COATEK INTERNATIONAL COATEK INTERNATIONAL LTDLTD

Fully DeliveredFully Delivered Coating Systems forCoating Systems for

Increased ProductivityIncreased Productivityandand

Increased Plant AvailabilityIncreased Plant Availability

In Steel, Cement and Lime ManufacturingIn Steel, Cement and Lime Manufacturing

. . . . . . Coatek . . .Coatek . . .

Company ProfileCompany Profile

Fully Delivered Coating Systems for Increased

Productivity and Plant Availability

A small independent Company backed by a Japanese Group with associated offices worldwide, operating in the Steel, cement and Lime manufacturing industries.

Rotary Kiln Services :Rotary Kiln Services :

Supply of lubricantsSupply of lubricants

Application of lubricantsApplication of lubricants

Monitoring and reporting of :Monitoring and reporting of : Uniformity of Kiln Twist (UOKT System)Uniformity of Kiln Twist (UOKT System) Monitoring performed during normal kiln operation.Monitoring performed during normal kiln operation.

Normal migration

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T yer

S hell

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S lipA bnormal migration（in c ase o f se izure）

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b d

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T yer

S hell

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S eizure

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Normal migration and abnormal migrationNormal migration and abnormal migration

S uppo r t ing blo c k Inne r s u r fac e o f t yre

S ide o f t yre

L e taine r blo c kT yre

P ro jec ting portions on the c ontac t surfac es between supporting bloc ks and the inner

surfac e of the tyre have se ized, and normal rotaition is impaired.

D ue to thermal defomation o f the shell, un even settlement o f the kiln foundation, etc .

U ne ve n s e t t le me nt o f t he k iln fo undat io n

D e fo mat io n o f t he s he ll

the pos ition o f the ro llers has deviated from the original pos ition, and the ro llers bear uneven loads .

受 ロー ラの 過 度 の 追 い 込 み

受 ロー ラ整 列 線

Causes of abnormal MigrationCauses of abnormal Migration

タイヤ下内面の摩耗タイヤ下内面の摩耗サポーティングブロックとタイヤ内面との接触面における異常摩耗

AVOID THiS SITUATION BY APPLICATION OF LUBRICANTS

Wasted Lubricant. If it can be seen, it isn’t doing anything.

Pitted rollers indicates possible lack of lubrication

APPLICATION - Sofmet® series APPLICATION - Sofmet® series

APPLICATION : Air assisted application equipment for liquids.

Grease pumps for heavier products.

APPLICATION :

Melt bars are a popular and efficient method of placing the solid lubricant exactly where it needs to be.

MONITORING :MONITORING :

The Uniformity of Kiln Twist (UOKT) systemThe Uniformity of Kiln Twist (UOKT) system

A portable system set up and used during normal kiln operationA portable system set up and used during normal kiln operation

Measures uniformity of kiln twist.Measures uniformity of kiln twist.

Generates graphical visualisations of kiln twist per kiln quadrant.Generates graphical visualisations of kiln twist per kiln quadrant.

Used to assess overall kiln mechanical performance.Used to assess overall kiln mechanical performance.

Used as a direct indicator of effectiveness of kiln tyre lubrication.Used as a direct indicator of effectiveness of kiln tyre lubrication.

T es t kiln

○ L e nghth o f t he k iln：80m（3s uppo rt )

○ Inne r diame te r o f t h s he ll：4.9m

○ C linke r pro duc t io n：229t／ h

○ R o tat io n S pe e d：3.4rpm

1 6 11 16 21 26 31 36 41 46 51 56 61 66 71 76 81 86 91 96

Time of measurements

Cal

ibra

tions

5m

s：

S1 AB／S1 BC／S1 CD／S1 DA／S1 AA／S2 AB／S2 BC／S2 CD／S2 DA／S2 AA／

1 6 11 16 21 26 31 36 41 46 51 56 61 66 71 76 81 86 91 96

Time of measurements

Cal

ibra

tions

5m

s：

S1 AB／S1 BC／S1 CD／S1 DA／S1 AA／S2 AB／S2 BC／S2 CD／S2 DA／S2 AA／

1 6 11 16 21 26 31 36 41 46 51 56 61 66 71 76 81 86 91 96

Time of measurements

Cal

ibra

tions

5m

s：

S1 AB／S1 BC／S1 CD／S1 DA／S1 AA／S2 AB／S2 BC／S2 CD／S2 DA／S2 AA／

T es t res ultB e f o re appr ic at io n o f S O F M E T

A f te r c o n t in u o u s u s e o f S O F M E T f o r h a lf ye ar

A f te r c o n t in u o u s u s e o f S O F M E T f o r 1 ye ar

MONITORING :MONITORING :The measuring of rotating pulsation And twisting of the shellThe measuring of rotating pulsation And twisting of the shell

Sofmet® products have been used by a number of plants worldwide belonging to multi-national groups such as : Lafarge, Vicat, Hanson, Taiheiyo, Mitsubishi, Ube, Taiwan Cement, Indocement (Heidelberg Group) and Kawasaki Heavy Industries.

Sofmet products have been approved for use by leading kiln equipment mnaufacturers worldwide including FLS, Thyssen, FCB, Polysius.

Email: ac@coatekinternational.com Tel : 0118 9309989 Mob : 07771 596755 www.coatekinternational.com

ROTARY KILN LUBRICANT PRODUCTS

AND SERVICES

● Proven ● Cost-Effective ● Decades of Development

approvalsapprovalsAREA PRODUCT MAIN FEATURES NOTES

PRE-HEATER REDUCED CLOGGING

New DNC Reduction of clogging and build up often found in dry-process pre-heating systems/tower.

Applied durign shutdown preferably onto new refractoriy

LIVE RINGLUBRICATION

Sofmet Aqua Copper and graphite in water dispersion – spray applied.

Precise application required as water based so flow is minimal. Service abailable.

Sofmet Grease Copper in non-melt grease – pump applied

Application more difficult but a very high performance product. Service available.

Sofmelt bars Copper and graphite in melting bar – apply by hand.

Zero waste and bars can be modified if required. Service available.

Sofmet Liquid Copper in oil – Use with problem rings, where extra penetration is required. When stable, use one of the standard materials.

Suggested for short term application only, as water based version is available. Service available.

Graphite/Water Graphite in water – spray applied. Low cos product – precise application is required. Service available.

KILN SUPPORT ROLL LUBRIC’NDEVELOPMENT

Graphite Blocks

OR any of the ring products, depending upon application techniques employed.

Enhanced blocks incorporating copper can be considered.

UOKT ANALYSIS An analysis can be made of any rotary kiln in normal operation which will show the uniformity of twist along the length of the kiln during operation. This is a direct indication of the effectiveness of lthe lubrication of the live rings. This analysis can be offered as a service as part of the provision of lubricants listed.

Email: ac@coatekinternational.com Tel : 0118 9309989 Mob : 07771 596755 www.coatekinternational.com

ROTARY KILN LUBRICANTS, PRODUCTS AND SERVICESC

ost

and

Per

form

ance

Wax Bar DevelopmentWax Bar Development

- Flammability perception – mixed !!- Flammability perception – mixed !!

- Reducing volatilities – what is working ingredient ?- Reducing volatilities – what is working ingredient ?

- Handling characteristics (bending during application)- Handling characteristics (bending during application)

- Melting/hardness characteristics (similar to current).- Melting/hardness characteristics (similar to current).

Factors Determining Melt Bar Design

FLAMMABILITY RIGIDITY

LUBRICITY / FLOW

Factors Determining Melt Bar Design

COST

Shell Temp Carrier Burning SmokeShell Temp Carrier Burning Smoke

HANSON KETTON UNIT 7 FEBRUARY/MARCH 2013270 degC SHELL TEMPERATURE 270/400 400 degC

20 2019 19

18 Average taken of 3 bars of each type 1817 1716 1615 1514 1413 : Smoke 1312 : Small flame 1211 : Large flame 1110 10

9 98 87 76 65 54 43 32 21 1

Orig L H HT UHT Orig L H HT UHTC O A T E K C O A T E K