Kiln Trunnion and Tire Seal Repair
Worn kiln trunnion roller and bearing seats rebuilt cold and dressed back to the running line, with the hot seal area coated for protection.
A job completed with Belzona. This describes what the Belzona system does and how it goes on, not a record of a specific project by this distributor.
The challenge
A rotary kiln rides on trunnion rollers that carry the tire and hold the shell on its running line. Over time the roller face and the bearing seats lose metal, the contact across the tire goes uneven, and the kiln starts to track off true. At the same time the seal area near the hot shell loses metal and opens up, letting air in around the kiln. When the contact is uneven and the seal leaks, the kiln runs rough, the bearings see uneven load, and the process loses the control that comes from a tight, true shell. The usual fix is to machine a new roller into place, which is slow and pulls the kiln out of service.
The Belzona approach
Assessment locates where metal has been lost on the trunnion roller face and the bearing seats, and the seal area is checked to see how far it has worn. The worn surfaces are cleaned and profiled so the repair bonds, then the roller face and the bearing seats are rebuilt cold with a machinable composite. Once it has cured, the rebuild is dressed back to the running line so the contact across the tire is even again. Around the seal area, a coating rated for the heat off the shell goes on, so the steel is protected and the seal runs against a sound surface. The kiln goes back on a true running line without machining a new roller into place.
- Assess and map wearThe trunnion roller face, the bearing seats, and the seal area are inspected to map where metal has been lost and confirm the running line.
- Clean and profileThe worn surfaces come back to clean, profiled substrate so the composite and the coating bond.
- Rebuild the roller and seats coldA machinable composite rebuilds the worn roller face and bearing seats, with no hot work on the shell.
- Dress to line and coat the sealThe rebuilt metal is dressed back to the running line for even contact across the tire, then the seal area is coated with a system rated for the heat off the shell.
- Return to serviceThe contact and the coating are checked and the kiln returns to service on a true running line.
The result
- Trunnion roller face and bearing seats rebuilt cold and dressed back to the running line
- Even contact restored across the tire without machining a new roller into place
- Seal area coated for the heat off the shell so the steel is protected and the seal runs against a sound surface
- Kiln returned to a true running line by factory-trained and factory-certified Belzona applicators
In the field
More Manufacturing & General Industry projects
Gearbox Housing Bearing Bore Rebuild
Spun, worn-oversize gearbox bearing bore rebuilt cold and reformed back to dimension without machining a new housing.
Plant Floor Anti-Slip Safety Resurfacing
Worn, slick plant walkway repaired and resurfaced with an anti-slip safety floor for dependable footing.
Compressor Casing Crack and Leak Repair
Cracked, weeping compressor casing sealed and the cracked section rebuilt cold, with no hot work to risk the casting.
Seeing something like this?
Belzona Houston is the authorized Belzona distributor for South Texas and the Gulf, based in Alvin, Texas, we’ll survey your equipment and recommend the right cold-applied Belzona system, with 24-hour support.