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Rotary kiln

Status: Student Design Contest Entry
by Enthusiast ‎06-23-2016 06:49 AM - edited ‎06-23-2016 06:51 AM

Greetings, my name is Nikita Bogdanov, I am a fourth year student of the Belgorod State Technological University named after Shukhov, I study at the Faculty of "Mechanical equipment" my specialty – is Mechanical Engineer and my specialization – is to use computer aided design systems in design of mechanical equipment, and I want to introduce you the topic of my qualifying, graduate work, which I will defend this year. Equipment that is used in my project - the rotary kiln for cement production.  Kiln - is the main process unit of any cement plant. And It is very important because klinker and cement quality depends on correct performance of this equipment.

 

As the construction of the rotary kiln is very complicated, this qualification work was shared between 3 students with my uni-comrades (Konstantin Vavilov and Mikhail Shvec). I believe, working on this project will give us essential experience  that will us help in future professional activities. Though, each of us creates  different assembly units of one machine, it is very important to avoid mistakes in this process. The final result of our qualifying project depends on our well-coordinated teamwork.

 

We began to work on this project ten  months ago, during a summer practice at the university, with the analysis of the equipment industry of building materials.   I carried out market analysis of this equipment and found products of leading Kiln manufacturers (Flsmidth, KHD Humboldt Wedag, ThyssenKrupp,  and others). We have analyzed advantages and disadvantages of presented examples. Kilns are different in the diameter and length, number of supports, design of the sealing device, the type of the support bearing and etc. Generally, Kilns have a number of drawbacks: the heat loss due to imperfect sealing device, the complexity of the repair, wear of tire and ring gear.

 

Manufacturers produce both 2-base kiln (which is considered to be more progressive solution, because of lower metal consumption) and 3-base-kiln (it is classical solution and that is why it is quite easy to operate). Therefore, We proposed possible solutions of these problems, approved by university professors staff, aimed to improve disadvantages of the kiln.

Then we formulated the goal of our project:

-Create a unified digital model, which allows to control the structure of equipment and have two different types of kiln- 2-base-kiln and 3-base-kiln 4x60m.

-Conduct improvement of assembly units of both kilns s in order to increase the efficiency of the kilns  based of patent search.

We use NX, and Teamcenter  to work on our graduation project. Opportunities of the software NX and Teamcenter allow us to make all what we have planned before. In unified digital model, we will create two options quite different in design kilns: 2-base-kiln and 3-base-kiln. While these kilns are of equal size, but they have different designs:

2-base-kiln have a friction drive, self-adjustable roller support

3-base-kiln have a gear drive, tangential, tangential mounting of the tyre.

These kilns have a different steel shells (order and number of shells)

And both of them have the same supporting bearing, sealing and hydraulic thrust devices.

 

After that, we developed the structure of our machine in the Teamcenter manager structure and divided the workload between each of us to have the implementation process of qualifying work more balanced. It is a very important, as the process of the structure development can be changed in extreme case. Here you can see assembly units and specification of our kiln made in Teamcenter structure manager:

1)Rotary part of the 3 base-kiln, 2) Rotary part of the 2 base-kiln, 3) Ø400 Roller support of 3-base kiln , 4) Ø450 Roller support of 3-base kiln , 5) Ø400 Roller support of 2-base kiln,  6) Gearing drive, 7)Ring gear, 8) Under-Ring gear, 9) Friction drive, 10) Cold end seal, 11) Hot end seal, 12) Hydraulic Thrust Device.

 

The finished components was revised by professors staff (technical control, compliance assessment, control of the project manager) with help of work process in Teamcenter. In case of mistakes, we discuss the problems with professors and improve parts and components until it finally approved, without the possibility of further changes.

 

Our project contains 12435 parts, including 552 unique parts.

 

In our work we also use a SSP -  prototype of the standard solutions. This is open data-model (prepared set of settings and methods) which Siemens PLM software deliver to users all over the world. In our work SSP helped us to adapt work of NX and Teamcenter to conditons of russian stantards - GOST and ESKD. Moreover SSP had great functional affecting process of creating drawings like automatic filling of labels on sheets. This features helped us a lot, and made process of implementation of our diploma work much more easy.

 

Then, as part of the degree project we  developed design documentation on 2-base-kiln, conducted strength l conditions of the kiln body in CAE-Nastran  and made a set of working drawings.rotary kilnsrotary kilns

friction drivefriction driveself-adjustable roller supportself-adjustable roller support

Structure manager with variantsStructure manager with variantsStress analysis of rotary partStress analysis of rotary part

Comments
by Dreamer
on ‎07-14-2016 07:59 AM

Gut gemacht!