Welcome back to the second of our two-part series on how to protect your rotary kiln when creating roofing granules. As we discussed in the first part, roofing granules are an extremely lucrative product that’s in high demand, but the abrasive nature of the granules can do a lot of damage to the drum interior. You need to stay on top of maintenance, or else you’ll be calling for rotary kiln repair far too often.
In this article, we’ll be focusing on more specific things that can go wrong, and what you can do to prevent them from causing undue damage to your kiln.
Five Rotary Kiln Problems To Watch For When Manufacturing Roofing Granules
1 – Worn-out liners
Your drum liner is going to be hit hardest by the roofing granules. If you manufacture them in high numbers, it’s guaranteed that the liner will be worn down quickly. This is a major issue, since as the liner wears out, maintaining the right temperature envelope becomes more difficult. If the worn-out liner starts allowing heat to reach the outer shell, you can also get warping that could do significant damage to your kiln.
Your drum liners should be regularly inspected and replaced whenever they show signs of wear. The potential damage done by a worn liner is too costly to allow.
2 – Fugitive material
Since roofing granules are made from small particles of rock and minerals, this makes it easier for small amounts of material to escape the kiln. They can make their way into trunnion pits, the pinch point, and more critical systems. Then their abrasive nature will start wearing through these components as well.
There’s no way to fully prevent fugitive material. Just be sure to inspect the area around the drum frequently, and immediately remove any rogue material before it causes damage.
3 – Insufficient lubrication
Along with causing physical damage to parts, fugitive material can also make its way into the graphite block lubrication which is needed to keep your kiln running smoothly. This can quickly ruin the lubricant. Keep an eye on the lubricant and be ready to replace it whenever it becomes too rough to work properly.
4 – Seal wear
The seals on your kiln are another component that can be affected by the granules, and if the seals develop leaks, you’ll have a hard time maintaining your heat envelope. The seals should also be inspected regularly and replaced whenever they show any signs of damage.
5 – Mis-aligned drums
Proper drum alignment is critical in any rotary kiln operation, but especially critical when working with roofing granules. The extra wear caused by a poorly-aligned drum will only be made worse by all the abrasives and can again lead quickly to a warped drum. Be sure to have professionals regularly check your rotary kiln alignment for issues.
Kiln Technology Company Co specializes in installing, repairing, and maintaining kilns across America. If you’re looking to move into roofing materials or are struggling to keep your kiln functioning properly as you do so, contact us for help!