In-Situ Grinding (Resurfacing)

The Importance Of Having Tyre-Rollers Surfaces Cylindrical And Flat

A typical kiln can grow 100 to 200 mm in length axially (due to temperature variation) from a shut down (cold) condition to its normal operating condition. Accordingly tyre position on roller changes axially. If the rollers are not cylindrical that will restrict the tyre movements leading to various component failures. Hence it is very much essential to keep the tyres and rollers surfaces cylindrical and flat. The same is achieved by our specially designed resurfacing machines. Each pair of support rollers carries considerable weight which can vary from a few tons to as much as over 1000 tons. With that much weight, even the smallest variations in the profiles of the rolling surfaces can have significant and detrimental effects on the entire unit.

If the rolling surfaces are not flat and cylindrical, any axial movement of tyres on the rollers causes additional loads to be transmitted throughout the mechanism. The magnitude of these additional loads can be substantial and severe. These loads are transferred from the shell, which is the prime mover, through the tyre retaining blocks to the tyre, to the roller, to the bearings, to the structural base and finally into the foundation. All the parts in this mechanical chain act to absorb the additional load. When tyres and rollers are not smooth they are not making even contact with each other. Wear patterns develop accelerating wear, increasing cost of operation and eventually causing component failure.

Tyre problems

When the load becomes excessive, that is, beyond the carrying capability of the weakest component, rapid deterioration and ultimately component failure occurs. Worn side faces of the tyres, worn stop blocks, and cracked welds will be visible.

When the tyre is prevented from moving freely across the face of the roller, even a micron of unevenness can create enormous additional pressure on the tyre. All of this pressure is absorbed by the unit, but the increased force requires the drive to exert additional effort. The shell is much harder to turn. The additional energy required by the drive translates to additional cost of electrical consumption. Unfortunately, the result does nothing but grind up metal.

Roller problems

The chain of reaction does not stop with the tyre. The additional loads created by the tyre’s inability to move freely in the axial direction are also transmitted to all the components of the unit. When the load becomes excessive, that is, beyond the carrying capability of the weakest component, rapid deterioration and ultimately component failure will occur. Broken roller shafts, hot thrust bearings, cracked or distorted base frames, cracked grout, and even wobbling piers are the tell-tale symptoms.

Since removal of material from the rolling surfaces produces immediate reactions of the unit, appropriate roller adjustments are required in order to avoid risking bearing failures. Before reconditioning the rollers are usually over-skewed. As reconditioning progresses the surface contact improves and the over-skewed position will create very high thrust loads. These must be relieved. Experienced reconditioning crews will watch and anticipate these reactions so that the reconditioning process can be completed without interrupting the normal operation of the kiln.

Mill problems

In mills having slide shoe bearings each slide ring with two self-aligning and hydrodynamically lubricated slide shoes. Damaged Slide rings can lead to premature failures, decreased productivity, and even safety hazards. Resurfacing of the slide rings allow running of the mill at 100% performance.

Advantages of In-Situ Grinding

Allows proper adjustment of support rollers.
Reduces power consumption.
Improves mechanical stability while decreasing operating costs.
Removes rolled over edges on tyres which can lead to cracks that propagates into the tyre, causing large pieces of metal to fall out or the entire face of the tyre to crack.
Improvement in the life of mechanical components of the kiln.
Reduces impact on the brick lining and coating.
Kiln floating is smooth.

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About Us

At Proficient Kiln Services, we're not just a company; we're your dedicated ally in the world of rotary equipment. With a legacy spanning three decades, our team of experts has been at the forefront of delivering exceptional services for rotary kilns, dryers, granulators, incinerators, calciners, coolers, and more. Our journey began as collaborators with renowned OEM organizations like FLS and Phillips Kiln Services, bringing unmatched expertise and reliability to your doorstep.
Today, we proudly stand as an independent entity, fueled by a singular commitment: to serve you better than ever before.