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Piyali Group Corporation is the well-known designer and manufacturer of high-quality cooler support roller assembly goods that are acknowledged as some of the best in the sector. Our products perform a variety of functions in many factories and industries. The 100 TPD Cooler Support Roller Assembly is a component used in the production of Direct Reduced Iron (DRI) in a sponge iron steel plant. A support roller rotates with the cooler drum, and a plummer block, which provides stationary support for the shaft, are typical components of the assembly. This assembly supports the cooler’s weight and ensures smooth rotation during the cooling process. It operates to endure the high temperatures and harsh environments of the DRI manufacturing process.

COOLER SUPPORT ROLLER ASSEMBLY PARTS:

The cooler support roller assembly is a critical component of a sponge iron plant’s operation. It is in responsible for supporting the cooler’s weight and assuring its smooth rotation. The cooler support roller system generally consists of the following components:

• Support rollers: These are round rollers that support the cooler’s weight while allowing it to rotate smoothly.
• The shaft links the cooler support roller assembly to the motor and transfers power to the gears.
• The plummer block is a housing unit that includes a bearing that enables the shaft to freely rotate while remaining aligned.
• Labyrinth rings are a form of sealing component that helps to prevent dust and other particles from entering the bearing area.

• Gears: These parts enable the cooler support roller assembly to rotate by transferring power from the motor to them.

1. SUPPORT ROLLER:

A 100 TPD cooler support roller refers to a cooler support roller that can support up to 100 tons per day of material. The support roller is an essential component of a ROTARY COOLER, which helps to support the cooler’s weight and ensures smooth rotation during the cooling process. Therefore, support rollers have become a crucial criterion for assessing the quality of rotary coolers. They use high quality steel and can withstand extreme heat, heavy weights and abrasive materials. We can provide casting and machining services for a variety of rotary kiln parts based on customers’ designs.

100 TPD Cooler Support Roller Technical Specifications

• DIAMETER -1000mmm Face width 560mm
• CERTIFICATION – ISO9001
• APPLICATIONS – 100 TPD Cooler Accessories for DRI Sponge Iron Steel Plant
• MATERIAL GRADE – Casting IS 2708 Grade – 3, IS 2644 Grade CS 700, GS30CrNiMo8, 42CrMo4
• MATERIAL – Cast Steel and Forged Steel
• DESIGN – As per the customer requirements (POPURI / IPS / ITC / MEC / LURGI etc.)

FEATURES OF COOLER SUPPORT ROLLER:

• To guarantee durability and resistance to wear and tear, the support roller use high-quality steel.
• The roller is carefully machined to ensure smooth operation and efficient rotary kiln support.
• Low-Maintenance cost.
• The roller can handle large loads of up to 100 tonnes per day.
• Easy installation
• The roller is able to endure high temps without breaking down or becoming harm.
• The roller is corrosion-resistant, guaranteeing a long service life.

2. COOLER SUPPORT ROLLER WITH SHAFT:

A shaft is a common and essential machine component in 100 TPD support roller assembly.  The roller shaft is the primary drive component of a support roller assembly. The term “100 TPD cooler support roller shaft” refers to a roller shaft that is capable of holding up to 100 tonnes of material per day. An essential component of a rotating kiln system for the production of cement, sponge iron steel, and other products is the cooler support roller shaft.

SHAFT MANUFACTURING PROCESS:

The machining process of a 100 TPD cooler support roller shaft involves cutting the raw material, centering, turning, facing, chamfering, grooving, drilling, heat treatment, grinding, polishing, and final inspection. This process guarantees the precision and quality of the shaft, making it an essential component of a rotary kiln system used in a variety of industrial processes.

Shaft machining process are as follows:

1. The first step is cutting the raw material, which is typically a high-quality steel or alloy steel. The raw material is cut to the length necessary to construct the support roller shaft.
2. The shaft is then positioned in a lathe machine to ensure that its axis is exactly in line.
3. The shaft is turned and turned to guarantee that its diameter and end faces are within the required tolerance limits.
4. The edges of the shaft are chamfered to prevent any sharp edges from causing harm during installation.
5. Grooving and drilling: The shaft is grooved and drilled to enable the roller bearings and other components to be installed.
6. Heat treatment improves the shaft’s strength and toughness, making it more resistant to wear and strain.
7. Grinding and polishing: Following this, the shaft is ground and polished to guarantee a smooth and precise surface finish.
8. Final inspection: The shaft goes through inspection to ensure that it fits the required specifications and tolerances.

100 TPD COOLER SUPPORT ROLLER SHAFT Technical Specifications

• DIAMETER – 300mmm
• CERTIFICATION – ISO9001
• APPLICATIONS – 100 TPD Cooler Accessories for DRI Sponge Iron Steel Plant
• MATERIAL GRADE – Forged Steel EN-9, EN-19, EN-24, 42CrMo4
• DESIGN – As per the customer requirements (POPURI / IPS / ITC / MEC / LURGI etc.)

FEATURES OF COOLER SUPPORT ROLLER SHAFT:

• The support shaft holds the substantial weight of the rotary cooler.
• Robust and powerful tool.
• Proper alignment and machining ensures smooth rotation during the cooling process.
• Ensures effective and secure functioning.
• To prevent possible safety risks and guarantee the long-term dependability and performance of the cooler, proper maintenance and routine inspection of the support shaft is crucial.

3. PLUMMER BLOCK

A cooler support roller plummer block is a part of a rotary kiln device used in the production of cement, SPONGE IRON STEEL PLANT, lime, and other industrial materials. It provides support to the cooler support roller and helps in its stability and efficiency. A 100 TPD cooler support roller plummer block is one that is capable of holding up to 100 tonnes of material per day.

FEATURES OF COOLER SUPPORT ROLLER PLUMMER BLOCK:

• High-quality cast iron or steel ensures its strength and longevity.
• The block is simple to install and replace if necessary.
• The block is corrosion resistant, guaranteeing a long service life.
• The block can withstand heavy loads of up to 100 tonnes per day with no danger of failure.
• The block is able to endure high temperatures without deformation.

100 TPD Cooler Plummer Block Technical Specifications

• APPLICATIONS – 100 TPD Cooler Accessories for DRI Sponge Iron Steel Plant
• CERTIFICATION – ISO9001
• MATERIAL GRADE – IS-2708 GRADE II, IS-2644 GRADE II, EN-19, EN-24 FORGED
• DESIGN – AS PER CUSTOMER PROVIDED (POPURI / IPS / ITC / MEC / LURGI etc.)

4. ROTARY KILN SUPPORT ROLLER LABYRINTH RINGS:

Labyrinth rings are a form of sealing component that helps to prevent dust and other particles from entering the bearing area. Also, They provide extra contamination protection and to keep debris out of the bearing. These rings or sleeves form a labyrinth-like path, requiring contaminants to pass through numerous barriers before reaching the bearing.

FEATURES OF COOLER SUPPORT ROLLER LABYRINTH RINGS:

he main features of cooler support roller labyrinth rings include:

1. Durability: These rings typically use high-quality materials that are resistant to wear and tear, ensuring that they can endure the harsh operating conditions that are common in heavy-duty applications.
2. Sealing: The main purpose of cooler support roller labyrinth rings is to provide a seal that helps prevent dirt, dust, and other contaminants from entering the bearing. This serves to protect the bearing from damage and extend its life.
3. Cooler support roller labyrinth rings are easy to install and can be easily fitted onto the shaft or housing.
4. Low Friction: These rings helps to form a labyrinth seal that reduces friction and heat buildup, improving overall performance and extending the bearing’s lifespan.
5. Versatility: These rings are suitable for a wide range of applications, including cooling towers, conveyor systems, and heavy-duty equipment. They come in a variety of sizes and materials to fit a variety of applications.