A properly functioning kiln requires precise distribution of heat within the drum, which can only happen if the kiln drum is turning smoothly on its kiln support rollers. Those support rollers hold up the entire weight of the kiln, potentially holding up to a thousand tons on each pair of rollers. As a result, even small issues with kiln alignment, or deformations in the kiln shell, can have significant impacts on operation, as well as potentially cause damage to the support structure.
So, the kiln support rollers must be properly maintained and protected to ensure the long-term proper functioning of the kiln. With decades of experience supporting and repairing kilns around the country, we are experts at properly protecting the rollers.
Common Issues with Kiln Support Rollers
1 – Kiln shell expansion
Because weight and balance are so critical to the proper turning of a kiln on its rollers, any changes to the shape of the kiln shell, even small changes, can have an oversized effect on operations.
If the kiln is improperly insulated or there is damage to the refractory lining, heat can make its way to the shell and cause it to deform. In turn, this causes extra stress on the rollers, as well as potentially throwing the load off balance. The potential damage done here goes beyond the rollers, to the entire support system, which is now dealing with stresses beyond the design tolerances.
2 – Dirt and grime on the rollers
Working with a kiln typically generates a lot of dirt, grime, and grease – but these cannot be allowed to build up on the rollers. Because of the pressures and forces involved, even very small particles can be forced into the surface of the rollers, creating micro-cracks. Over time, these then become weak points that may expand into larger visible cracks that threaten the kiln rollers.
Proper kiln maintenance calls for keeping the rollers as clean as possible and monitoring them for any buildup of dirt and other waste.
3 – Uneven wear
Even if a kiln is properly balanced, the tires which help the support rollers move may cause damage over time. The tires are always smaller than the roller, so the point of contact will wear down. After years, this can cause the rollers to become slightly concave, throwing off proper balance and rotation.
4 – Reducing Pollution in Kiln Operations
Effective pollution control in kilns starts with maintaining the kiln support rollers. Regular cleaning and dust control measures are key. Operators should keep the kiln at optimal temperatures to lower gas emissions.
5 – Maintenance and Operating Procedures
Scheduled maintenance of support rollers is crucial to avoid inefficiencies and pollution. This includes regular inspections and training operators in proper loading and speed management to ensure even heating and reduced emissions.
6 – Enhancing Kiln Energy Efficiency with New Kiln Support Roller
To improve energy efficiency, consider upgrading to modern, energy-efficient kiln support rollers and implementing variable speed drives. These adjustments optimize energy use and reduce wear. Additionally, switching to cleaner alternative fuels can significantly lower the kiln’s environmental impact.
It’s a good idea to periodically measure your rollers and ensure they’re still in the right shape. If they’ve become concave, replacing them may be called for.
Kiln Technology Company Company Company is here to keep your kiln rolling smoothly. If you’re having technical issues, or need spare parts or repairs, just contact us!