Massive Rotary Kiln Fabrication
Rotary kilns are the beating heart of continuous thermal processing operations in the mining, cement, and metallurgy industries. Because they rotate constantly while subjecting massive internal loads to extreme temperatures, the structural integrity of the kiln shell and drive components must be flawless.
With 180 acres of facility space and 250-ton lifting capacities, Openex specializes in the heavy plate rolling, massive welding, and precision CNC machining required to manufacture colossal rotary kiln sections, riding rings (tires), and support rollers. We custom-fabricate kiln shells section-by-section for seamless on-site assembly worldwide.
Kiln Manufacturing Specifications
We fabricate rotary kiln components strictly to OEM blueprints and international quality standards. Below are our general facility capacities for kiln production:
| Max Shell Diameter | Up to 8,000 mm (8 Meters) |
|---|---|
| Heavy Plate Rolling | Thickness up to 150+ mm Cold / Hot Rolling |
| Materials Processed | Carbon Steel (SA516 Gr 70), Heat-Resistant Alloys, Stainless Steel, Forged Alloy Steels (for rings/gears). |
| Components Built | Kiln Shell Sections, Riding Rings (Tires), Trunnion Rollers, Thrust Rollers, Girth Gears, Discharge Heads. |
| Quality Assurance | 100% UT/RT on critical welds, Laser Tracker alignment, Full Dimensional Metrology. |
"The rotary kiln is a key part of the process flow sheet at Araguaia. The 11 individual sections of the kiln will now be welded together over the course of the next month, before the sections are lifted into place on top of the kiln piers for final welding and alignment. We wish to extend our thanks to everyone involved in the massive logistics process required to deliver the kiln to site."
The Manufacturing Process
Using extreme-capacity heavy plate bending rolls, we form the massive steel plates into perfect cylindrical shell sections, maintaining strict roundness tolerances.
The longitudinal and circumferential seams are welded using automated Submerged Arc Welding (SAW) to ensure deep penetration, followed by 100% Non-Destructive Testing (NDT).
For the kiln's riding rings (tires) and trunnion rollers, we utilize our massive Vertical Turning Lathes (VTLs) to machine heavy alloy forgings to exacting tolerances.
Assembled shell sections undergo thermal stress relief in our massive on-site furnaces before being test-fitted in the shop to guarantee seamless on-site assembly at the mine.