Optimal Kiln Support Roller Adjustment Methods

Kiln support rollers are at the center of kiln operation by supporting the rotating kiln shell. Over time, these rollers can become misaligned or damaged, requiring adjustment or repair. Properly maintaining and adjusting kiln support rollers is essential to ensure smooth kiln rotation, prevent shell damage, and maximize kiln life. Here are some optimal kiln support roller adjustment methods.

Risks of a Damaged Kiln Support Roller

Damaged or misaligned kiln support rollers can lead to several issues:

  • Vibration and noise during kiln operation
  • Uneven rotational speed
  • Excessive wear on kiln shell and tires
  • Shell cracking or damage
  • Bearing failure
  • Increased power consumption

These problems will worsen over time if not addressed, leading to unplanned kiln downtime for repairs.

Adjustment Methods on a Switch Support Roller

On a switch-type support roller, the following methods can be used to realign and adjust the roller:

  • Shimming under the roller brackets to raise or lower the roller. Shims should be installed in pairs on both sides of the bracket.
  • Adjusting the jack screws on the roller brackets to fine-tune the roller height.
  • Checking the roller axial and radial runout and realigning if excess runout is found.
  • Ensuring proper roller-to-shell clearance.

Roller Adjustment Aim

The aim of kiln support roller adjustment is to:

  • Achieve uniform shell-to-roller clearance of around 1 mm across all rollers
  • Align the roller axis parallel to the kiln centerline
  • Minimize roller runout
  • Ensure proper roller height to carry shell weight
  • Reduce vibration and noise
  • Allow smooth rotation without binding

Adjustment Methods if Changing the Roller

When replacing a worn or damaged support roller, follow these steps:

  1. Match the new roller dimensions to the old roller.
  2. Adjust bracket jack screws to approximately the previous height.
  3. Check runout and slowly lower jack screws until proper clearance is reached.
  4. Verify several points around the shell have even clearance to the new roller.
  5. Complete any shimming required to fine-tune the height.

Running-State Repair Device

For minor adjustments while the kiln is running, a roller adjustment device can be used. This allows safely raising or lowering a roller by a few millimeters.

Surface Repairs

If the roller or shell surface becomes damaged, methods like metal build-up through welding or epoxy fillers can repair minor imperfections to restore the surface.

Get in Touch with Kiln Technology Company Company for Kiln Support Roller Repair or Replacement

For major kiln support roller repairs, adjustments beyond your team’s capabilities, or complete roller replacements, contact Kiln Technology Company Company. Our service technicians can safely handle major roller repairs and realignments during a scheduled kiln outage. Investing in proper support roller maintenance helps avoid unplanned downtime and extends the kiln’s working life.