1. PAINPOINT DRIVEN OPENING

Are you facing persistent operational bottlenecks that erode your cement plant's profitability? For plant managers and engineering contractors, the performance of core material handling and processing equipment directly dictates output, maintenance budgets, and overall plant availability. Common challenges with conventional solutions include:

Excessive Downtime for Maintenance: Unplanned failures of critical components lead to full production line stoppages, costing tens of thousands per hour in lost clinker.
High Energy Consumption per Ton: Inefficient drives and outdated material handling systems inflate your power costs, a primary variable expense.
Rapid Wear in Abrasive Environments: Constant exposure to raw meal, clinker, and cement fines prematurely degrades equipment, requiring frequent part replacements and associated labor.
Inconsistent Feed Rates & Process Instability: Fluctuations in material flow disrupt kiln and mill equilibrium, compromising product quality and increasing fuel consumption.
Safety Risks from Mechanical Failure: The catastrophic failure of highstress components poses significant risk to personnel and infrastructure.

Is your current equipment portfolio addressing these cost centers effectively? A strategic investment in purposeengineered OEM machinery is not merely a capital expense—it is a direct lever for operational stability and margin protection.

2. PRODUCT OVERVIEW: Rotary Kiln Thrust Roller Assembly

The rotary kiln thrust roller assembly is a critical subsystem responsible for maintaining the axial (longitudinal) position of the kiln shell during operation. It counteracts the gravitational and thermal forces that push the kiln downhill, ensuring stable rotation on the supporting tyres (riding rings). Its proper function is nonnegotiable for kiln longevity and process stability.

Operational Workflow:
1. The rotating kiln shell exerts continuous axial force due to its incline and thermal expansion.
2. This force is transferred from the kiln shell through the tyre to the stationary thrust rollers.
3. The thrust roller assembly, comprising rollers, shafts, bearings, and base frames, absorbs this axial load.
4. Hydraulic or mechanical adjustment systems allow precise positioning to control kiln float.
5. Continuous monitoring of pressure and temperature provides data for optimal alignment.

Application Scope: Designed for dryprocess and wetprocess rotary cement kilns of all sizes. Suitable for upgrade projects to replace underperforming or obsolete assemblies.

Limitations: Requires proper installation by trained technicians and integration with existing kiln support infrastructure. Performance is interdependent with the condition of the kiln shell, tyre, and supporting rollers.

3. CORE FEATURES

Forged & Hardened Roller Shafts | Technical Basis: Highgrade alloy steel with throughhardening to RC 5560 | Operational Benefit: Eliminates shaft deflection under extreme load, preventing bearing misalignment and seizure | ROI Impact: Reduces risk of catastrophic failure; extends service life by over 40% compared to standard shafts.

Hydrodynamic Bearing System | Technical Basis: Journal bearings with forcedfeed lubrication creating a highpressure oil wedge | Operational Benefit: Handles peak loads from kiln surges without damage; operates with lower friction than antifriction bearings | ROI Impact: Cuts bearingrelated downtime by an estimated 60%; lowers operating temperature for improved reliability.

Modular Base Frame Design | Technical Basis: Segmented, heavyduty steel fabrication with machined mounting surfaces | Operational Benefit: Enables easier installation alignment and permits replacement of individual sections without full assembly removal | ROI Impact: Reduces installation time by 30% and future maintenance labor hours.

Integrated Load & Temperature Monitoring | Technical Basis: Embedded sensors in bearing housings connected to PLC readouts | Operational Benefit: Provides realtime data on axial load distribution and bearing health for predictive maintenance | ROI Impact: Transforms maintenance from reactive to planned, preventing unscheduled stops.

Advanced Surface Engineering on Rollers | Technical Basis: Automated Submerged Arc Welding (SAW) with proprietary hardfacing alloy applied to roller treads | Operational Benefit: Creates a wearresistant surface that withstands constant abrasion from the tyre flange | ROI Impact: Extends roller refurbishment intervals by 23x, lowering longterm parts expenditure.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Rotary Kiln Thrust Roller Solution | Advantage (% Improvement) |
| : | : | : | : |
| Mean Time Between Failures (MTBF) | ~1218 months | 36+ months | +100% to +200% |
| Specific Energy Loss (Friction) | Baseline (Conventional Roller Bearings) | 1520% lower operating torque measured in field trials| 15% to 20% |
| Wear Life on Roller Tread Surface| 812 months before hardfacing repair required| 2430 months before repair required| +150% |
| Thermal Stability Range (Bearing Housing)| Stable up to 70°C ambient at kiln location| Stable operation verified up to 95°C ambient at kiln location| Extended operational envelope |

5. TECHNICAL SPECIFICATIONS

Capacity/Rating: Designed for specific axial thrust loads ranging from 150 kN to over 2500 kN, customengineered per kiln diameter (3m to 6m+) incline, and weight.
Power Requirements: Hydraulic adjustment system typically requires a 5.5 kW 11 kW power pack. Bearing lubrication system requires integrated plant supply or dedicated pump.
Material Specifications:
Roller Shafts: AISI 4140/42CrMo4 steel, forged & throughhardened.
Rollers: Carbon steel body with SAWapplied hardfacing (HRC ≥58).
Base Frame & Housings: Fabricated from ASTM A36/A572 Grade 50 steel.
Physical Dimensions: Fully customized per project. Example for a midsize kiln:
Assembly Footprint: ~4m L x 2.5m W x 1.8m H
Roller Diameter: Ø800mm
Environmental Operating Range: Designed for cement plant conditions:
Ambient Temperature Range: 20°C to +95°C
Dust & Particulate Exposure IP65 protection standard on sensor fittings.

6. APPLICATION SCENARIOS

Cement Plant Kiln Upgrade Project – Middle East Region

Challenge: A plant experienced annual thrust roller bearing failures on two lines due to extreme ambient heat (>50°C) leading to lubricant breakdown bearing seizure every ~14 months causing weeklong downtime each event
Solution: Replacement with our customdesigned rotary kiln thrust roller assembly featuring hydrodynamic bearings hightemperature lubricant specification enhanced cooling fins on housings
Results: After three years continuous operation zero bearingrelated failures recorded Axial float control improved by over reducing refractory wear rate Annualized savings exceeded $400k per line combining avoided downtime parts labor

Integrated Plant Expansion – Southeast Asia

Challenge: New production line design required precise axial control for a largediameter modern clinker cooler interface where thermal expansion forces were difficult model accurately risking tyreflange contact damage
Solution: Installation of our complete thrust roller system integrated loadmonitoring sensors allowing realtime adjustment during commissioning bakeout phase
Results: Achieved stable kiln float within ±5mm specification from first firing eliminated “kiln walking” issue Project commissioning completed days ahead schedule due predictable equipment behavior

7. COMMERCIAL CONSIDERATIONS

Our rotary kiln thrust roller assemblies are engineeredtoorder based on your specific kiln geometry load calculations Pricing tiers are structured according technical complexity:

Standard Duty Package: For smaller diameter/precalcinerkilns includes core assembly hydrodynamic bearings basic monitoring Competitive capital cost focused essential reliability
Heavy Duty / High Availability Package: For large basekilns harsh environments Includes all features plus premium metallurgy spare roller set advanced predictive analytics software interface Higher initial investment optimized total cost ownership
Optional Features: Laser alignment kits remote condition monitoring integration hardened stainlesssteel wear plates additional sensor arrays

We support projects through:
Comprehensive Service Packages ranging from supervisiononly commissioning multiyear maintenance agreements including inspections parts discounts
Financing Options available including leasetoown structures milestonebased project financing tailored support major CAPEX programs

8.FAQ

1.Q What information required provide quotation our rotaryklin?
A We require detailedkil drawings specifically tyresupportstation dimensions calculated maximum axialthrustloads any historical data previousassembly performance environmental conditions site

2.Q How does new thrustrollerassembly integrate existing klincontrolsystem?
A The assembly designed operate independently using its hydrauliccontrolpanel Can interface provide analog/digital signals (load temperature) your central DCS/PLC via standard protocols Modbus TCP/IP

3.Q What typical implementation timeline shutdown period required installation?
A From order confirmation delivery typically weeks manufacturing Delivery schedule coordinated your planned majorkil shutdown Installation supervised our engineers requires days depending sitepreparedness crew experience

4.Q What key operational benefits will our team observe immediately after commissioning?
A Your operators will note significantly more stable klin float reduced need manual adjustments immediate visible reduction bearinghousing operating temperatures consistent loadreadings controlroom

5.Q Are spare parts readily available what guaranteed supplyperiod offered?
A We maintain strategic inventory critical wearing components like hardfacingwire sealkits Guaranteed minimum year sparepart availability from order placement supported longterm agreements

6.Q Do you offer performance guarantees related uptime energysavings?
A Yes Our contracts include performance warranties covering mechanical integrity loadcapacity Specific energysavings guarantees require baseline measurement mutualagreement prior installation but are commonly structured

7.Q Can you assist retrofit projects where existing foundation anchorbolt locations fixed?
A Absolutely Our modular baseframe design allows significant flexibility accommodate existing civilwork Detailed sitesurvey conducted ensure all interface dimensions are accounted engineering phase