FEECO is a leading manufacturer of highly engineered, custom rotary kilns for processing solids. Our high temperature kilns have earned a reputation for their durability, efficiency, and longevity. We offer both direct- and indirect-fired units.
Rotary kilns work by processing material in a rotating drum at high temperatures for a specified retention time to cause a physical change or chemical reaction in the material being processed. The kiln is set at a slight slope to assist in moving material through the drum.
Direct-fired kilns utilize direct contact between the material and process gas to efficiently process the material. Combustion can occur in a combustion chamber to avoid direct flame radiation, or the flame can be directed down the length of the kiln.
All FEECO equipment and process systems can be outfitted with the latest in automation controls from Rockwell Automation. The unique combination of proprietary Rockwell Automation controls and software, combined with our extensive experience in process design and enhancements with hundreds of materials provides an unparalleled experience for customers seeking innovative process solutions and equipment.
Indirect-fired kilns are used for various processing applications, such as when processing must occur in an inert environment, when working with finely divided solids, or when the processing environment must be tightly controlled.
Calcination refers to the process of heating a material to a temperature that will cause chemical dissociation (chemical separation). This process is used frequently in the creation of inorganic materials, for example, the dissociation of calcium carbonate to create calcium oxide and carbon dioxide.
Thermal desorption is also a separation process. This process uses heat to drive off a volatile component, such as a pesticide, from an inorganic mineral, such as sand. The component is vaporized at the increased temperature, causing a separation without combustion. In some cases, an indirect rotary kiln would be best for this application, because the volatile chemicals may be combustible. The indirect kiln will supply the heat for desorption, without the material coming into direct contact with the flame.
Organic combustion refers to the treatment of organic wastes with the intent of reducing mass and volume. Organic waste is treated in the kiln, leaving behind an ash with considerably less mass and volume. This allows for more efficient and effective deposit of waste materials into landfills.
Sintering is the process of heating a raw material to the point just before melting. This increases the strength of the material, and is commonly used in the proppant industry, where sand or ceramic materials are made stronger.
Heat setting involves bonding a heat resistant core mineral with another, less heat resistant coating material. Unlike an unheated coating process, here, a rotary kiln heats the coating material to just below liquefaction point, allowing it to coat the heat resistant core more evenly and more securely. This process is commonly seen in the manufacture of roofing granules, where a mineral such as granite is coated with a colored pigment, producing a product that is both durable and aesthetically pleasing.
Reduction roasting is the removal of oxygen from a component of an ore usually by using carbon monoxide (CO). The CO is typically supplied by mixing a carbonaceous material such as coal or coke with the ore or by feeding it separately. Examples are the reduction roasting of a hematite containing material to produce magnetite that can be magnetically separated. In the Waelz process, zinc oxide in steel mill wastes is reduced to metallic zinc and volatilized for recovery in the off-gas system.
Thermal Desorption for Spent CatalystsRotary Kiln3D Indirect Kiln for Activated CarbonPyrolysis Kiln Seal3D FEECO Pyrolysis KilnPyrolysis KilnWorn Rotary Kiln RefractoryBatch Rotary Kiln TestingKiln Alignment SoftwareProcessing Challenges When Working with Rotary KilnsFEECO Batch Kiln BrochureIndustry Focus COVID-19 Demands Medical Waste Incineration CapacityIndirect Fired Rotary Kiln ReplacementRotary Kiln IncineratorsResource of the Week: Thermal Testing with Kilns3D Model of a FEECO Carbon Activation KilnRotary Kiln Testing ThumbnailRotary Kiln TestingIndirect Batch Rotary Kiln Testing, Batch Calciner Testing, Thermal Process DevelopmentKnowing When its Time to Replace Your Rotary Drum Seal, Leaf SealRotary Drum Drive ComponentsRotary Drum BreechingReplacement Rotary Drum BearingsBoomin Catalyst Market Drives Demand for Rotary Kiln Repair Services, Rotary KilnsReplacement Dryer (Drier) and Kiln BurnersCombustion ChambersReplacement Rotary Drum ShellRotary Drum Laser Alignment Process, Rotary Drum AlignmentWhy Post Maintenance Alignment is Critical to Rotary DrumsCauses of Tire (Tyre) and Trunnion Wear, Rotary Drum TireFEECO Tire (Tyre) Grinding Machine, Tire and Trunnion Grinding in ProgressRotary Drum Tire (Tyre) Wear Pattern from Excessive Wheel Skewing, Rotary Drum Tire in Need of Tire GrindingRotary Drum Tire (Tyre) Wear Pattern from Poor Housekeeping Practices, Rotary Drum Tire in Need of Tire GrindingRotary Drum Tire (Tyre) Wear Pattern from Misalignment, Rotary Drum Tire in Need of Tire GrindingRotary Drum Tire (Tyre) Wear Pattern from Using Improper Tire Lubricant, Rotary Drum Tire in Need of Tire GrindingTire (Tyre) and Trunnion Wheel GrindingTire (Tyre) and Trunnion GrindingIndirect Rotary Kiln (Calciner) for Plastics PyrolysisPlastic to Fuel Conversion via Pyrolysis Replacement Rotary Drum PartsRotary Drum Thrust RollersRotary Drum Trunnion Wheels (Rollers)Rotary Drum Riding Ring (Tire/Tyre)Resource of the Week: Girth Gears PageRotary Kiln System Optimization, Rotary Kiln Process AuditSpring-Mounted Replacement Rotary Drum Girth GearRotary Kiln Gains Traction as E-Waste Crisis Looms, Metal Recovery from E-WasteIndirect Batch Rotary Kiln Testing, Batch Calciner Testing, Thermal Process Development, Metal RecoveryDirect-Fired Rotary KilnRotary Kiln Chain and Sprocket Drive AssemblyRotary Kiln Gear and Pinion Drive AssemblyRotary Kiln Friction Drive AssemblyRotary Kiln Direct Drive AssemblyRotary Kiln Trunnion BaseRotary kiln end dam for increasing loading, retention time, and bed depthResource of the Week: Rotary Kiln Customization Slideshare PresentationKaolin Clay CalcinationLithium-ion Battery Recycling OpportunitiesRotary Kilns in Expanded Clay Aggregate ProductionBatch Kiln for Testing Expanded Clay AggregatesRotary Kiln Refractory Failure Illustration, Rotary Kiln Shell Hot SpotRotary Kiln Refractory InspectionDirect-Fired Rotary Kiln for SpodumeneCalciner (Indirect Kiln) for Lithium Recovery from SpodumeneRotary Kiln Complete SystemFEECO Batch Kiln for Testing CalcinationRotary Drum Drive BaseRotary Kilns for Advanced Thermal Processing in SustainabilityResource of the Week: Project Profile on a Rotary Kiln (Calciner) Resource Recovery SystemResource of the Week: Tire Grinding BrochureResource of the Week: Slideshare Presentation on Rotary Kiln Sizing and DesignResource of the Week: Unitized Drive Base BrochureDiagram Showing a Rotary Kiln with Co-current AirflowDiagram Showing a Rotary Kiln with Counter Current AirflowDiagram Showing Co-current Airflow View All >
The advantages to a FEECO rotary kiln are that it is built to the highest quality standards and is backed by over 60 years of process design experience. The FEECO Innovation Center offers batch and pilot scale kilns that can simulate conditions in continuous commercial rotary kilns, allowing our customers to test small samples of material under various process conditions, as well as part of a continuous process. With options in both co-current and counter-current flow, and direct or indirect configurations, the FEECO test kilns offer a variety of options to suit your thermal testing needs. We also offer support equipment such as a combustion chamber, afterburner, baghouse, and wet scrubber for testing.
The POLRO rotary kiln has a statically determined support configuration on only two roller stations and has a direct drive system. The kiln shell with its splined tyres rotates on self-aligning rollers, which automatically adjust themselves to the momentary running conditions. The kiln is directly driven via the rollers of the inlet-end roller station. This system supersedes the previously conventional girth gear and pinion mechanism. The POLRO system is rounded off by pneumatic inlet and outlet seals, hydraulic axial thrust system and air-cooled inlet trough.
Thanks to the statically determined support configuration, this kiln design is characterised by high operating reliability, minimal maintenance and inspection requirements and therefore very low operating costs.
Depending on the process-technological requirements, rotary kilns can be equipped with e.g. peripheral tertiary air blowers, which ensure the controlled infeeding of combustion air in a reduction process. Other modifications are also possible; for instance co-rotating burner systems or gas injection systems.
Worldwide, it is estimated that one billion scrap tires are produced every year. Instead of burning the tires, the Metso Outotec system roasts them at a lower temperature in an atmosphere devoid of oxygen (so that no actual burning will occur). This method of roasting is called pyrolysis, and is used for many different processes. By using pyrolysis, the tire shreds are broken down into their three basic components: carbon black char, steel radials and oil/gas.
From a single tire, approximately 1/3 of the weight is steel, 1/3 becomes pyro black (carbon black plus additives) and the final 1/3 is oil/gas. The products from the tire pyrolysis system arecarbon black char, oil (similar to number2 grade fuel oil), steel and non-condensable gases.
The tire pyrolysis system consists of an indirectly fired rotarykiln, steel recovery, char handling,grinding & pelletizing circuit, oil condensing system and gas cleaning system. The system is designed to operate 24 hours per day, 7 days per week.
Metso Outotec researched commercially available oil condensing systems and found them to be inadequate for consistently recovering oil from the difficult to handle pyrolysis process gas stream. As a result Metso Outotec developed our own condensing system and has been granted U.S. Patent No. 7,101,963 for Condensing and Recovery of Oil from Pyrolysis Gas.
The indirect kiln the pyrolysis reaction is carried out and the chips go through three stages inside the kiln. First, the rubber becomes brittle and separates from the steel (we call this rubber char). In the second stage, the oil and gas are forced from the rubber char and swept from the kiln. In the last tirepyrolysis stage, the char is fully processed into a carbon black-like substance and separated from the steel wires.
The off-gas from the kiln is pulled through the Metso Outotec patented two stage condenser system where oil is extracted. This recovered oil is very similar to diesel fuel in viscosity, heating value and other quality parameters, except that it has a significantly higher sulfur content and a lower flashpoint. This pyrolysis oilcould be used by any industry that currently burnsoils with higher sulfur contents, such as number 4 through 6 fuel oils, or it can befurtherrefined to remove the sulfur compounds.
In addition, there is a pyrolysis exhaustgas stream of non-condensable oil that can be used as a process fuel gas for industrial equipment or can be burned in a boiler and used for generating steam (for heating or power generation).
Working hand-in-hand with the top fabricators ISO 9001-2000, ASME Section 8 -Division 1 in the industry our kiln, dryer and cooler shells are rolled to exacting tolerances and thermal stresses. We provide our customers with a large range of kiln dryer and cooler shell fabrication materials to cover a wide variety of specific applications. Our roller supports are designed using the latest technology and procedures for forging, shrink-fitting and hardening.
Using the latest most innovative and reliable lifting equipment and kiln shell cutting tools in the industry, World Wide Kiln Service can accomplish kiln shell section replacements in record time. Gear reversals, gear and tire changes, as well as kiln, dryer and cooler support roller & thrust roller replacements are accomplished with the minimum downtime thereby saving dollars in both installation costs and lost production time.
Our designers use the latest innovative kiln design tools, including both Auto Cad and Solid Works to interface with our customers engineering departments to provide the right unit for the right application.
Tire and trunnion grinding & resurfacing. World Wide Kiln Service's grinding machines have undergone a complete overhaul to the point that our research and development team has created the newest most unique machines in the industry today. Our kiln tire and trunnion grinding team will travel to your site and resurface your kiln tires and trunnions to 'like new' surfaces without causing any downtime. Our new machines use the latest in computer operated technology to provide the highest quality results with no negative impact on your productivity.
What is accomplished by tire and trunnion grinding or resurfacing? As your rotary equipment ages various wear problems occur. Noticeable signs or conditions of wear such as spalling, pitting, cracking, roller over edges or "lips" can appear on the tires or trunnions. If the wear is allowed to continue these conditions can cause vibration, resulting in alignment problems. Costly power consumption, shortened bearing life of the rollers occur. If not corrected the problems can cause premature wear on the rollers bearing failure as well as damage to the tire retaining bars, the bases and drive components. Our specialized grinding machines can return the surfaces to "as new" condition often with a minimum removal of surface material. The grinding crew will then realign your kiln to provide mechanical stability.
World Wide Kiln Service performs kiln alignment with the unit shut down and cold. This enables us to "completely" inspect the kiln without being subjected to the high radian heat in and around the hot zones. At the same time we check for possible cracks at the filler pads and check for clearance between the tire I.D. and filler pad O.D. on the kiln. This is a more practical method than calculating tire gap by the "creep" method while the unit is in operation and hot. Tire and trunnion diameters are easily taken and the trunnion shafts are inspected for abnormalities. Having the tires and trunnions measured allows World Wide Kiln Service to return the kiln to its original centerlines in both planes of operation. This greatly reduces the stresses caused by misalignment and the potential for cracks on the kiln shell and refractory failure. When an alignment is performed while the unit is cold it allows the technicians to report back to the client if there are any tapers - so informed decisions can be made to have the carrying surfaces ground when the kiln starts up.
Maintaining and increasing the efficiency of your rotating equipment and associated systems requires specialized and expert maintenance, care and vigilance. At World Wide Kiln Service, our expertise with rotating equipment provides our Customers with the depth of experience and technical capability that may not be efficient for them to carry within their own maintenance teams. Our specialized major maintenance contracts minimize your effort at keeping your rotating equipment operating at peak efficiency, reliability and productivity. Our reputation is based on our success at meeting these goals. Our specialized focus on this type of equipment allows us to provide you with superlative, state-of-the-art technology and service, optimizing the profitability of your rotating equipment and associated systems. Providing our Customers with exceptional service, making sure that their rotating equipment is operating at peak values, is the core focus of our business.
World Wide Kiln Service Inc. founded in 1991 is dedicated to building on the high quality of service we provide to our customers. World Wide Kiln Service Inc. specializes in Engineering, Design, Installation, and Maintenance of all types of Rotary Equipment: Rotary Kilns, Trunions, Gears, Pinions, Rotary Dryers, Balling Drums, Debarking Drums, Rotary Coolers and more. We have answered the needs of rotary equipment users in North America, Mexico, Central America and Africa. With offices in Canada, USA and the Middle East we are constantly expanding to serve our customers world wide. Our range of products and services enable us to work on diverse applications of Rotary Equipment: in the Cement Industry, Mining Industry, Chemical Plants, Pulp and Paper Industry, Food Industry, and the Pharmaceutical Industry.
Achieving high kiln availability is essential to the competitiveness and profitability of your entire plant. You need to identify the root causes of kiln failure and eliminate problems before a breakdown occurs.
Instead of simply treating the symptoms, its really important to identify and deal with the root causes of kiln failure, such as kiln axis misalignment, kiln shell ovality/shell flex, kiln crank, and kiln axial misbalance.
How can you get the best out of your kiln and keep production maximised? A comprehensive hot kiln alignment every two to three years helps you avoid unforeseen breakdowns and maintain full kiln availability and productivity.
Let us analyse your kilns performance using advanced measuring techniques and customised hardware and software solutions. The alignment is carried out by an experienced kiln specialist during normal operation of the kiln, so that production can continue.
Well help identify potential causes of failure before problems occur as part of a preventative maintenance strategy. And if youve already experienced an issue with your kiln, our service will diagnose the actual cause behind the problem and recommend an efficient solution.
The need for reconditioning develops from various types of wear and tear. Tyres and rollers naturally form irregular surface profiles from roller skew, in addition to pitting, spalling, irregular markings and rolled-over edges. Left unaddressed, these conditions can lead to increased power consumption, alignment problems and reduced bearing life.
Our reconditioning service corrects problems such as concave/convex wear, rolled-over edges, facets, taper wear and irregular face profiles. And you wont experience costly downtime or interrupted plant operation; we resurface the worn faces of support rollers and tyres in-situ, while the kiln is in normal production.
To extend the life of your ROTAX-2 kiln , you need a clear picture of the tangential suspension system, and you must check the frequency drive settings. This reduces the risk of vibration and facet creation on kiln tyres and supporting rollers.
For you to enjoy the best results and peace of mind, we offer turnkey services that cover all your needs. Turnkey services are a combination of technical advisory support, skilled craft labour and state-of-the-art tools to execute work at the highest standards. We can provide this type of service for a variety of jobs from installations and adjustments to repairs, part replacements or rebuilds. Our level of involvement is up to you so you can choose what works best for your business.
FLSmidth provides sustainable productivity to the global mining and cement industries. We deliver market-leading engineering, equipment and service solutions that enable our customers to improve performance, drive down costs and reduce environmental impact. Our operations span the globe and we are close to 10,200 employees, present in more than 60 countries. In 2020, FLSmidth generated revenue of DKK 16.4 billion. MissionZero is our sustainability ambition towards zero emissions in mining and cement by 2030.
The first rule of operating a rotary kiln without any problem is distributing the forces equally to each piers. This can be done best, by full contact on ring and supporter roller surfaces and minimum ovality in kiln shell.
As known; rotary kilns work in %3 4 slope depended on design, model and brand. This slope determines the final products specifications with turn speed, additive materials and thermo-conditions. A facility wants to present the best product to its customers in this formula.
There is a direct proportion between energy / staff / working hours and kiln problems. It means by the time you have more problems on rotary kilns, you need more energy to operate the kiln in normal conditions, more staff and more working hours to solve the technical problems.
It is important to take periodic measurements and analysis on the kiln and solve the problems on time to have a hassle-free kiln.Despite it seems like a huge construction, a hot rotary kiln is similar to a nylon bag full of water. The kiln stands over the supporter rollers and the shell shows oscillation because of the ring which is thicker than the shell. Ring presses the shell down and creates ovality. By the time the ovality carries itself to whole shell and creates a crank. The surface between ring and supporter roller reduces.
Local over heated places on the shell, drop downs, belts and irregular heat diffusion builds ovality on the kiln shell and this ovality carries the kiln rotation centre out of geometric centre. It is harder to measure and align an eccentric kiln. This situation creates arrhythmic contacts between ring and supporter rollers surfaces. So the tire and supporter rollers become more stressed and this causes over heating on surface and sides, arrhythmic pressures, yielding, cracks and failures. By the time tire and rollers become concave, convex or conical depending to the situation. The axial pressure creates waves on the surface. A kiln in this position locks itself to up and down movements.
This movement problem over heats the roller shaft beds because of the tire forcing the roller to move up or down and it is harder to align a kiln in this situation because the tire and roller machines each other and all the measurement values changes. All the alignment becomes invalid by the time.
On the other hand; tire and thrust roller contact surface problems causes poor contact and wavy structure on surfaces and irregular movements caused by waves. This situation increases the surface stress and heat-ups the roller beds. Also wrong angles on the surfaces of thrust roller and tire machines the surface and increases the problems.
Such a hassled kiln can be tamed only by following where the problem is going and early intervention by grinding (resurfacing) the tire, supporter rollers and thrust roller surfaces. Yet we cannot expect to align such a kiln for a long term use.
For carrying tire and rollers out of the problematic position, the only way is machining and grinding the surface. As a result; contact surface will increase, surface stress and connected problems will end, vibration will end, it will be possible to align the kiln for long term expectations. A hassle-free kiln will collapse down the working costs dramatically
The on-site services bring machine shop capabilities directly to the job site, thereby drastically reducing all costs linked to the disassembly, rigging and transportation of machinery for repairs. The onsite services also reduce the downtime associated with planned and emergency maintenance outages. The services are classified as follows:
Rotary Kilns and other Rotary Vessels form the hub of may manufacturing systems including pyro-processing, material drying and particle size reduction systems. The vessels constantly operate under extremely harsh conditions that are characterized by mechanical stress and intense heat, amongst other adversities. DGCs range of the Rotary Kiln and Rotary Vessel Services are aimed at optimizing and enhancing the reliability of these vessels, the main Onsite Rotary Kiln / Vessel Services are described below.
Tires and supporting rollers of rotary kilns, dryers and mills have to continuously absorb large forces. Over time, wear problems are bound to occur. Uneven wear on the tire and trunnion surfaces may cause vibration, chattering and reduce efficiency. DGCs Onsite Grinding Services provides on-line and in-situ tyre, roller and thrust roller grinding services, which enable worn or damaged running faces of tyres, rollers, thrust rollers to be machined while the vessel is in operation.
A number of problems associated with rotary kilns can be attributed to misalignment, as such, alignment may be considered as the starting point of rotary kiln mechanical maintenance programs. Comprehensive hot kiln alignment ensures that rotary kilns are able to achieve maximum efficiency and helps in avoiding unforeseen breakdowns. Most of our Hot Kiln Alignment processes are done while the rotary vessel is functioning; without the need to interrupt production processes.
The companys Onsite Line Boring Services encompass in-line boring or machine bores of large items in stationary plants which cannot be removed from site for repairs. Applications are found in earth moving machines, coupling-hole aligning & line boring as well as other major worn or damaged equipment. A range of portable boring and facing machines are available to cover a wide range of repair or modification projects on-site / in-site for emergency or planned maintenance situations.
Our onsite machining teams have unique machining problem solving abilities including the redesign and manufacture of machinery for particular needs. Our qualified technicians work with close tolerances and provide the necessary precision and surface finishes to meet manufacturer or customer satisfaction. The companys onsite machining services are summarised below: