Tongli rotary kiln support roller shaft Introduction

A rotary kiln support roller shaft is a critical component of a rotary kiln, which is a large, rotating cylindrical forged object used in various industrial processes such as cement production line, lime production line, and other thermal processing applications. The support roller shaft is an integral part of the support device that helps maintain the proper alignment and stability of the rotary kiln. The support roller shaft is designed to bear the weight of the rotating kiln along with the material being processed inside it. It is usually made of high-strength steel and is mounted on the kiln's shell through a set of support rollers, which are positioned underneath the kiln. Rotational motion is crucial for the heat treatment processes taking place within the kiln, as materials inside are exposed to controlled temperature conditions along its length. The proper alignment and maintenance of the rotary kiln support roller shaft and support roller are crucial to ensure the efficiency and longevity of the kiln's operation. Tongli, as a professional rotary kiln part manufacturer, provides various types of rotary kiln support roller shaft with different specifications and materials. Tongli rotary kiln 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.

Tongli rotary kiln structure

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.

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.

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.

Design principles of cement rotary kiln support roller shaft

Auto-Molding: Tongli adopts automatic sand release system and sand recovery system, the ratio of resin and sand is fully automated, the molding effect is good, and the strength of the sand mold is high.

Advanced design: Unique design for the sand molding of steel castings. All millstone molds are used on the same day of manufacture to ensure that the sand molds are not damp. After the box is closed, a dehumidifier is used to ensure that the interior of the sand molds is dry.

Process control: Optimized the casting process of steel castings. The riser of the casting is 1.5 times larger than the traditional riser, and the riser is added at the position where the defect of the wire is relatively easy to exit.

Simulation software: Tongli used the simulation software to repeatedly verify the runners of the steel castings, combined with actual casting experience, and finally obtained the optimal casting process.

Mold Preparation: The pattern is used to create a mold, which is a negative impression of the rotary kiln support roller shaft. 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 support roller shaft is 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 support roller shaft. 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.

Forging: the rotary kiln support roller shaft is forged using the 4000T forging hammer, and then after it cooled down, it can proceed to the next step.

Machining: The forged support roller shaft is not yet ready for use as a rotary kiln support roller shaft. 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 support roller shaft 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 support roller shaft meets specified standards. This may involve dimensional measurements, non-destructive testing, and visual inspections.

Specifications of cement rotary kiln support roller shaft

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.   

Industry Knowledge extension

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.