1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you facing persistent operational bottlenecks that erode your cement plant's profitability? Pour les directeurs d’usine et les entrepreneurs en ingénierie, the performance of core material handling and processing equipment directly dictates output, budget d'entretien, and overall plant availability. Common challenges with conventional solutions include:

Temps d'arrêt excessif pour la maintenance: Unplanned failures of critical components lead to full production line stoppages, coûtant des dizaines de milliers par heure en clinker perdu.
Consommation d'énergie élevée par tonne: Inefficient drives and outdated material handling systems inflate your power costs, a primary variable expense.
Usure rapide dans les environnements abrasifs: Constant exposure to raw meal, mâchefer, and cement fines prematurely degrades equipment, requiring frequent part replacements and associated labor.
Débits d'alimentation incohérents & 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. APERÇU DU PRODUIT: 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.

Flux de travail opérationnel:
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, arbres, roulements, 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.

Champ d'application: Designed for dryprocess and wetprocess rotary cement kilns of all sizes. Suitable for upgrade projects to replace underperforming or obsolete assemblies.

Limites: 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. CARACTÉRISTIQUES PRINCIPALES

Forgé & Hardened Roller Shafts | Base technique: Highgrade alloy steel with throughhardening to RC 5560 | Avantage opérationnel: Eliminates shaft deflection under extreme load, preventing bearing misalignment and seizure | Impact sur le retour sur investissement: Réduit le risque de panne catastrophique; extends service life by over 40% par rapport aux arbres standards.

Hydrodynamic Bearing System | Base technique: Journal bearings with forcedfeed lubrication creating a highpressure oil wedge | Avantage opérationnel: Handles peak loads from kiln surges without damage; operates with lower friction than antifriction bearings | Impact sur le retour sur investissement: Cuts bearingrelated downtime by an estimated 60%; lowers operating temperature for improved reliability.

Conception du cadre de base modulaire | Base technique: Segmenté, heavyduty steel fabrication with machined mounting surfaces | Avantage opérationnel: Enables easier installation alignment and permits replacement of individual sections without full assembly removal | Impact sur le retour sur investissement: Réduit le temps d'installation de 30% and future maintenance labor hours.

Integrated Load & Temperature Monitoring | Base technique: Embedded sensors in bearing housings connected to PLC readouts | Avantage opérationnel: Provides realtime data on axial load distribution and bearing health for predictive maintenance | Impact sur le retour sur investissement: Transforme la maintenance de réactive à planifiée, preventing unscheduled stops.

Advanced Surface Engineering on Rollers | Base technique: Automated Submerged Arc Welding (SAW) with proprietary hardfacing alloy applied to roller treads | Avantage opérationnel: Creates a wearresistant surface that withstands constant abrasion from the tyre flange | Impact sur le retour sur investissement: Extends roller refurbishment intervals by 23x, lowering longterm parts expenditure.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie | Our Rotary Kiln Thrust Roller Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Temps moyen entre les pannes (MTBF) | ~1218 mois | 36+ mois | +100% à +200% |
| Specific Energy Loss (Friction) | Référence (Conventional Roller Bearings) | 1520% lower operating torque measured in field trials| 15% à 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. SPÉCIFICATIONS TECHNIQUES

Capacité/cote: Designed for specific axial thrust loads ranging from 150 kN to over 2500 kN, customengineered per kiln diameter (3m to 6m+) inclinaison, et le poids.
Exigences d'alimentation: Hydraulic adjustment system typically requires a 5.5 kW 11 kW power pack. Bearing lubrication system requires integrated plant supply or dedicated pump.
Spécifications matérielles:
Roller Shafts: AISI 4140/42CrMo4 steel, forged & throughhardened.
Rollers: Carbon steel body with SAWapplied hardfacing (HRC ≥58).
Cadre de base & Housings: Fabricated from ASTM A36/A572 Grade 50 acier.
Dimensions physiques: Fully customized per project. Example for a midsize kiln:
Assembly Footprint: ~4m L x 2.5m W x 1.8m H
Roller Diameter: Ø800mm
Plage de fonctionnement environnementale: Designed for cement plant conditions:
Plage de température ambiante: 20°C to +95°C
Poussière & Particulate Exposure IP65 protection standard on sensor fittings.

6. SCÉNARIOS D'APPLICATION

Cement Plant Kiln Upgrade Project – Middle East Region

Défi: 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
Résultats: 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

Défi: 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
Résultats: 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. CONSIDÉRATIONS COMMERCIALES

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

Forfait service standard: For smaller diameter/precalcinerkilns includes core assembly hydrodynamic bearings basic monitoring Competitive capital cost focused essential reliability
Robuste / 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
Fonctionnalités facultatives: 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