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Large kiln body riveted and welded components

I. Introduction to Riveted and Welded Components of Large Kiln Bodies

The large kiln body—a core piece of equipment in industries such as cement, metallurgy, and chemical engineering (e.g., rotary kilns, lime kilns)—is constructed by rolling and welding thick steel plates into a cylindrical shell. It is further assembled into a massive rotating structure through riveting or welding, incorporating additional components like wheel bands, retaining rings, and kiln mouth guards.
Core function: Achieve material calcination or chemical reactions under high-temperature (300–1600°C), heavy-load, and corrosive conditions.

II. Common Materials Used for Kiln Body Riveted and Welded Components

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

Main cylinder body material

Materials	Application	Features
Q235B/C, Q345B/C/D/E	Low-temperature section (feed end/kiln tail) or non-high-temperature pressurized shell.	Carbon structural steel or low-alloy high-strength steel offers low cost and excellent weldability, but it has poor high-temperature strength (>350°C) and oxidation resistance.
Q245R, Q345R	Steel plates for pressure vessels used in medium- and low-temperature applications, conforming to GB/T 713 standard.	It boasts superior purity and impact toughness compared to ordinary structural steel, making it suitable for withstanding moderate pressure and temperature.
High-temperature alloy steel (critical high-temperature section)
Materials	Application	Features
15CrMoR, 12Cr1MoVR	High-temperature zones such as the transition zone and firing zone (operating temperature: 500–600°C)	Cr-Mo-V alloy steel, featuring excellent high-temperature strength, creep resistance, and oxidation resistance.
04H, 321H, 316H Austenitic Stainless Steel	Extremely high-temperature or highly corrosive areas (such as kiln mouth guards severely affected by alkali erosion)	Resistant to high-temperature oxidation and corrosion, but costly and featuring a high thermal expansion coefficient—thermal fatigue should be carefully considered.

III. Selection of Welding Method

Method	Applicable Scenarios	Advantages
Gas Tungsten Arc Welding (GTAW)	Thin plates (≤6mm), root welds for pipes, precision components	High quality, minimal deformation
Flux-Cored Arc Welding (FCAW)	Structural welds for medium-to-thick plates (6–50 mm) and on-site installation	High efficiency, strong wind resistance
Submerged Arc Welding (SAW)	Thick plates (>20mm) with straight, long welds (furnace bottom plates/shells)	Large penetration, no spatter

4. Key Processes in Welding Technology

Pre-weld preparation: material cutting, forming, and beveling (with precision control).

Strict cleaning: Remove oil, rust, water, oxide scale, and other contaminants from the bevel and surrounding areas.

Assembly tack welding: Use the same welding materials and processes as for the final welds to ensure high-quality tack welds of appropriate length and spacing. Also, inspect assembly gaps and misalignment.

Preheating (if required): Heat evenly to the specified temperature and monitor/record accordingly.

Welding process:

Weld strictly according to the WPS and welding sequence.

Control interlayer temperature (monitor and record).

When performing multi-pass, multi-layer welding, carefully clean away interlayer slag and spatter. Ensure proper fusion of the weld beads to prevent defects.

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

Welding Process	Application Scenarios
Material preparation process	Flame cutting (CNC cutting), plasma cutting, laser cutting, shearing, and sawing. High-precision bevel machining (such as edge milling and bevel cutting machines).
Forming process adopted	Rolling (cylindrical and conical shapes), bending (using a bending machine), pressure forming (with large-scale presses), and roll forming.
Assembly and Alignment	Using large-scale tooling fixtures and platforms—such as welding positioners and roller stands—ensures the precise positioning and dimensions of each component. This is a critical step in quality control.
Common Welding Methods	Application Scenarios
Submerged Arc Welding	Suitable for long straight welds and circumferential seams (such as longitudinal and circumferential seams of cylindrical shells).
Gas-shielded welding	MAG (CO2 or mixed gas), MIG (inert gas). Widely used and highly versatile (manual, semi-automatic, automatic), suitable for various positions and joint types.
Shielded Metal Arc Welding	Suitable for positions that are difficult to automate, short welds, and repair welding. It is less efficient and relies heavily on the welder's skill.
Electroslag Welding	Vertical welding for extra-thick plates (such as box-beam diaphragms).
Narrow-gap welding	Designed for butt welding of ultra-thick plates, it offers high efficiency and minimal deformation.
Post-weld treatment
Stress	Large components generally require post-weld heat treatment—either overall or localized (typically stress relief annealing)—to remove weld slag and spatter, followed by grinding of the weld seam and its surrounding areas. This process helps relieve residual welding stresses, preventing deformation, cracking, and improving the material's toughness.
Orthopedic	Flame straightening, mechanical straightening (using a press), to control welding deformation.
Mechanical Processing	Perform precision machining operations such as milling, boring, and drilling on critical mating surfaces and hole locations.

We will conduct non-destructive testing, inspection, and testing on the products:

Testing Items	Content
Visual Inspection	Surface defects (cracks, undercut appearance inspection (VT), porosity, arc craters, etc.).
Ultrasonic Testing (UT)	Detecting internal defects (such as lack of fusion, incomplete penetration, slag inclusions, and cracks) is especially critical for thick plates.
Radiographic Testing (RT)	Intuitively displays internal defects and is commonly used for critical butt joints.
Magnetic Particle Testing (MT)	Detection of Surface and Near-Surface Defects (Ferromagnetic Materials)
Penetrant Testing (PT)	Detecting surface opening defects (non-magnetic materials).
Destructive Testing (Sampling)	Such as tensile, bending, impact, hardness, and metallography tests (typically conducted during process qualification or random inspections).
Dimensional Inspection	Check whether the overall structural dimensions and dimensions of key components meet the drawing requirements.
Pressure/Leak Test (if required)	Such as hydraulic tests, pneumatic tests, and leak-tightness tests.

V. Specification Range

The kiln body has a wide range of weights, depending on its diameter, length, wall thickness, and material. Typical data are as follows:

Kiln Type	Specifications (Diameter × Length)	Weight range	Contributing factors
Small and Medium-Sized Cement Rotary Kilns	Φ3.2 × 50m	200 to 300 tons	The cylinder shell has a plate thickness of 25–40 mm and includes the wheel belt/gear ring.
Large Cement Rotary Kiln	Φ4.8 × 72m	800 to 1,200 tons	High-temperature section uses 15CrMoR thick plates (≥50mm)
Metallurgical Lime Kiln	Φ3.6 × 60m	400 to 600 tons	Heat-resistant steel accounts for a high proportion and has a more complex structure.
Alumina Calcination Kiln	Φ4.5 × 110mm	1,500 to 2,000 tons	Extra-long cylindrical body + heavy-duty support structure

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Next： Large furnace riveted and welded components

Large kiln body riveted and welded components

Large-scale 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. Commonly used steels include Q245R, Q345R, 04H, 321H, 316H austenitic stainless steel, among others. These materials are applied in medium- and small-sized cement rotary kilns and lime kilns.

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TOP

I. Introduction to Riveted and Welded Components of Large Kiln Bodies

II. Common Materials Used for Kiln Body Riveted and Welded Components

Main cylinder body material

III. Selection of Welding Method

4. Key Processes in Welding Technology

V. Specification Range

Large kiln body riveted and welded components

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