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1. Polysius Services 2. Grinding of supporting rollers, kiln tyres and thrust rollers 3. Grinding of supporting rollers in progress 4. Measuring device to check the diameter and out of roundness of tyres and supporting rollers 5. Dimensional stability after refurbishment 6. Damages due to miss alignment 7. Refurbishment of Mill slide rings
Service Forum Ha Noi Vietnam (Oct 2010) - Grinding of supporting rollers and tyres (Rotary Kiln and rotary drums) - Refurbishment of Mill slide rings Senior Service Engineer Udo Feldotto Polysius Anlagenservice Polysius Services: Refurbishment of kiln tyres and supporting rollers by grinding units Titel des Vortrags Titel der Schulung Datum und Ort Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Refurbishment by grinding is required in case of geometrical errors and surface damages of kiln tyres and or supporting rollers Reason for geometrical errors and surface damages: - Poor maintenance - Process difficulties (kiln bending due refractory failures, not uniform coating) - Increased surface wear, due to malfunctioning of axial kiln movement - Misalignment (Skewing, Inclination failures) Abnormal contour of kiln tyres and supporting rollers: - Concave, convex and conical shape - Surface damages, scoring and scuffing in circumference direction und corrugation across - Surface deformations Titel des Vortrags Titel der Schulung Datum und Ort Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Grinding service by Polysius: The following grinding units are available Big grinding unit (Quantity 1) Operational field: Rotary Kiln : Tyre diameter Ø > 5m, Tyre width max.1500 mm : Roller diameter Ø max 3m, Roller width max.1500 mm Smaller grinding unit (Quantity 2) Operational field: Rotary Kiln : Tyre diameter Ø < m, Tyre width < 900 mm : Roller diameter Ø < m, Roller width < 900 mm Mill Slide ring : Slide ring diameter max 10 m, Slide ring width < 900 mm Trunnion shaft : Trunnion shaft Ø max m Rotary drums : Tyre diameter Ø < m, Tyre width < 900 mm : Roller diameter Ø < m, Roller width < 900 mm Cup wheel grinder unit (Quantity 2x2) Operational field: Rotary Kiln: Lateral tyre surface : Thrust rollers (Fixed and or Hydraulic thrust units) Titel des Vortrags Titel der Schulung Datum und Ort Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Surface damage Kiln supporting roller: Corrugation due to kiln drive vibrations Kiln tyre: Convex shape of kiln tyre Refurbishment in progress Titel des Vortrags Titel der Schulung Datum und Ort Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Surface damage Tyre and roller surface damages in circumference direction Example: The inclination of the supporting rollers differed by 0.5% Due to the inclination failure the customer skewed the supporting rollers wrong Finally the skewing failure create the surface damage Titel des Vortrags Titel der Schulung Datum und Ort Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Grinding of supporting rollers, kiln tyres and thrust roller Before After Titel des Vortrags Titel der Schulung Datum und Ort Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Grinding of supporting rollers, kiln tyres and thrust roller Polysius is providing the full service for refurbishment of damaged surfaces, including necessary adjustment Titel des Vortrags Titel der Schulung Datum und Ort Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Grinding of supporting rollers in progress Titel des Vortrags Titel der Schulung Datum und Ort 10 Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Grinding of supporting rollers in progress Titel des Vortrags Titel der Schulung Datum und Ort 11 Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Thrust roller: Alignment of thrust rollers to theoretical Kiln axis Titel des Vortrags Titel der Schulung Datum und Ort 14 Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Thrust roller: Possibilities of miss alignment Titel des Vortrags Titel der Schulung Datum und Ort 15 Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Thrust roller: Alignment of thrust rollers to theoretical Kiln axis Different inclination between thrust roller and kiln axis Angle miss alignment due to settlements, or wrong assembly Titel des Vortrags Titel der Schulung Datum und Ort 16 Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Thrust roller: - Offset to the vertical centre line - Due to our experience offsets bigger than mm will cause surface damages - Realignment by using circle measuring device = = Titel des Vortrags Titel der Schulung Datum und Ort 17 Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Thrust roller offset in accordance to theoretical kiln centre line A A B B A : Kiln rotation direction B : Allowable lateral offset = 2.0 to 5.0 mm The lateral offset must be selected that the tyre slightly presses the thrust roller downward! = Titel des Vortrags Titel der Schulung Datum und Ort 18 Polysius = Grinding of supporting rollers, kiln tyres and thrust rollers Damages due to miss alignment Titel des Vortrags Titel der Schulung Datum und Ort 19 Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Damages due to miss alignment Titel des Vortrags Titel der Schulung Datum und Ort 20 Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Grinding of tyre lateral surface and thrust roller Titel des Vortrags Titel der Schulung Datum und Ort 21 Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Grinding of tyre thrust surface and thrust Roller in progress Titel des Vortrags Titel der Schulung Datum und Ort 22 Polysius Refurbishment of Mill slide rings Important slide ring surface areas Contact area of slide shoe bearings Contact area of the housing seals Damaged slide ring surfaces have to be refurbished for a trouble free mill operation Polysius is providing a full service of slide ring surface refurbishment Refurbishment with powerful belt grinding machines Different grinding belts are available (from rough up to fine quality) Measuring device to check the diameter and out of roundness of slide rings The grinding works have to be done with the mill auxiliary drive The maximum mill speed is 1,5 rpm Polysius provides mill turning device, if required Titel des Vortrags Titel der Schulung Datum und Ort 24 Polysius Refurbishment of Mill slide rings Measuring device to check the diameter and out of roundness of the slide ring Titel des Vortrags Titel der Schulung Datum und Ort 25 Polysius Refurbishment of Mill slide rings Measuring device to check the diameter and out of roundness of the slide ring Titel des Vortrags Titel der Schulung Datum und Ort 26 Polysius Refurbishment of Mill slide rings Refurbishment with powerful belt grinding machine Titel des Vortrags Titel der Schulung Datum und Ort 27 Polysius Refurbishment of Mill slide rings Slide ring surface before grinding /after grinding • Executed biggest radius reduction of seal area up to 12 mm carried out in 2003 • Reduction of slide ring diameter < mm will not effect the contact between slide ring and bearing shoes Titel des Vortrags Titel der Schulung Datum und Ort 28 Polysius Titel des Vortrags Titel der Schulung Datum und Ort 30 Polysius [...]... theoretical Kiln axis Titel des Vortrags Titel der Schulung Datum und Ort 14 Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Thrust roller: Possibilities of miss alignment Titel des Vortrags Titel der Schulung Datum und Ort 15 Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Thrust roller: Alignment of thrust rollers to theoretical Kiln axis Different inclination... Different grinding belts are available (from rough up to fine quality) Measuring device to check the diameter and out of roundness of slide rings The grinding works have to be done with the mill auxiliary drive The maximum mill speed is 1,5 rpm Polysius provides mill turning device, if required Titel des Vortrags Titel der Schulung Datum und Ort 24 Polysius Refurbishment of Mill slide rings Measuring device... Ort 15 Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Thrust roller: Alignment of thrust rollers to theoretical Kiln axis Different inclination between thrust roller and kiln axis Angle miss alignment due to settlements, or wrong assembly Titel des Vortrags Titel der Schulung Datum und Ort 16 Polysius Grinding of supporting rollers, kiln tyres and thrust rollers Thrust roller: