Large kiln body riveted and welded parts
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  • Large kiln body riveted and welded parts

1. Introduction to Large Kiln Body Riveted and Welded Parts

Large kiln bodies are core equipment in industries such as cement, metallurgy, and chemical engineering (e.g., rotary kilns, lime kilns). They are cylindrical structures formed by rolling and welding thick steel plates, with additional components like tire bands, retaining rings, and kiln mouth protective plates attached by riveting or welding to form a large rotating structure.
Core function: To achieve material calcination or chemical reactions under high temperature (300~1600℃), heavy load, and corrosive environments.

2. Common Materials for Kiln Body Riveted and Welded Parts

Material selection must comprehensively consider high-temperature strength, oxidation resistance, thermal fatigue resistance, weldability, and cost. Common steels are as follows:

Main Cylinder Material

Material

Application

Characteristics

Q235B/C, Q345B/C/D/E

Low-temperature section (feed end/kiln tail) or non-high-temperature pressure shell.

Carbon structural steel or low-alloy high-strength steel, low cost, good weldability, but poor high-temperature strength (>350℃) and oxidation resistance.

Q245R, Q345R

Steel plates for medium-low temperature pressure vessels, compliant with GB/T 713 standard.

Purity and impact toughness superior to ordinary structural steel, suitable for withstanding certain pressure and temperature.

High-temperature alloy steel (critical high-temperature sections)

Material

Application

Characteristics

15CrMoR, 12Cr1MoVR

High-temperature areas such as transition zones and firing zones (operating temperature 500~600℃).

Cr-Mo-V alloy steel with excellent high-temperature strength, creep resistance, and oxidation resistance.

04H, 321H, 316H Austenitic stainless steel

Extremely high temperature or highly corrosive areas (e.g., kiln mouth protective plates with severe alkali corrosion).

Resistant to high-temperature oxidation and corrosion, but costly, with a large thermal expansion coefficient; thermal fatigue must be considered.

3. Welding Method Selection

Method

Applicable Scenarios

Advantages

Gas Tungsten Arc Welding (GTAW)

Thin plates (≤6mm), pipe root welding, precision components.

High quality, minimal deformation.

Flux-Cored Arc Welding (FCAW)

Medium-thick plates (6~50mm) structural welds, on-site installation.

High efficiency, strong wind resistance.

Submerged Arc Welding (SAW)

Thick plates (>20mm) straight long welds (furnace bottom plates/shells).

Deep penetration, no spatter.

4. Key Welding Process Steps

Pre-welding preparation: material cutting, forming, groove processing (precision control).

Thorough cleaning: remove oil, rust, water, scale from groove and adjacent areas.

Assembly positioning weld: use the same welding materials and processes as formal welding to ensure positioning weld quality, with appropriate length and spacing. Check assembly gaps and misalignment.

Preheating (if needed): uniformly heat to specified temperature and monitor/record.

Welding process:

Strictly follow WPS and welding sequence.

Control interpass temperature (monitor and record).

For multi-layer multi-pass welding, carefully clean interpass slag and spatter. Ensure good weld fusion and avoid defects.

Monitor key parameters (current, voltage, speed, gas flow, etc.).

Welding Process

Application Scenarios

Cutting Process

Flame cutting (CNC cutting), plasma cutting, laser cutting, shearing, sawing. High-precision groove processing (e.g., milling edges, groove cutting machines).

Forming Process

Plate rolling (cylinders, cones), bending (press brakes), pressure forming (large presses), rolling.

Assembly and Fit-up

Use large tooling fixtures and platforms (e.g., welding positioners, roller racks) to ensure precise position and dimensions of components. This is a key quality control step.

Common Welding Methods

Application Scenarios

Submerged Arc Welding

Suitable for long straight welds and circumferential welds (e.g., cylinder longitudinal and circumferential seams).

Gas Shielded Welding

MAG (CO2 or mixed gas), MIG (inert gas). Widely used, highly flexible (manual, semi-automatic, automatic), suitable for various positions and joint types.

Shielded Metal Arc Welding

Suitable for positions difficult to automate, short welds, and repair welding. Lower efficiency, dependent on welder skill.

Electroslag Welding

Used for vertical welding of ultra-thick plates (e.g., box girder diaphragms).

Narrow Gap Welding

Used for butt welding of ultra-thick plates, high efficiency, minimal deformation.

Post-Weld Treatment

 

Stress

Large components generally require overall or partial post-weld heat treatment (usually stress relief annealing), removal of welding slag and spatter, grinding of weld seams and surrounding areas to release residual welding stress, prevent deformation and cracking, and improve toughness.

Straightening

Flame straightening, mechanical straightening (press, etc.) to control welding deformation.

Machining

Precision machining such as milling, boring, and drilling on key mating surfaces and hole positions.

 

We conduct nondestructive testing and inspection of products:

Inspection Items Content

Visual Inspection

Surface defects (cracks, undercut appearance inspection (VT), porosity, arc pits, etc.).

Ultrasonic Testing (UT)

Detect internal defects (lack of fusion, incomplete penetration, slag inclusion, cracks, etc.), especially important for thick plates.

Radiographic Testing (RT)

Directly displays internal defects, commonly used for important butt joints.

Magnetic Particle Testing (MT)

Detect surface and near-surface defects (ferromagnetic materials).

Penetrant Testing (PT)

Detect surface open defects (non-ferromagnetic materials).

Destructive Testing (Sampling)

Such as tensile, bending, impact, hardness, metallographic tests (usually performed during process evaluation or sampling inspection).

Dimensional Inspection

Check whether the overall structural dimensions and key part dimensions meet drawing requirements.

Pressure/Leakage Testing (if needed)

Such as hydraulic test, pneumatic test, airtightness test.

 

5. Specification Range

The kiln body weight varies greatly, depending on diameter, length, wall thickness, and material. Typical data are as follows:

Kiln Type

Specification (Diameter × Length)

Weight Range

Influencing Factors

Small and Medium Cement Rotary Kilns

Φ3.2×50m

200~300 tons

Shell plate thickness 25~40mm, including tire ring/gearing

Large Cement Rotary Kilns

Φ4.8×72m

800~1200 tons

High-temperature section uses 15CrMoR thick plate (≥50mm)

Metallurgical Lime Kilns

Φ3.6×60m

400~600 tons

High proportion of heat-resistant steel, more complex structure

Alumina Roasting Kilns

Φ4.5×110m

1500~2000 tons

Extra-long shell + heavy-duty support structure

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Large kiln body riveted and welded parts
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  • Large kiln body riveted and welded parts

Large kiln body riveted and welded parts

Large kiln bodies are core equipment in industries such as cement and metallurgy (e.g., rotary kilns, lime kilns). Material selection must comprehensively consider high-temperature strength, oxidation resistance, and thermal fatigue resistance. Common steels include Q245R, Q345R, 04H, 321H, 316H austenitic stainless steels, which are used in small to medium-sized cement rotary kilns and lime kilns.

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