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Main focus of our services

Our internationally experienced maintenance experts develop comprehensive solutions for a wide range of problems which occur in the course of rotary kiln and ball mill operation and jeopardise further production:

  • Problems with the kiln lining
  • Problems with tyre fixation, wobble, run-out
  • Uneven contact pattern between tyre and supporting rollers
  • Cracks/material breakage at tyres, supporting rollers, girth-gear, kiln/mill shell, mill head
  • Problems with installation drive
  • High current consumption at the drive
  • "Knocking" of the drive (girth-gear/pinion)
  • Unnatural vibration of the installation
  • Uneven wear of supporting rollers/tyre
  • No "floating" of the installation on the supporting rollers, hydralik thrust system
  • Supporting rollers "hot bearings"
  • Tyre lift-off from a supporting roller
  • Shell Deformation or "banana effect"
  • High degree of shell eccentricity at the kiln inlet/outlet
  • Hydrostatic problems with slide shoe mills

For every installation we offer an extensive range of maintenance services from which we can select various modules to suit your specific requirements. Alternatively we can also provide fully tailor-made service. In addition we perform routine installation inspections recurring in two year intervals as well as in the case of major repairs.

Our methods

The following individual services and areas of testing are central elements for the measurement of rotary kilns, rotary driers and rotary coolers:

  • Vertical and horizontal axis of rotation of rotary kilns as of 3 piers
  • Geometry of the tyre stations
  • Ovality (shell test)
  • Deformation profile of the kiln shell
  • Thermal profile of the kiln shell/infrared profile (photo/video documentation)
  • Wobble and run-out of tyres
  • "Relative movement" of tyres (tyre creep)
  • Run-out of supporting rollers
  • Axial deflection of supporting rollers, kiln shell curvature ("banana effect")
  • Wobble and run-out of girth-gears
  • Temperature profile of girth-gear and pinion
  • Root to tip clearance measurement between girth-gear and pinion
  • Inclination of base frames of tyre stations
  • Inclination of base frames, station to station
  • Cold clearance measurements at loosen tyres
  • Vibration and thermal measurements, e.g. at the kiln drive (motor/gear box)
  • Wall thickness measurement at the kiln shell (up to 350 °C)
  • Wall thickness measurement at other components up to 200 mm
  • Hardness measurement of components in accordance with HB, HRB, HRC,HSD, HV
  • Roughness measurements Ra, Rz, Rq and Rt, e.g. at bearing shafts

The data obtained from measurement and inspection may necessitate immediate action to prevent damage. This is where you can rely on the dependable individual service provided by our experienced specialists.

We offer the following maintenance services for the mechanical systems of rotary equipment:

  • Visual inspection of the installation
  • Assessment/evaluation of the system mechanism
  • Detailed analysis and reporting of the measurement data, including evaluation and recommendations for sustained stable equipment operation
  • Adjustment of the axis of rotation
  • Checking and adjustment of "supporting roller skewing", installation balance and the contact patterns of girth-gear and pinion
  • Machining of the contact surfaces of girth-gear and pinion
  • Inspection of girth-gear/pinion lubrication for correct operation, lubricant quantity and spray pattern
  • Non-destructive crack tests
  • Dye penetrant testing red/white (PT)
  • Magnetic particle inspection (MT)
  • Accompanying assembly monitoring
  • Accompanying commissioning of new installations or re-commissioning following repair work
  • Production acceptance of components such as supporting rollers, tyre, kiln shell section, girth-gear/pinion in accordance with manufacturer/customer specification
  • Technical preparation of customised service check lists
  • Education and training courses
  • In-situ resurfacing of:
    • Tyres and rollers
    • Lateral grinding of tyres and thrust rollers, for equalisation of the angles of longitudinal guide systems

We offer the following services for the measurement of ball mills:

  • Geometry of bearing stations
  • Thermal profile of the mill shell/infrared profile
  • Wobble and run-out of tyres
  • Run-out of supporting rollers
  • Run-out of journals
  • Run-out of trunnions
  • Wobble and run-out of mill flanges
  • Wobble and run-out of girth-gears
  • Temperature profile of girth-gear and pinion
  • Root to tip clearance measurement between girth-gear and pinion
  • Inclination of base frames of bearing stations
  • Inclination of base frames, station to station
  • Vibration and thermal measurements, e.g. at the mill drive (motor/gear box)
  • Wall thickness measurement at the mill shell/mill head
  • Wall thickness measurement at other components up to 200 mm
  • Hardness measurement of components (HB, HRB, HRC, HSD, HV)
  • Roughness measurements Ra, Rz, Rq and Rt, e.g. at bearing shafts

In the case of mills, too, immediate measures may be necessary after the analysis of the measurement results. Here, too, our knowledgeable experts are at your side with tried and tested know-how and individual service:

  • Visual inspection of the installation
  • Assessment/evaluation of the plant mechanism
  • Detailed analysis and reporting of the measurement data
  • Evaluation and recommendations for sustained stable operation of the installation
  • Checking and adjustment of the contact patterns of girth-gear and pinion
  • Inspection of girth-gear/pinion lubrication for correct operation, lubricant quantity and spray pattern
  • Machining of the contact surfaces of girth-gear and pinion
  • Smoothing of trunnions
  • Non-destructive crack tests
  • Dye penetrant testing red/white (PT)
  • Magnetic particle inspection (MT)
  • Accompanying assembly monitoring in the case of repair or new construction/supervision
  • Accompanying commissioning of new installations or re-commissioning following repair work
  • Fabrication approval of components such as rollers, tyres, kiln shell, girth gear and pinion according to OEM or customers’ specifiction
  • Technical preparation of customised service check lists
  • Education and training courses

Your benefits

  • Proven, independent expertise in line with the technical and scientific state of the art
  • Our specialists are available at all times for even the most complex maintenance work.
  • For every installation we offer a specific service portfolio from which we can select various modules to suit your requirements. In addition we can provide fully tailor-made service.

Our Service Offer

You can download our Service Offer as a PDF file here

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Other services in which operate

Environment

We can offer integrated consultation on all environmental aspects associated with the production and processing of cement, lime, concrete and other construction products. With a view to enhancing your environmental performance we can identify your specific requirements and accordingly offer you a complete package of various services. For example, this involves the production of environmental expert reports and the optimisation of your process steps and products.

More information

Technical Reviews and Benchmarking

We can provide you with tailor-made Technical Reviews and Energy Reviews to make your current and future cement production as efficient as possible. Our experienced experts work all around the world and conduct integrated, scientifically based analyses and benchmarking for either certain aspects of your production or for your entire production process (e.g. equipment, raw materials, energy demand, fuels, cement portfolio, emissions, environmental protection legislation etc.). So we can develop independent, customised solutions to optimise your installations.

To the service

Thermal process technology

We offer a comprehensive service portfolio covering the entire field of thermal process technology. We can advise you on every aspect of process optimisation, product quality, energy efficiency and the use of alternative fuels and raw materials. In addition we also conduct measurements in high-temperature processes as well as performing process technology modelling.

Learn more

Mechanical process technology

In the field of mechanical process engineering, we offer a wide range of services, from the characterisation of solids in powder form and the performance of complex grinding and classification trials, right through to the optimisation of industrial plants. Above and beyond this, our interdisciplinary teams of experts can advise you on how to deal with technical problems in existing installations and on the planning of new plants.

To the service

Digital process support

Digital process support covers process-related subjects in the field of digitalisation and industry 4.0, as well as the directly associated aspects of simulation technology. The central areas of work include the creation of standard data structures, the utilisation and in particular the robustness of Artificial Intelligence (AI) applications, as well as the development and use of a wide range of simulation methods for process optimisation and training purposes.

To the service

Person to contact

Do you have questions regarding this service?

Frank Henning
Environment and Plant Technology

+49-211-45 78-369
frank.henning@vdz-online.de

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