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Rotary Kilns
Refratechnik June 2015
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REFRATECHNIK
International Training
June 2015
This is a simple procedure also applied to other tasks The internal alignment method is an accurate way of
such as tunneling, and setting large diameter sections of measuring the position of the shell axis. This is often the
pipe and so on. way a new kiln is installed. Most times a new kiln shell
is shipped in sections and these have to be assembled
and welded into a straight tube. The method involves
establishing physical centers at each of the supports
using measurements made from the inside surface of
the shell. Once having established these centers, it is
only a matter of viewing them, either by the naked eye,
using a theodolite, or most recently, using a laser to see if
they line up. With this very simple technique, it is easy to
established if all these points are in a straight line or not.
If this were the procedure selected to replace the A more conventional alignment for a new section, is
center tire section of a kiln, the targets would have by joint run-out measurement. However, there are
been positioned at tire #1 and tire #3. Now the kiln can situations which preclude the ability to turn the shell for
be locked out, the center section removed and a new run out measurements, so this is an alternate method.
section with tire placed and aligned accordingly. New
sections intended to be aligned using this method,
would have spiders at both ends of the shell, not only
keeping the shell round for machining and shipping,
but also having centers machined in them for bore sight
alignment purposes.
The bore sight procedure uses three or multiples of three All the measurements are made to the kiln shell.
discrete shell positions to find the centers of rotation. Measurements are repeated on both sides of the kiln
With a rotating shell, there is the potential for continuous as well as once uphill and then again downhill of the
measurements of shell positions. The challenge is doing tire. Of significance, this is done without measuring any
this from the outside. The shell rotates about a center diameters of tires or rollers.
which is rarely its physical center, since the shell is not
perfectly round and has axial bends in it. Rotation
centers can be found without knowing the shape of
the shell or considering shell bends. To find the center
of rotation requires only locating three average shell
positions somewhere around its periphery.
The external alignment procedure is routinely used Centers are established by a series of external
for new installations and when components such measurements. These are usually the roller and tire
as support rollers are replaced. Until hot alignment diameters, and the roller spacing etc. This can be
made its appearance, it was the only way alignment described as alignment by measuring roller support
was measured. It continues to be a valid method even geometry. The most difficult challenge is measuring
though it has its limitations for re-checking alignment on the roller spacing since no easy reference surface may
operating kilns. be available to measure from. On some kilns, where the
rollers and tires are badly worn, diameter measurements
With the external alignment method, the kiln still needs
can also be a problem. It must be remembered, the
to be shut down.
accuracy of the final alignment is only as good as
the worst measurement made. With kilns in poor
mechanical condition, this type of alignment can easily
give marginal results. Since down-time is still required
and since results are often limited, this method is not a
popular choice as a preventive maintenance tool.
A variety of arrangements can be used to measure The prism is used to optically locate the position of the
the three positions at each cross section of the shell or monopod within the reference grid. Each laser scans the
two positions for the tire. Photographed here, is one circumference of the shell. The total station calculates
configuration of the side shot set up. Shown is a single the coordinates of the mean shell position. With two
laser monopod arrangement with a locating prism. This additional points at different locations on the shell, the
arrangement is the most convenient for the largest kilns. shell’s center of rotation can be calculated.
It allows the exact location of the laser to be determined
Our newest method is “target-less” whereby the laser
accurately.
and the optical prism target are no longer needed. This
is also used in the two point method.
Why don’t kiln manufacturers provide a document of Done properly, these analytical measures can be revenue
completion, verifying ovalities and alignment as soon as generators.
the kiln is commissioned?