cylindrical vessel used for a variety of processes, such as drying, calcination, and chemical reactions. It's commonly used in industries like cement production, lime manufacturing, and more. The structure of a rotary kiln can vary depending on its specific application, but I'll provide a general overview of its typical components and construction:
Shell: The main cylindrical body of the rotary kiln is called the shell. It is typically made of steel and lined with refractory materials to withstand high temperatures and chemical reactions. The shell is inclined slightly from the horizontal and rotates on its axis.
Riding Rings and Rollers: The shell is supported by a set of riding rings and rollers. The riding rings are large rings that encircle the shell at various intervals along its length. The rollers, placed between the riding rings, support the weight of the kiln and allow it to rotate smoothly.
Tyres (Tires): Tyres are large, circular steel components that are attached to the shell. They usually have a conical shape to provide support and help distribute the load evenly. Tyres are sometimes fitted with riding pads to further reduce friction and wear.
Girth Gear: The girth gear is a large ring gear that is attached to the shell and meshes with a pinion gear. This arrangement drives the rotation of the kiln. The girth gear is often supported by trunnion rollers to maintain proper alignment.
Pinion Gear: The pinion gear is a smaller gear that meshes with the girth gear. It is usually driven by a motor through a gearbox, which imparts the rotational motion to the kiln.
Rotary kiln thrust roller：The thrust roller is a critical part of the rotary kiln system. It serves the purpose of supporting the kiln's weight and maintaining its axial position, ensuring that the kiln remains properly aligned along its axis. The thrust roller is typically positioned on the downhill side of the kiln and is attached to the kiln shell. It consists of a central shaft or journal and a roller assembly.Rotary kiln bearing housing: The bearing housing serves as the support structure for the kiln's rotating motion and is responsible for holding and guiding the kiln's trunnion bearings. Trunnion bearings are large, heavy-duty bearings that support the weight of the kiln and allow it to rotate smoothly.
Supporting Rollers: Supporting rollers are additional rollers placed along the length of the kiln to help prevent excessive deflection of the shell due to thermal expansion and other forces. They play a crucial role in maintaining the kiln's stability and alignment.
Refractory Lining: The interior of the kiln is lined with refractory materials to protect the shell from the high temperatures and chemical reactions occurring inside. Different sections of the kiln might have different types of refractories to withstand varying conditions.
The steps of making girth gear are as follows, you can also check out the rotary kiln girth gear making process on our Youtube channel.
Mold Preparation: The pattern is used to create a mold, which is a negative impression of the rotary kiln girth gear. This is done by placing the pattern in a casting flask and packing it with molding sand. The sand is carefully packed around the pattern to create a cavity that matches the gear's shape.
Metal Pouring: Once the mold is ready, molten metal is poured into the cavity. The type of metal used depends on factors like the application, load, and environmental conditions. Typically, rotary kiln girth gears are made from cast steel, alloy steel, or ductile iron.
Cooling and Solidification: After the metal is poured into the mold, it cools and solidifies, taking on the shape of the rotary kiln girth gear. This process can take some time, and the cooling rate can affect the final properties of the casting.
Shakeout and Cleaning: Once the metal has solidified, the mold is broken open, and the casting is removed. The casting may have excess sand and other debris attached to it, which needs to be removed through shakeout and cleaning processes.
Machining: The casting is not yet ready for use as a rotary kiln girth gear. It often requires machining to achieve the desired dimensions, surface finish, and accuracy. Machining operations can include turning, milling, drilling, and grinding.
Heat Treatment: Depending on the material and desired properties, the rotary kiln girth gear must undergo heat treatment processes such as quenching and tempering to enhance its mechanical properties, such as strength and hardness.
Quality Control: Throughout the manufacturing process, quality control checks are performed to ensure that the rotary kiln girth gear meets specified standards. This may involve dimensional measurements, non-destructive testing, and visual inspections.
Note: *The diameter is the inner diameter, Weight excludes refractory material.
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Zhejiang Tongli Heavy Machinery Manufacturing Co., Ltd (Formerly known as Tongxiang Coal&Mining Machinery Factory) established in year 1958 is a member of the Chinese National Building Material Machinery Association. Tongli is on the vendor list of designated production enterprise of the Ministry of Coal Industry. ISO9001、ISO14001、ISO45001 certified, accredited as High-tech & new technology enterprise of Zhejiang Province. With 65+ years of experience, Tongli has earned first class R&D and manufacturing capabilities, dedicated to provide satisfactory manufacturing equipments for global customers.
After years of development, there are more than 650+ sets of heavy machinery manufacturing equipments in our workshop, some of them are as follows:
One of the largest equipment in our factory, the maximum processing diameter is 12 meters, and the maximum processing length can reach 26 meters. This Lathe is specially crafted for processing mega cylinders.
One of the super-large equipment in our factory, the maximum processing height can reach 6 meters, and the maximum processing diameter can reach 12 meters, which ensures that the accuracy of the cylinder flange can reach the required level.
Workbench effective size: 4000*12000mm;
Gantry Width: 4900mm;
Processing height: 4000mm;
Three angled milling heads, square ram;
Load-bearing 350 tons;
CNC system: SIEMENS 840D.
Workbench effective size: 3000*8000mm;
Gantry width: 4100mm;
Spindle speed: 2000RPM
Workbench effective size: 2000*4000mm;
Processing Width: 2800mm;
Processing Height: 1100mm;
Full-CNC milling heads；
Workbench effective size: 4500x5000mm
Processing Length: 14000mm;
Processing Height: 5000mm;
CNC system: SIEMENS 840D.
Workbench effective size: 5000x5000m;
Processing Length: 11000mm;
Processing Height: 6300mm;
Tongli rotary kilns are designed to be energy efficient, with features like pre-heaters and calciners that recover and reuse waste heat, and ss304 lining and ceramic felt to improve the sealing effect.
Adcanced instrumentation and control systems are employed to monitor and regulate the kiln's operation, ensuring stable and consistent production process.
Tongli held independent intellectual property rights, developed core technologies of mechanical, and electrical systems provide high reliability at all events.
Tongli rotary kiln can handle a wide range of materials with varying size and property, which is suitable for different types of production.
What is the step Prior to the rotary kiln calcination?
The first step of making cement is the raw material crushing, conveying and storage. The limestone raw material from the mine needs to be crushed, ground and mixed, and the crushing process is carried out by cement crusher. When the maximum size of the input ore is ≤1600mm and the output particle size is ≤80mm, the limestone discharged from the crusher is then sent to the Φ80m circular pre-homogenization yard by the belt conveyor for pre-homogenization and storage.
What is the relationship between vertical roller mill and rotary kiln?
The rotary kiln is usually used as an intermediate process. The large raw materials are crushed by the crusher and then enter the grinding equipment for grinding. After being mixed with other raw materials, they are added to the rotary kiln for redox reactions. The calcined finished products need to enter the vertical roller mill or ball mill for secondary grinding to get the finished product.