Cement Plant Equipment Oem Factory Catalog
1. PAINPOINT driven اوپننگ
ڇا توهان مسلسل آپريشنل رڪاوٽن کي منهن ڏئي رهيا آهيو جيڪي توهان جي سيمينٽ پلانٽ جي منافعي کي ختم ڪن ٿا? پلانٽ مينيجرز ۽ انجنيئرنگ ٺيڪيدارن لاءِ, the performance of core material handling and processing equipment directly dictates output, سار سنڀال جي بجيٽ, and overall plant availability. Common challenges with conventional solutions include:
سار سنڀال لاءِ اضافي وقت: Unplanned failures of critical components lead to full production line stoppages, costing tens of thousands per hour in lost clinker.
اعلي توانائي واپرائڻ في ٽون: Inefficient drives and outdated material handling systems inflate your power costs, a primary variable expense.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, ڪلينر, and cement fines prematurely degrades equipment, requiring frequent part replacements and associated labor.
نامناسب فيڊ جي شرح & 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. پيداوار جو جائزو: 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.
آپريشنل ڪم فلو:
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, شافٽ, بيئرنگ, 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.
ايپليڪيشن جو دائرو: Designed for dryprocess and wetprocess rotary cement kilns of all sizes. Suitable for upgrade projects to replace underperforming or obsolete assemblies.
حدون: 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. بنيادي خاصيتون
جڙيل & Hardened Roller Shafts | ٽيڪنيڪل بنياد: Highgrade alloy steel with throughhardening to RC 5560 | آپريشنل فائدا: Eliminates shaft deflection under extreme load, preventing bearing misalignment and seizure | ROI اثر: تباهي واري ناڪامي جي خطري کي گھٽائي ٿو; extends service life by over 40% معياري شافٽ جي مقابلي ۾.
Hydrodynamic Bearing System | ٽيڪنيڪل بنياد: Journal bearings with forcedfeed lubrication creating a highpressure oil wedge | آپريشنل فائدا: Handles peak loads from kiln surges without damage; operates with lower friction than antifriction bearings | ROI اثر: Cuts bearingrelated downtime by an estimated 60%; lowers operating temperature for improved reliability.
ماڊل بيس فريم ڊيزائن | ٽيڪنيڪل بنياد: ورهايل, heavyduty steel fabrication with machined mounting surfaces | آپريشنل فائدا: Enables easier installation alignment and permits replacement of individual sections without full assembly removal | ROI اثر: تنصيب جو وقت گھٽائي ٿو 30% and future maintenance labor hours.
Integrated Load & Temperature Monitoring | ٽيڪنيڪل بنياد: Embedded sensors in bearing housings connected to PLC readouts | آپريشنل فائدا: Provides realtime data on axial load distribution and bearing health for predictive maintenance | ROI اثر: بحالي کي رد عمل کان منصوبابندي ۾ تبديل ڪري ٿو, preventing unscheduled stops.
Advanced Surface Engineering on Rollers | ٽيڪنيڪل بنياد: Automated Submerged Arc Welding (SAW) with proprietary hardfacing alloy applied to roller treads | آپريشنل فائدا: Creates a wearresistant surface that withstands constant abrasion from the tyre flange | ROI اثر: Extends roller refurbishment intervals by 23x, ڊگھي مدت جي حصن جي خرچن کي گھٽائڻ.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار | Our Rotary Kiln Thrust Roller Solution | فائدو (% سڌارو) |
| : | : | : | : |
| ناڪامين جي وچ ۾ وچولي وقت (ايم بي ايف) | ~ 1218 مهينا | 36+ مهينا | +100% جي طرف +200% |
| Specific Energy Loss (Friction) | بيس لائين (Conventional Roller Bearings) | 1520% lower operating torque measured in field trials| 15% جي طرف 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. ٽيڪنيڪل وضاحتون
قابليت / درجه بندي: Designed for specific axial thrust loads ranging from 150 kN to over 2500 kN, customengineered per kiln diameter (3m to 6m+) مائل, and weight.
بجلي جي گهرج: Hydraulic adjustment system typically requires a 5.5 ڪلواٽ 11 kW power pack. Bearing lubrication system requires integrated plant supply or dedicated pump.
مواد جي وضاحت:
Roller Shafts: AISI 4140/42CrMo4 steel, forged & throughhardened.
رولرس: Carbon steel body with SAWapplied hardfacing (HRC ≥58).
Base Frame & Housings: Fabricated from ASTM A36/A572 Grade 50 اسٽيل.
جسماني طول و عرض: Fully customized per project. Example for a midsize kiln:
Assembly Footprint: ~4m L x 2.5m W x 1.8m H
Roller Diameter: Ø800mm
ماحولياتي آپريٽنگ رينج: Designed for cement plant conditions:
Ambient درجه حرارت جي حد: 20°C to +95°C
مٽي & Particulate Exposure IP65 protection standard on sensor fittings.
6. درخواست جا منظر
Cement Plant Kiln Upgrade Project – Middle East Region
چيلنج: 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
حل: Replacement with our customdesigned rotary kiln thrust roller assembly featuring hydrodynamic bearings hightemperature lubricant specification enhanced cooling fins on housings
نتيجا: 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
چيلنج: 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
حل: Installation of our complete thrust roller system integrated loadmonitoring sensors allowing realtime adjustment during commissioning bakeout phase
نتيجا: 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. تجارتي خيالات
Our rotary kiln thrust roller assemblies are engineeredtoorder based on your specific kiln geometry load calculations Pricing tiers are structured according technical complexity:
معياري ڊيوٽي پيڪيج: For smaller diameter/precalcinerkilns includes core assembly hydrodynamic bearings basic monitoring Competitive capital cost focused essential reliability
ڳري ڊيوٽي / 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
اختياري خاصيتون: 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
