Blog

KILN TYRE

PIYALI GROUP manufactures and exports 200 TPD kiln tyre with shell in accordance with the designs and specifications given by clients. The 200 TPD kiln tyre is a massive steel casting that provides support to the kiln shell and the materials processed inside the kiln. This component is attached to the kiln shell and rotates on rollers or bearings, enabling smooth rotation of the kiln.

200 TPD Kiln Tyre Dimensions

• MATERIAL – Cast Steel / Forged Steel / Ductile Carbon / Alloy Steel
• CAPACITY – 200 TPD Rotary Kiln Tyre for Sponge Iron Steel Plant
• CERTIFICATION – ISO9001
• DIAMETER –
• Capacity – up to 8500mm
• MATERIAL GRADE – EN-8,EN-19,EN-24,GS20Mn5,32CrNiMo8V,42CrMo4,IS 2708 Grade – III,IS 2708 Grade -2
• DESIGN – AS PER CUSTOMER PROVIDED (POPURI / IPS / ITC / MEC / LURGI etc.)
• CUSTOMIZABLE – YES

KILN TYRE MANUFACTURING PROCESS:

Manufacturing kiln tyres is a multi-step, complex procedure that includes various phases. Here is a summary of each phase:

STEP 1: SIMULATION

PIYALI GROUP uses casting simulation to ensure that its cast components meet the highest quality standards. This helps ensure that the finished product meets the necessary requirements and performance standards.

• CAD model design: The first step is to create a 3D CAD model of the component. PIYALI uses special software that includes essential features includes sprue channels, feeders, and gating systems.

• Material properties: The properties of the casting material (usually steel or iron) include density, specific heat, thermal conductivity, melting temperature, and viscosity.

• Boundary conditions: Boundary conditions, including temperature and velocity, are specified for each element. This allows engineers to simulate the behavior of molten metal in the mold.

• Simulation and Analysis: The simulation uses the special software, which solves the mathematical equations that govern the behavior of the molten metal. Analysis uses simulation to identify potential defects.

• Optimization: Based on the analysis, engineers can optimize the casting process by adjusting the gating system, mold design, and material properties. This helps to ensure that the casting process produces high-quality components that meet the required specifications.

STEP 2: CASTING

Casting process involves pouring the liquid material in to the mould which contains an internal cavity of the desired shape. Casting is one of the manufacturing methods used for producing kiln tyre. Molding molten metal into a mold to create a tyre shape and size. Sand casting is a preferred manufacturing process for kiln tyres. The procedure includes the use of a sand mold to shape the molten metal into the desired form. The sand mold is packing sand around a pattern that represents the finished tyre shape.

STEP 3: WOOD PATTERN

WOODEN PATTERN INSPECTION

• Dimensional Inspection: Dimensional inspection allows to check the pattern to ensure that it is of the correct size and shape for the casting.Dimensional inspection uses various precision instruments, including calipers, micrometers, and gauges, for measurements.
• Material Inspection: The material inspection is necessary to ensure that it is of high quality and complies with the casting process’s requirements.
• Surface quality: The pattern’s surface must be flawless and free of flaws like knots, fissures, or rough patches.
• Alignment: Proper alignment is essential for accurate casting.
• Inspection of the pattern assembly: In this type of inspection, the pieces should fit together correctly to make sure that there are no flaws in the joints or connections.

STEP 4: POURING PROCESS

Molding is the procedure of pouring liquid into a specific mold to ensure it solidifies in a modified form. Sand and a binding substance packs around the pattern to make a mold. To form the shape of the finished product, the molten or liquid material pours into a mold cavity or hole.The pouring process involves filling a mold with molten metal, which solidifies to form the kiln tyre.

STEP 5: HEAT TREATMENT

Heat treatment process enhances the hardness, strength, and durability of kiln tyre and their resistance. Heat treatment process improves the mechanical properties of a kiln tyre. The various heat treatments include carburizing, quenching and tempering, normalizing, and annealing. The  type of heat treatment depends on the material composition of the edge and the desired mechanical properties.

HEAT TREATMENT PROCESS FOR KILN TYRE AS FOLLOWINGS :

• Cleaning: It is the process to clean the kiln tyre properly to get rid of any debris, oil, or other impurities that could interfere with the heat treatment procedure.
• Preheating: To remove any remaining stresses and lower the possibility of thermal shock during the heat treatment procedure, the kiln tyre is preheated to a temperature of about 300–400°C.
• Austenitizing: The kiln tyre is then heated to a temperature of around 850-900°C and held at this temperature for a specified time to transform the steel into an austenitic phase. This process helps to improve the hardness and strength of the steel.
• Quenching: To quickly cool the metal and change its austenitic phase into a martensitic phase, the kiln tyre is submerged in a quenching liquid, such as water or oil. This procedure produces a material that is hard and brittle.
• Tempering: As a crucial step in the heat-treating process for kiln tyre is tempering that involves reheating the hardened tyre to a specific temperature to reduce the metal’s deformation and kept at this temperature for a predetermined period of time.
• Machining: The kiln tyre is then machined to achieve the required dimensions and surface finish.

STEP 6: MACHINING

• Rough Machining: In this procedure, the kiln tyre is first roughed out to eliminate extra material using a cutting tool, like a lathe or milling machine. This process creates the basic shape of the kiln tyre.

• Proof Machining: The kiln tyre goes through proof machining after rough machining. In this process, The tyre cut in to its final dimensions. Proof machining makes sure the tyre has the necessary measurements and adheres to the design requirements.

• Final Machining: In this step, the kiln tyre subjects to the final machining procedure, which entails polishing and completing the tyre’s surface. This procedure guarantees that the tyre’s surface is flawless and free of flaws or blemishes. The final machining procedure contributes to the tyre’s increased toughness and wear-and-tear resistance.

STEP 7: FINAL INSPECTION

Final inspection in kiln tyre manufacturing is a critical procedure to guarantee that manufactured products meet the required specifications and are of high quality.

• DIMENSIONAL TEST: Final machining dimensional testing is a quality assurance process that makes sure the finished item or component complies with the requirements for its intended use. In dimensional test, measure the key dimensions of the kiln tyre to ensure that it meets the required specifications.
  • Inspect the kiln tyre for any visible defects.
  • Measure the diameter of the kiln tyre at various points along its circumference.
  • Measure the width of the kiln tyre at its widest point.
  • Measure the thickness of the kiln tyre at various points along its circumference.
  • Check the roundness of the kiln tyre by measuring the distance between two points on its circumference.
  • Compare the measured dimensions to the design specifications and margins.

• DP TEST: DP test is a non-destructive testing (NDT) method for inspecting kiln tyres for surface defects in metallic and non-metallic materials.
  • DWELL TIME: A liquid dye penetrant is applied to the surface of a kiln tyre, absorbed into cracks and surface defects, and a solution is applied to remove color and highlight defects.

STEP 8: PACKAGING AND DELIVERY

MATERIAL DISPATCH PLANNING : 200 TPD KILN TYRE

Material dispatch planning is the process of making sure the right materials are available at the appropriate time and in the proper quantity to satisfy the production needs of the kiln tyre manufacturing.This involves identifying the materials necessary for each production phase, choosing the materials from the stock, and delivering them to the production unit.

• Wooden Box Packing: A wooden box can be a good choice for packing heavy equipment for storage or transportation. To determine the proper size of the required wooden box, measure the kiln tyre first. Choose a large, solid wooden box that can hold the equipment and leave the enough space for protection and security. The box needs to be strong enough to support the weight and pressure of the equipment.
  • Carefully align the kiln tyre.
  • Place the kiln tyre in a wooden box.
  • Seal the box carefully to prevent movement.
  • It is important to include all the relevant shipping information on the box’s label, along with the proper handling directions.

DELIVERY:

The 200 TPD kiln tyre with shell product is delivered to the customer.

How you select a best materials grade for Kiln Tyre?

• Working conditions: The material grade should be able to handle specific loads and stresses in the kiln.
• Budget: Choosing the finest material grade for the kiln tyre will depend in part on how much the materials will cost.
• Type of process: Different kiln processes affect tyre wear and tear.
• Size and weight of the kiln: The size and weight of the kiln affect tyre loads and stresses.

KILN TYRE CHAIR PAD:

The kiln tyre chair pad is a component that connects the kiln tyre to the kiln shell. It uses ceramic fibre, a high-temperature, robust material that can withstand shocks and vibrations. Kiln tyre chair pad protects kiln from harm and high temperatures.

CHAIR PAD POSITIONING:

Position of chair pad with kiln tyre should ensure safe, stable, and comfortable surface for workers. The guided strip fit into a groove or channel on the surface of the kiln support, which helps to stabilize and guide the chair pad.

CHAIR PAD AND BLOCKS CONNECTION:

Blocks support and stabilize the kiln parts, and chair pads give employees a secure and comfortable place to work. Chair pad integrates with kiln blocks to support walls with some special features to fasten to blocks.It is important to ensure that the chair pad is compatible with the blocks with proper fitting to give users a stable and safe working environment in the kiln.

CHAIR PAD WORKING PROCESS:

The chair pad works in tandem with the 200 TPD kiln tyre and shell to give users of the kiln a secure and comfortable working environment. The position of the chair pad is on top of the kiln tyre, a large metal ring that holds the kiln. The outer framework of the kiln that encloses the firing chamber is kiln shell. The chair pad integrates with kiln blocks to support walls, with some special features to fasten the blocks. The chair pad acts as a cushion or shock absorber, which helps to absorb any vibration or movement between the kiln tyre and shell.

MAINTENANCE: Replacement of chair pads and blocks in a rotary kiln is essential for safe and efficient operation.

FEATURES OF KILN TYRE CHAIR PAD:

• Kiln tyre chair pad are able to withstand the high temperatures.
• Kiln tyre chair pads provide stable base for rotary kiln operation.
• Reduces risk of damage and improves efficiency and output.
• Tyre chair pads reduce wear and tear on kiln components.
• Kiln tyre chair pads improve heat transfer efficiency.
• Kiln tyre chair pads reduce downtime and increase productivity.

KILN SHELL:

• A rotary kiln shell is usually made of steel plate, a large cylindrical furnace, is used at high temperatures for operations like annealing, roasting, and drying materials.  
• Several steel plates are typically welded together to make a cylindrical shape for the shell.
• The size and shape of the kiln shell can change depending on the intended use and production needs.
• Refractory materials are used to protect kiln shells from corrosive atmospheres and high temperatures.
• The rollers and bearings that support the kiln shell allow it to gently rotate around its longitudinal axis.
• The drive system for the kiln shell, which rotates the kiln shell, is made up of a motor, gearbox, and other components.

200 TPD Kiln Shell Technical Specifications

• CAPACITY – 200 TPD Rotary Kiln Shell for Sponge Iron Steel Plant
• CERTIFICATION – ISO9001
• MATERIAL GRADE – BOILER QUALITY (BQ) IS 2002, SA 516 Grade 70
• DESIGN – AS PER CUSTOMER PROVIDED (POPURI / IPS / ITC / MEC / LURGI etc.)
• CUSTOMIZABLE – YES

KILN SHELL FABRICATION PROCESS:

“Kiln shell fabrication” is the process of manufacturing kiln shell. Usually, several steel plates are welded together to form the cylindrical shape of the kiln shell.

The fabrication process of kiln shells steps are as follows:

1. Design: The first stage in the fabrication process of a kiln shell is design, which involves choosing the appropriate materials, determining the shape and size of the kiln shell, and other necessary specifications.
2. Materials: Depending on working temperature, chemical environment, and mechanical stresses, kiln shells are made.
3. Chamfering: Chamfering is the process performs to remove sharp edges, protect against scratching and cracking, and enhance the kiln shell’s appearance. Using a chamfering tool, a cutting tool, to create a beveled edge or surface is a necessary step in the chamfering process.
4. Cutting and Bending: Cut and shape the raw materials into the required shape and size of the kiln shell parts. The bending process involves the shaping of a metal plate or sheet into a curved shape to create the cylindrical shell of a kiln.
   • PLATE BENDING PROCESS: The plate bending process involves shaping the steel plates into the desired shape to form the shell.

5. Welding and Assembly: Welding techniques are used to join and prepare edges for welding includes GTAW, SMAW, and GMAW are used to join and prepare edges for welding. In the assembly process, the kiln shell assembles with the help of bolting or welding additional components.

6. Machining and Finishing: After the kiln shell structure is complete, it performs machining and finishing process to ensure that it is the right size, shape, and surface finish.

7. Quality Control: Quality control methods ensure the kiln shell is safe and meets production requirements.

200 TPD KILN TYRE WELDED FITTED WITH SHELL:

Welding is the process to fit a 200 TPD kiln tyre with a shell. Other methods include shrink-fitting and bolted connections to fit a kiln tyre with a shell.

The basic procedures for welding a kiln tyre to a shell are as follows:

1. Cleaning: Clean the surfaces of the 200 TPD kiln tyre and shell is the first step. Remove the dirt, rust, or other contaminants to ensure a strong bond.
2. Tack welding: The next step is to use tack welds to hold the kiln tyre in place on the shell. This involves placing the small welds at specific distances all around the kiln tyre.
3. Preheating: To help the weld penetrate the metal and form a solid bond, the metal is heated to a high temperature after the tack welds are in position. 
4. Welding: After preheating, the kiln tyre is joined to the shell by welding. This entails melting the metal and joining the kiln tyre to the shell using a welding equipment. To guarantee a solid and long-lasting bond, the welding process needs to be carefully managed.
5. Cooling: After welding is finished, the metal is given time to gently cool. This is crucial to keep the metal from brittleness and to maintain the strength of the joint.
6. Finishing: This process is used to remove any extra weld substance after the metal has cooled. The surface is polished to create an even, smooth, and rotating surface.

200 TPD KILN TYRE SHELL REPLACEMENT:

A complex procedure that requires specific knowledge and tools to replace the 200 TPD kiln tyre and shell. The procedure entails a number of stages, including disassembling the current kiln, getting rid of the old tyres and shells, and substituting the new parts.

kiln tyre shell replacement process:

1. Dismantling the kiln: Dismantling or Breaking the kiln is the first stage in the replacement process. This involves taking out the burner, refractory lining, and other parts of the existing kiln.
2. Removing the old tyre: Remove the old tyre from the kiln by cutting the bolts and separate it from the shell.
3. Removing the old shell: After removing the tyre, Split the old shell pieces out of the kiln.
4. Installing the replacement tyre: Mount the new kiln tyre on the support rollers of the kiln and line up with the shell.
5. Installing the new shell:  Install the new shell by welding the individual pieces together and lining them up with the tyre.
6. Fixing the kiln: After the replacement parts installation, add the refractory lining, burner, and other parts to the kiln.
7. Checking and assembling: The final step is to test the kiln and put into service to make sure it is functioning properly.

Why you should buy Kiln tyre with shell from PIYALI?

PIYALI Engineering Corporation is a well-known and reputable manufacturer and supplier of 200 TPD kiln tyres with shells. Here are some reasons why you should consider buying 200 TPD kiln tyres with shells from PIYALI:

• PIYALI commits to provide high-quality products.
• PIYALI offers customized kiln tyres with shells to meet customer needs.
• PIYALI works closely to understand the requirements and design of kiln tyres with shells.
• PIYALI has experienced and knowledgeable professionals who provide valuable advice and guidance to customers.
• PIYALI provides excellent customer service and support.
• PIYALI offers competitive pricing for kiln tyres with shells, providing value for money.