Kiln Alignment

kiln alignment serves to align the trunnion wheels with the drum's centerline with respect to the actual and overall slope of the drum. The end result is the even distribution of the load across all the components of the kiln. This in turn ensures operational; efficiency and minimizes the rate of wear and tear of the kiln.

More information on kiln alignment

Causes of misalignment

Structural issues with the plant such as sinking foundations and environmental issues such as the levels of dust in the air are the major causes of misalignment. The varying loads on the kiln, the fluctuations in the temperatures and power failures could also result in a certain degree of misalignment. Overall, it is hard to predict with certainty what may cause the distortion in the alignment of different components and therefore the need to keep checking the kiln to detect any form of misalignment early on.

Importance of kiln alignment

There are a number of reasons why you should pay special attention to kiln alignment. A misaligned kiln has a lot of operational inefficiencies. The inefficiencies result into lost time and resources which ultimately leads to financial losses of different scales. Even the slightest misalignment in the kiln increases the rate of wear and tear of the entire rotary kiln which in turn may result into total damage and equipment failure.

Regular maintenance

Being one of the most common causes of damage for any kiln, it is essential to keep an eye on the alignment. To ensure that misalignment is detected at the earliest possible occurrence, this should be regularly checked. The frequency of the checks could be higher than that of regular maintenance in order to enhance early detection and rectification. However, before the problem is rectified, you need to conduct a comprehensive survey that will help you in determining the extent of the misalignment and therefore the measures that will be taken to rectify the situation.

Kiln alignment methods

There are a number of methods that can be used to do this effectively. However, the traditional manual alignment method is still by far the most widely used method. This includes taking the measurements of the kiln manually, doing the calculations manually and then carrying pout the adjustments with respect to the results. However, the traditional method's greatest limitation is that it is prone to error especially during the measurement and the calculation stages.

Technological advancements have led to the development of new and improved methods such as the laser tracking system method. A three dimension map of the kiln is established through the use of laser beams. Software is then utilized to compute the level of misalignment and the necessary adjustments required to restorer efficient operations. The use of software for calculations minimizes the likelihood and level of error making this method more accurate compared to the traditional one.

Expert Assistance

While it might be a great idea to have an in house expert on the alignment, it might not be always the case. As an organization, if you do not have a specialist, you should outsource the work to a qualified, skilled and experienced individual or organisation as using trial and error methods of alignment may cause more harm than good in the long run.