1. ABERTURA ACIONADA POR PAINPOINT

Are you facing persistent operational bottlenecks that erode your cement plant's profitability? Para gerentes de fábrica e empreiteiros de engenharia, the performance of core material handling and processing equipment directly dictates output, orçamentos de manutenção, and overall plant availability. Common challenges with conventional solutions include:

Tempo de inatividade excessivo para manutenção: Unplanned failures of critical components lead to full production line stoppages, custando dezenas de milhares por hora em clínquer perdido.
Alto Consumo de Energia por Tonelada: Inefficient drives and outdated material handling systems inflate your power costs, a primary variable expense.
Desgaste rápido em ambientes abrasivos: Constant exposure to raw meal, clínquer, and cement fines prematurely degrades equipment, requiring frequent part replacements and associated labor.
Taxas de alimentação inconsistentes & 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. VISÃO GERAL DO PRODUTO: 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.

Fluxo de Trabalho Operacional:
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, eixos, rolamentos, 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.

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

Limitações: 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. RECURSOS PRINCIPAIS

Forjado & Hardened Roller Shafts | Base Técnica: Highgrade alloy steel with throughhardening to RC 5560 | Benefício Operacional: Eliminates shaft deflection under extreme load, preventing bearing misalignment and seizure | Impacto do ROI: Reduz o risco de falha catastrófica; extends service life by over 40% compared to standard shafts.

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

Design de estrutura de base modular | Base Técnica: Segmentado, heavyduty steel fabrication with machined mounting surfaces | Benefício Operacional: Enables easier installation alignment and permits replacement of individual sections without full assembly removal | Impacto do ROI: Reduz o tempo de instalação em 30% and future maintenance labor hours.

Integrated Load & Temperature Monitoring | Base Técnica: Embedded sensors in bearing housings connected to PLC readouts | Benefício Operacional: Provides realtime data on axial load distribution and bearing health for predictive maintenance | Impacto do ROI: Transforma a manutenção de reativa em planejada, preventing unscheduled stops.

Advanced Surface Engineering on Rollers | Base Técnica: Automated Submerged Arc Welding (SERRA) with proprietary hardfacing alloy applied to roller treads | Benefício Operacional: Creates a wearresistant surface that withstands constant abrasion from the tyre flange | Impacto do ROI: Extends roller refurbishment intervals by 23x, reduzindo despesas com peças a longo prazo.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Our Rotary Kiln Thrust Roller Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Tempo médio entre falhas (MTBF) | ~1218 meses | 36+ meses | +100% para +200% |
| Specific Energy Loss (Friction) | Linha de base (Conventional Roller Bearings) | 1520% lower operating torque measured in field trials| 15% para 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. ESPECIFICAÇÕES TÉCNICAS

Capacidade/Classificação: Designed for specific axial thrust loads ranging from 150 kN to over 2500 kN, customengineered per kiln diameter (3m to 6m+) inclinação, e peso.
Requisitos de energia: Hydraulic adjustment system typically requires a 5.5 kW 11 kW power pack. Bearing lubrication system requires integrated plant supply or dedicated pump.
Especificações de materiais:
Roller Shafts: AISI 4140/42CrMo4 steel, forged & throughhardened.
Rolos: Carbon steel body with SAWapplied hardfacing (HRC ≥58).
Estrutura básica & Housings: Fabricated from ASTM A36/A572 Grade 50 aço.
Dimensões Físicas: Fully customized per project. Example for a midsize kiln:
Assembly Footprint: ~4m L x 2.5m W x 1.8m H
Roller Diameter: Ø800mm
Faixa operacional ambiental: Designed for cement plant conditions:
Faixa de temperatura ambiente: 20°C to +95°C
Pó & Particulate Exposure IP65 protection standard on sensor fittings.

6. CENÁRIOS DE APLICAÇÃO

Cement Plant Kiln Upgrade Project – Middle East Region

Desafio: 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
Solução: Replacement with our customdesigned rotary kiln thrust roller assembly featuring hydrodynamic bearings hightemperature lubricant specification enhanced cooling fins on housings
Resultados: 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

Desafio: 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
Solução: Installation of our complete thrust roller system integrated loadmonitoring sensors allowing realtime adjustment during commissioning bakeout phase
Resultados: 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. CONSIDERAÇÕES COMERCIAIS

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

Pacote de serviço padrão: For smaller diameter/precalcinerkilns includes core assembly hydrodynamic bearings basic monitoring Competitive capital cost focused essential reliability
Serviço Pesado / 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
Recursos opcionais: 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.Perguntas frequentes

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