PAPER TECHNOLOGY INTERNATIONAL Rotary kiln predictive maintenance to prevent downtime. Nicholas Dannias, Marketing Manager, Jammbco Industrial Solutions Ltd - Paper Technology International 2026 - Book - Page 100
PAPER TECHNOLOGY INTERNATIONAL Rotary kiln predictive maintenance to prevent downtime. Nicholas Dannias, Marketing Manager, Jammbco Industrial Solutions Ltd
PAPERTECHNOLOGYINTERNATIONAL
Figure 1: Infrared shell temperature profile rotary kiln predictive maintenance.
Why unplanned kiln downtime becomes so expensive.
A kiln outage is not only lost production hours. It often
includes energy losses during cooldown and heat-up, damage to
adjacent equipment, missed shipment targets, unplanned labour,
and commercial pressure to restart before the root cause has been
fully addressed.
In pulp and paper mills, lime kiln downtime can quickly push
the recausticizing cycle into a capacity or chemistry constraint.
In cement plants, kiln downtime can disrupt clinker inventory,
burner tuning, refractory campaign plans, cooler performance, and
downstream grinding schedules.
The operational cost comes from four compounding effects:
•
Thermal Losses: Restarting a kiln consumes time and
energy before stable operation is restored.
•
Mechanical Escalation: Minor defects often damage
neighboring components when operation continues too
long.
•
Shutdown Compression: Work that should have been
planned becomes urgent, crowded, and higher risk.
•
Restart Instability: A kiln restarted without fully
addressing the cause often returns with the same
symptoms.
Which failure modes predictive maintenance should catch 昀椀rst.
The 昀椀rst goal is not to monitor everything equally. It is to
monitor the failure modes that most often create forced outages,
repeated slowdowns, or hidden performance loss.
Mechanical failure modes.
Mechanical problems usually develop gradually, but they
accelerate when heat and load patterns change.
•
Tyre and Roller Contact Problems. Poor contact
patterns increase localized stress, wear, thrust
behavior, and bearing temperature.
100
•
Alignment Drift. Kiln axis movement, shell run-out, and
support geometry changes can create abnormal load
distribution and drive instability.
•
Shell Ovality And Flexing. Excessive ovality reduces
refractory life and increases risk around tyre stations.
•
Drive Train Distress. Gear, pinion, gearbox, coupling,
and motor issues often show up 昀椀rst as vibration, noise,
temperature rise, or load variation.
•
Lubrication De昀椀ciencies. Heat, contamination, and
inadequate application degrade bearings, gear sets,
and riding ring interfaces.
Process and material failure modes.
Process problems are just as important because they often
cause or intensify mechanical damage.
•
Refractory Wear or Brick Loss. A changing shell
temperature pro昀椀le may indicate thinning refractory,
unstable coating, or a developing hot spot.
•
Ring Formation and Build-up. Build-up changes gas
昀氀ow, material movement, heat transfer, and local load
conditions.
•
Dust Recycle and Dusting. Excessive dust recycling
reduces thermal ef昀椀ciency and can destabilize the
chain area or downstream equipment.
•
Poor Heat Recovery. High exit gas temperature often
signals lost recovery opportunity, drying problems, or
ineffective chain performance in lime kilns.
•
Burner And Combustion Instability. Unstable 昀氀ame
behavior can shift heat pro昀椀les and increase refractory,
shell, and product quality risk.
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