1. PEMBUKAAN PAINPOINT DRIVEN

Adakah anda menghadapi kesesakan operasi berterusan yang menghakis keuntungan loji simen anda? Untuk pengurus loji dan kontraktor kejuruteraan, the performance of core material handling and processing equipment directly dictates output, belanjawan penyelenggaraan, and overall plant availability. Common challenges with conventional solutions include:

Masa Henti Berlebihan untuk Penyelenggaraan: Unplanned failures of critical components lead to full production line stoppages, berharga puluhan ribu sejam dalam klinker yang hilang.
Penggunaan Tenaga Tinggi setiap Tan: Inefficient drives and outdated material handling systems inflate your power costs, a primary variable expense.
Haus Pantas dalam Persekitaran Melelas: Constant exposure to raw meal, klinker, and cement fines prematurely degrades equipment, requiring frequent part replacements and associated labor.
Kadar Suapan Tidak Konsisten & 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. GAMBARAN KESELURUHAN PRODUK: 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.

Aliran Kerja Operasi:
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, aci, galas, 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.

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

Batasan: 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. CIRI TERAS

Dipalsukan & Hardened Roller Shafts | Asas Teknikal: Highgrade alloy steel with throughhardening to RC 5560 | Faedah Operasi: Eliminates shaft deflection under extreme load, preventing bearing misalignment and seizure | Kesan ROI: Mengurangkan risiko kegagalan bencana; extends service life by over 40% compared to standard shafts.

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

Reka Bentuk Rangka Asas Modular | Asas Teknikal: bersegmen, heavyduty steel fabrication with machined mounting surfaces | Faedah Operasi: Enables easier installation alignment and permits replacement of individual sections without full assembly removal | Kesan ROI: Mengurangkan masa pemasangan dengan 30% and future maintenance labor hours.

Integrated Load & Temperature Monitoring | Asas Teknikal: Embedded sensors in bearing housings connected to PLC readouts | Faedah Operasi: Provides realtime data on axial load distribution and bearing health for predictive maintenance | Kesan ROI: Mengubah penyelenggaraan daripada reaktif kepada terancang, preventing unscheduled stops.

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

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | Our Rotary Kiln Thrust Roller Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Masa Min Antara Kegagalan (MTBF) | ~1218 bulan | 36+ bulan | +100% ke +200% |
| Specific Energy Loss (Friction) | Garis dasar (Conventional Roller Bearings) | 1520% lower operating torque measured in field trials| 15% ke 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. SPESIFIKASI TEKNIKAL

Kapasiti/Penilaian: Designed for specific axial thrust loads ranging from 150 kN to over 2500 kN, customengineered per kiln diameter (3m to 6m+) condong, dan berat badan.
Keperluan kuasa: Hydraulic adjustment system typically requires a 5.5 kw 11 kW power pack. Bearing lubrication system requires integrated plant supply or dedicated pump.
Spesifikasi Bahan:
Roller Shafts: AISI 4140/42CrMo4 steel, forged & throughhardened.
Rollers: Carbon steel body with SAWapplied hardfacing (HRC ≥58).
Rangka Dasar & Housings: Fabricated from ASTM A36/A572 Grade 50 keluli.
Dimensi Fizikal: Fully customized per project. Example for a midsize kiln:
Assembly Footprint: ~4m L x 2.5m W x 1.8m H
Roller Diameter: Ø800mm
Julat Operasi Persekitaran: Designed for cement plant conditions:
Julat Suhu Ambien: 20°C to +95°C
habuk & Particulate Exposure IP65 protection standard on sensor fittings.

6. SENARIO APLIKASI

Cement Plant Kiln Upgrade Project – Middle East Region

Cabaran: 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
Penyelesaian: Replacement with our customdesigned rotary kiln thrust roller assembly featuring hydrodynamic bearings hightemperature lubricant specification enhanced cooling fins on housings
Keputusan: 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

Cabaran: 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
Penyelesaian: Installation of our complete thrust roller system integrated loadmonitoring sensors allowing realtime adjustment during commissioning bakeout phase
Keputusan: 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. PERTIMBANGAN KOMERSIL

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

Pakej Duti Standard: For smaller diameter/precalcinerkilns includes core assembly hydrodynamic bearings basic monitoring Competitive capital cost focused essential reliability
Tugas Berat / 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
Ciri Pilihan: 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.Soalan Lazim

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