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Service Forum Ha Noi Vietnam (Oct. 2010)
- Grinding of supporting rollers and tyres (Rotary Kiln and rotary drums)
- Refurbishment of Mill slide rings

Senior Service Engineer Udo Feldotto
Polysius Anlagenservice


Polysius Services:
Refurbishment of kiln tyres and
supporting rollers by grinding units

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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers
Refurbishment by grinding is required in case of geometrical errors and
surface damages of kiln tyres and or supporting rollers
Reason for geometrical errors and surface damages:
- Poor maintenance
- Process difficulties (kiln bending due refractory failures, not uniform coating)
- Increased surface wear, due to malfunctioning of axial kiln movement
- Misalignment (Skewing, Inclination failures)

Abnormal contour of kiln tyres and supporting rollers:
- Concave, convex and conical shape

- Surface damages, scoring and scuffing in circumference direction und corrugation
across
- Surface deformations
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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers
Grinding service by Polysius: The following grinding units are available

Big grinding unit (Quantity 1)
Operational field: Rotary Kiln : Tyre diameter Ø > 5m, Tyre width max.1500 mm
: Roller diameter Ø max. 3m, Roller width max.1500 mm

Smaller grinding unit (Quantity 2)
Operational field: Rotary Kiln : Tyre diameter Ø < 5 m, Tyre width < 900 mm
: Roller diameter Ø < 2 m, Roller width < 900 mm
Mill Slide ring : Slide ring diameter max. 10 m, Slide ring width < 900 mm
Trunnion shaft : Trunnion shaft Ø max 3 m
Rotary drums : Tyre diameter Ø < 5 m, Tyre width < 900 mm
: Roller diameter Ø < 2 m, Roller width < 900 mm

Cup wheel grinder unit (Quantity 2x2)
Operational field: Rotary Kiln: Lateral tyre surface
: Thrust rollers (Fixed and or Hydraulic thrust units)
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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers
Surface damage

Kiln supporting roller:
Corrugation due to kiln drive vibrations

Kiln tyre:
Convex shape of kiln tyre
Refurbishment in progress

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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers
Surface damage

Tyre and roller surface damages in circumference direction
Example: The inclination of the supporting rollers differed by 0.5%. Due to the inclination failure

the customer skewed the supporting rollers wrong. Finally the skewing failure create the surface
damage.
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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers
Grinding of supporting rollers, kiln tyres and thrust roller

Before

After

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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers
Grinding of supporting rollers, kiln tyres and
thrust roller
Polysius is providing the full service for
refurbishment of damaged surfaces, including

necessary adjustment

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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers
Grinding of supporting rollers in progress

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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers
Grinding of supporting rollers in progress

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Polysius

Grinding of supporting rollers, kiln tyres and thrust rollers

Measuring device to check the diameter and out of roundness of tyres and
supporting rollers

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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers

Measuring device to check the diameter and out of roundness of tyres and
supporting rollers

Dimensional stability after refurbishment:
- Supporting rollers Diameter deviation +/- 0,10 mm (Rotary Kiln, Rotary drum)
- Kiln tyres
Diameter deviation +/- 0,15 mm (Rotary Kiln, Rotary drum)
- Supporting rollers Out of roundness max. 0,20 mm (Rotary Kiln, Rotary drum)
- Slide ring
- Slide ring

Diameter deviation +/- 0,05 mm (Mill slide ring Trunnion shaft)
Out of roundness max. 0,15 mm (Mill slide ring, Trunnion shaft)

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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers
Thrust roller:
Alignment of thrust rollers to theoretical Kiln axis

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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers
Thrust roller:
Possibilities of miss alignment

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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers

Thrust roller:
Alignment of thrust rollers to theoretical Kiln axis
Different inclination between thrust roller and kiln axis
Angle miss alignment due to settlements, or wrong assembly

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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers

Thrust roller:
- Offset to the vertical centre line
- Due to our experience offsets
bigger than 5 mm will cause surface
damages
- Realignment by using circle
measuring device

=

=

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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers

Thrust roller offset in
accordance to theoretical
kiln centre line

A

A
B
B

A : Kiln rotation direction
B : Allowable lateral offset =
2.0 to 5.0 mm
The lateral offset must be
selected that the
tyre slightly presses the
thrust roller downward!

=

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Polysius

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Grinding of supporting rollers, kiln tyres and thrust rollers
Damages due to miss alignment

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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers
Damages due to miss alignment

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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers
Grinding of tyre lateral surface and thrust roller

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Polysius


Grinding of supporting rollers, kiln tyres and thrust rollers
Grinding of tyre thrust surface and thrust
Roller in progress

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Polysius


Refurbishment of Mill slide rings
Important slide ring surface areas
1. Contact area of slide shoe bearings

2. Contact area of the housing seals
Damaged slide ring surfaces have to be refurbished for a trouble free mill operation

Polysius is providing a full service of slide ring surface refurbishment
Refurbishment with powerful belt grinding machines
Different grinding belts are available (from rough up to fine quality)
Measuring device to check the diameter and out of roundness of slide rings
The grinding works have to be done with the mill auxiliary drive
The maximum mill speed is 1,5 rpm
Polysius provides mill turning device, if required
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Polysius


Refurbishment of Mill slide rings

Measuring device to check the diameter and out of roundness of the slide ring

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Polysius

Refurbishment of Mill slide rings
Measuring device to check the diameter and out of roundness of the slide ring

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Polysius


Refurbishment of Mill slide rings

Refurbishment with powerful belt grinding machine

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Polysius