FLSmidth Rotary Kiln For Cement Features Easy Maintenance

FLSmidth’s ROTAX-2 Rotary Kiln for cement delivers high production capacity and requires minimal energy and space, according to the company. The two-base design saves on construction time and costs and this rotary kiln never needs kiln axis alignment: Pyroprocessing with proven operational reliability.

Imagine a rotary kiln for cement designed to completely eliminate the risk of shell constriction and the need for tire migration monitoring systems. That’s the ROTAX-2, which suspends the kiln shell inside tangentially suspended tires on self-adjusting rollers. That means there’s no wear between tire and kiln, and no need for lubrication. Instead, the drive is connected to the supporting rollers, and the kiln rotation is driven by friction between the rotating support rollers and the kiln tire.

The innovative suspension design of the ROTAX-2 means it can offer optimal mechanical reliability compared with traditional rotary kilns. And when it’s time to inspect or maintain the kiln, there are no hidden parts. Everything is visible, for easy inspection and maintenance.

And the kiln alignment isn’t affected by the settling of the foundation, which means you don’t have to worry about periodical kiln axis realignment.

The lack of a kiln girth gear and the low number of supporting rollers help keeps maintenance costs low.

The ROTAX-2 is kept in position by an automatic hydraulic thrust device (HTD) that controls the axial motion of the kiln. The HTD can take up the full axial load of the kiln, meaning that roller skewing is not required to take up axial forces.

A rotary kiln for cement is only as efficient as the seals on its inlet and outlet zones. After all, if false air enters the kiln system, fuel consumption goes up, production output goes down, and operating expenses skyrocket.

The ROTAX-2’s impressive graphite seals use a staggered arrangement. Two rows of graphite blocks are held in place with a wire rope system. This means a good, tight seal against the outer air casing.

Take note: the relatively slow speed at the kiln inlet cuts down on dust circulation. That means less kilocalorie consumption and easier operations.

This low-maintenance rotary kiln for cement includes:

Self-aligning roller support system. ROTAX-2 Rotary Kiln installations feature direct electro-mechanical drive-through rollers, as well as a fully self-aligning roller support system. The roller suspension maintains constant contact with the supporting rollers. This ensures the efficient transmission of torque and cuts down on the stress that causes pitting and cracks.

No lubrication required between tire and kiln. Kiln rotation is driven by friction between the rotating support rollers and the kiln tire. At the same time, a redesigned tire attachment system allows the kiln shell to expand radially, which means there’s no need for lubrication between the tire and kiln.

Periodical realignment not required. Because there’s no kiln girth gear and only two supports, maintenance costs are low. And kiln axis alignment is not affected by settling of the foundation, so periodical kiln axis realignment is unnecessary.

Seals require no greasing. Graphite seals at the inlet and the outlet of the kiln reduce false air intake, but they are flexible enough to follow the kiln’s movements. These seals require no greasing and are practically maintenance-free, according to FLSmidth.

Other key benefits include:

  • Two-base design saves on space, costs. With only two bases, the ROTAX-2 offers low civil investment costs, low operating costs, and never needs realignment.
  • All the parts are visible. Because it has fewer parts than other rotary kilns and all of them are visible, maintenance costs are lower than on more complex rotary kilns for cement.
  • Lowest heat consumption in its class. The ROTAX-2 saves energy too: it has the lowest specific heat loss and energy consumption in its class.
  • Designed for long life. Its low kiln-shell ovality and long brick-lining lifetime means it can offer exceptional durability.

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