Maintaining regular kiln lubrication will prevent galling between mating surfaces, helping prevent cracking and other forms of damage to the oven.
Kiln alignment measurements using the Direct Method (a hot alignment technique conducted during operation of the kiln) help ensure that fixed and rotating elements remain proportionate with one another, protecting tyres, chair pads and girth gear from excessive wear due to capacity increases or thermal expansion.
Kiln Gearbox Repairs
Warping or bowing of the kiln shell may result in increased brick wear, which decreases overall efficiency. A common solution is to cut away part of its outer wall and realign its carrying rollers and riding rings accordingly.
Misalignment of the girth gear may lead to an unpredictable or vibrating movement of kiln, due to improper meshing between main gear teeth and pinion teeth.
Plant personnel frequently make adjustments to close gaps between tyre and roller surfaces, creating an unstable thrust condition and increased energy demands on the drive system. Resurfacing and alignment procedures were conducted without any production delays; subsequent energy cost savings and reduced maintenance requirements paid for an entirely new girth gear in just months.
Kiln Gearbox Services
Kilns used for quicklime production must operate efficiently to maintain production and quality, one of the primary challenges being lubrication issues.
Problems associated with unbalanced loads, metal-to-metal contact, high temperatures and contamination compounds the issue further, potentially leading to scuffing, pitting, carbon buildup, lubricant starvation and even complete failure of components.
Heavy-duty synthetic Pyroshield Open Gear Lubricants provide an ideal lubrication solution for this application, with exceptional film strength that adheres tenaciously to metal surfaces and offers reliable corrosion protection. They also help prevent unscheduled downtime by reducing gear and kiln wear while simultaneously maintaining cleanliness of lubricants and temperature reduction. Together these benefits result in significant savings on energy, maintenance expenditures, and shutdown costs; all achieved through an proactive lubrication reliability program.
Kiln Gearbox Rebuild
Taken offline for repairs can drastically impact production capacity and impact business operations negatively. GearWorld offers comprehensive kiln gearbox repair services that will get the job done properly and save your company money in doing so.
Diagonal marks often result from incorrect adjustment of support rollers or from worn-down rolling surfaces in tyres, leading to poor transition surfaces for tires and increasing frictional drag on them and roller shafts.
Resolving this issue would involve altering the load distribution in a kiln or moving the retaining elements that hold support rollers – neither of which are feasible without extensive rebuilding program. Instead, increasing bearing area against tyres will significantly decrease unit loading while keeping abrasion within acceptable levels.
Kiln Gearbox Refurbishment
Gearboxes are essential components of industrial equipment, helping ensure high levels of production and efficiency. However, for optimal functioning they must be regularly inspected and serviced, in order to stay in good condition and save money with lower maintenance costs and increased productivity. Regular inspections can save both money and increase productivity simultaneously.
Kiln gearbox overhaul can provide many important advantages, including keeping gears and shafts in good condition and reducing energy usage – this helps avoid premature failures as well as increase profitability and environmental benefits. Furthermore, thorough overhaul procedures will save time and money, typically completed in two to three weeks; detailed repair records can also help identify any future issues that might arise.
Kiln Gearbox Overhaul
At a cement plant, rotary kilns are essential in heating and cooking limestone at high temperatures for concrete production, so any malfunction can halt operations for days. When one of the gearboxes in one of these kilns failed, their maintenance manager called Atlanta Gear Works immediately for help.
The technician suggested mechanical analysis (also referred to as “hot alignment”) for the kiln. This in-production process uses continuous scans to establish its operational axis of rotation, rather than traditional ovality reading methods that require removal of support rollers or tyres before alignment can take place. Furthermore, mechanical analysis (hot alignment) takes less measurements and less time – saving production time and money for plants alike.