Fuels and Combustion

FTI CS40 OUTLET
SEAL
REV.00
Table Of Contents
1. DESIGN OBJECTIVES .......................................................................................................................................................... 2

2. DESIGN FEATURES .............................................................................................................................................................. 2
2.1. LEAK TİGHTNESS.............................................................................................................................................................. 2
2.2. NOSE RİNG COOLİNG ....................................................................................................................................................... 2
2.3. TEMPERATURE REGULATİON .......................................................................................................................................... 2
2.4. BACK PRESSURE ............................................................................................................................................................... 2
3. DESCRIPTION ........................................................................................................................................................................ 3
3.1. BEARİNG RACE ................................................................................................................................................................. 5
3.2. CONNECTİNG CONE .......................................................................................................................................................... 5
3.3. CASİNG .............................................................................................................................................................................. 5
3.4. GRAPHİTE PLATES ............................................................................................................................................................ 5
3.5. NOSE-RİNG COOLİNG ....................................................................................................................................................... 6
3.6. GRAPHİTE COOLİNG ........................................................................................................................................................ 6
4. INSTALLATION ..................................................................................................................................................................... 6
4.1. TRANSPORT ....................................................................................................................................................................... 6
4.2. PRE-START ........................................................................................................................................................................ 7
4.3. MAİNTENANCE.................................................................................................................................................................. 7
4.3.1. Replacing the Graphite Plates ................................................................................................................................. 9
5. THERMOCOUPLE AND FAN ............................................................................................................................................ 10
5.1. GRAPHİTE PLATES COOLING ......................................................................................................................................... 10
5.2. TEMPERATURE REGULATION ........................................................................................................................................ 10
5.3. THERMOCOUPLE ASSEMBLY .......................................................................................................................................... 10
5.4. THERMOCOUPLE TEMPERATURE REGULATION ........................................................................................................... 12
5.5. GRAPHITE PLATES COOLING FAN FUNCTION ............................................................................................................... 12
5.6. NOSE RING COOLING ..................................................................................................................................................... 13
6. APPENDIX ............................................................................................................................................................................. 13
6.1. SPARE PARTS ................................................................................................................................................................... 13
Table of Figures
Figure 1 ______________________________________________________________________________________________ 3
Figure 2 ______________________________________________________________________________________________ 3
Figure 3 ______________________________________________________________________________________________ 4
Figure 4 ______________________________________________________________________________________________ 8
Figure 5 ______________________________________________________________________________________________ 9
Figure 6 _____________________________________________________________________________________________ 11
Figure 7 _____________________________________________________________________________________________ 12
Figure 8 _____________________________________________________________________________________________ 14
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1. DESIGN OBJECTIVES
The goal was to manufacture a seal inplementing simple mechanical solutions to meet the following
objectives:
 Provide effective leaktightness around the kiln discharge hood to prevent cold air ingress or release of
hot gases and particles
 Improve cooling of the nose ring refractory plates
 Improve pressure stability in the kiln
2. DESIGN FEATURES
2.1. Leak Tightness
Graphite plates are installed to form a static barrier between the discharge hood and a circular bearing
race rotating with the kiln. Friction wear of the graphite plates on the bearing race diminishes after the
startup period. The service life of the graphite plates is 3 years or longer on some seals.
2.2. Nose Ring Cooling
A continuously operating high-capacity blower is used to cool the shell and nosering refractory plates.
The blower volume is isolated from the discharge hood to prevent air from entering the kiln.
2.3. Temperature Regulation
Temperature regulation is provided inside the casing to extend the service life of the graphite plates by
maintaining the temperature below the graphite oxidation threshold by the means of a low pressure fan
( maximum 60 mm H2O). The air flow is regulated by opening or closing a valve on the connecting
line between the seal and the fan.
The temperature in the casing is monitored by a pyrometer sensor that supplies a control signal to the
regulator.
2.4. Back Pressure
A side-effect of the temperature regulating fan is to maintain a back pressure in the discharge hood.
This enhances kiln operation, by allowing the possibility of working at a slight positive pressure in the
discharge hood, therefore, increasing productivity anddecreasing calorific consumption.

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Figure 1
3. DESCRIPTION
Figure 2

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Figure 3
1- Kiln shell 9- Dust cone

2- Dummy shell 10- Kiln hood connection flange
3- Dummy Shell extension 11- Baffle plate
4- Nose ring plates 12- Bearing race
5- Seal 13- Leaktight casing
6- Links 14- Plate retention wire
7- Graphite plates 15- Backing plate
8- Cooling fan 16- Connecting flange

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3.1. Bearing Race
A circular bearing race (mark 12) ; (20 mm thickness) is installed concentric with the kiln centerline.
The race is mounted on the kiln shell using links (mark 6). This permit to absorb the Radius expansion
of the kiln. During assembly, the bearing race is aligned and adjusted with centering tools to avoid
ovality.
3.2. Connecting Cone
A light-gauge sheet metal cone (mark 3) is welded to the tapered end of the dummy shell to ensure
leaktight separation between the cooling zones.
3.3. Casing
The self-supporting fixed casing, generally delivered in three sub-assemblies, rests on two legs. The
casing comprises:
An inlet flange bolted or welded to the kiln discharge hood (the assembly method is determined at the
design stage depending on the type and layout of the discharge hood, even with removable hoods);
 A graphite plate guiding flange
 A graphite plate retaining ring
 A casing with access panels, a regulating air inlet, a dust recovery hopper, and a double flap valve for
dust removal without cold air ingress.
3.4. Graphite plates
The seals comprises between 80 and 90 graphite plates 40 mm thickness. The graphite plates are
arranged symetrically and are interlocking to enhance their leaktightness.
At the top of each plate, a grooved metal insert supports the cables to prevent friction wear.
Guiding stops welded to the casing inlet flange prevent the plates from rotating.
The plates are held in contact with the bearing race by metal cables and counterweights.
The upper cable restrains about 40 % of the plates, while the others are secured by the lower cable.

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The casing includes a threaded support rod for installation of each lower plate to ensure safety in the
event of a cable failure.
The counterweight tension is adjusted on installation. Ten extra plates are provided in case of damage.
3.5. Nose-ring Cooling
The nose-ring is cooled by a high capacity blower (e.g; for the kiln with 4 m diameter, 34000 m3/h,
300 mm H2O static pressure).
A circular manifold mounted on the seal casing includes from 4 to 6 air nozzles depending on the kiln
and on the blower airflow rate. The objective is to obtain an air velocity exceeding 50 m / s from each
nozzle.
The price of this option includes a cooling air duct approximately 10 m long between the blower and
the distributor manifold.
3.6. Graphite Cooling
The graphite plates are cooled by a continuously operating low capacity blower (for the kiln with 4 m
diameter, 3000 m3/h, 60 mm H2O static pressure).
The airflow rate is regulated according to the casing temperature.
The temperature probe and a measurement signal converter supplies a 4 – 20 mA signal to a regulator
controlling an electro-pneumatic actuator installed directly on the butterfly valve at the blower outlet.
Control is ensured by clean, dry compressed air at a pressure of 7 bars.
The standard air duct from the blower to the air inlet (generally located at the top of the casing) is
about 10 meters long.
4. INSTALLATION
4.1. Transport
To remove the fans when moving from one place to another, only lifting eyes should be used. Crane
should be used at proper capacity. The use of sling has to be observed in safety rules. The eyelet bolt
(eg for motor) must be firmly connected before use.

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4.2. Pre-start
In the beginning phase, no special requirements are needed except for the following issues.
- Wearing of Graphite Plates:
After starting the rotary kiln for the first time, increase the weight of the graphite blocks (5 or 6 extra
weights) to ensure a constant high pressure. This will increase the amount of wearing of the graphite
plates and will ensure that the lower portions will take full contact with the graphite bed.
After finishing the desired abrasion process, leave only 5 or 6 weights for the upper rope. For the
lower tensioning rope, remove the weight plates until the graphite plates are in contact with the
graphite pressing surface. Add 2 weight plates after seeing that the contact is cut off. This wear, which
is made for precise application of graphite plates, should not exceed an estimated 15 days under
normal operating conditions (the most significant wearing occurs during the furnace extension). For
this reason, the first 2 days should be checked every 3 hours, then every 12 hours until the desired
wear level of the graphite plates is reached.
- Adjustment of Cooling System of Graphite Plates:
On the cooling system piping is adjusted to compensate for the amount of air flowing below and above
the torso by means of one inlet clasp. This process is carried out in accordance with the body
temperature. When there is restricted air in the channel.
4.3. Maintenance
The maintenance required is very low degree as most of the sealing parts are fixed.
The working life of graphite plates depends on several reasons.
Operational life depends on the kiln hood pressure being regular. If the pressure is low, it means that
there is little risk of dust coming out and that there is less wearing due to friction.
In any case, the condition of the cables must be checked with simple visual inspection every 3 months.
The wear quantities of the graphite plates must be checked separately at the bottom and at the top of
each yearly stance. Care must be taken to ensure that there is not anything on graphite plates that may
cause wearing on the pressed ring surface before its time. Sometimes a graphite plate jam may be the
issue. In this case, the powder flushes between the graphite plate and the side guide or between the
graphite plate and the flange. In this case, the housing plate retaining bolts holding the graphs
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mentioned in Figure-01 are loosened and compressed air is held between the graphite plate and the
cover plate to clean the dusts in between.
The height of a new graphite plate is 200 mm. If the total length of graphite plate is 80mm wear, all
graphite plates are replaced with new ones. If any graphite plate is broken, the plate must be replaced
immediately.
Steel Rope Graphite plate
Wedge
Protection
Load
Load
Figure 4

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4.3.1. Replacing the Graphite Plates
The weight is taken to allow the release of the steel rope in the graphite zone to be replaced. The
wedge to which the housing is attached is removed from the area where the bolts are removed. The
worn or broken graphite in the relevant region is removed from the place and replaced with new
graphite.
Figure 5

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5. THERMOCOUPLE AND FAN
5.1. Graphite Plates Cooling
The graphite plates are cooled by a continuously running low-capacity fan.
The fan capacity is 3000 Nm3 / h, 60 mmH2O and the motor power is 2.2 kW.
The air flow seal is manually adjusted by means of the valve in the fan outlet, depending on the
temperature in the housing. The interior temperature is measured by means of a thermocouple sensor
located in the sealing housing user.
5.2. Temperature Regulation
By means of a low pressure fan, the temperature setting provided in the enclosure will increase the
working life by ensuring that the temperature of the graphite plates is kept below the oxidation limit.
The oxidation limit of the graphite plates is about 200 centigrads.
If the graphite plates are damaged in any way, it is advisable to change them immediately.
5.3. Thermocouple Assembly

The thermocouple will be secured by welding a muffle to the center of the air duct as shown in Fig.
3A-A on the housing. When looking at the seal against the vortex it is advisable to place it between 1
and 2 o'clock, so that it remains opposite the clinker bed (Figure - 03).

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Figure 6

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Air Channel
Figure 7
5.4. Thermocouple Temperature Regulation
The fan will be operated at full capacity until the regime is entered after the rotary kiln starts to
operate. After the kiln is regenerated, it will be adjusted according to the situation. Under normal
operating conditions, the temperature inside the enclosure should be 50 Celsius degrees. Graphite
cooling fan inlet suction flap is operated continuously at 30% - 40% setting.
If the thermocouple set is set to 120 degrees Celsius and exceeds this limit, the fan inlet suction flap is
fully opened to operate in full capacity (100%).
5.5. Graphite Plates Cooling Fan Function
The graphite cooling fan is to increase the working life by keeping the temperature of the graphite
plates under the oxidation limit.
A side-effect of the temperature regulating fan is to maintain a back pressure in the discharge hood.
This enhances kiln operation, by allowing the possibility of working at a slight positive pressure in the
discharge hood, therefore, increasing productivity anddecreasing calorific consumption.
Termocouple specifications; K couple 100°C~1200°C, diameter 6mm, L=80mm, R1/4”

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5.6. Nose Ring Cooling
The nose ring is cooled by a high capacity fan.

Fan specifications; 34000 Nm3/h, 300 mmH2O, 45 kW and speed 1450 rpm.
5.6.1. Nose Ring Cooling Function
Nose ring cooling fan blowes the air through the dummy shell by means of a circular manifold
mounted on the seal casing. The circular manifold that mounted on the seal casing has 6 air nozzles.
The fan air is isolated from the discharge hood to prevent air from entering the kiln. The circular
manifold shape is as a C. Thus can be seen possible red area on the kiln shell surface because of any
temperature rising in the case of refractory lost.
6. APPENDIX
6.1. Spare parts
DESCRIPTION POSITION
1 GRAPHITE PLATE
2 ROPE GUIDE
3 10mm (6x7) TS-EN 12385 – DIN 3055 steel wire rope 20 Meter
4 Wire rope grips DIN 1142 EN 13411-5a
5 WIRE ROPE THIMBLES DIN 6899

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Figure 8

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FTI CS40 OUTLET

1. DESIGN OBJECTIVES .......................................................................................................................................................... 2

FONS TECHNOLOGY INTERNATIONAL Page 1

2.2. Nose Ring Cooling

2.3. Temperature Regulation

2.4. Back Pressure

FONS TECHNOLOGY INTERNATIONAL Page 2

FONS TECHNOLOGY INTERNATIONAL Page 3

1- Kiln shell 9- Dust cone

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3.1. Bearing Race

3.2. Connecting Cone

3.4. Graphite plates

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3.5. Nose-ring Cooling

3.6. Graphite Cooling

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- Wearing of Graphite Plates:

- Adjustment of Cooling System of Graphite Plates:

The working life of graphite plates depends on several reasons.

Steel Rope Graphite plate

FONS TECHNOLOGY INTERNATIONAL Page 8

4.3.1. Replacing the Graphite Plates

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The graphite plates are cooled by a continuously running low-capacity fan.

5.2. Temperature Regulation

The oxidation limit of the graphite plates is about 200 centigrads.

5.3. Thermocouple Assembly

FONS TECHNOLOGY INTERNATIONAL Page 10

FONS TECHNOLOGY INTERNATIONAL Page 11

5.4. Thermocouple Temperature Regulation

5.5. Graphite Plates Cooling Fan Function

Termocouple specifications; K couple 100°C~1200°C, diameter 6mm, L=80mm, R1/4”

FONS TECHNOLOGY INTERNATIONAL Page 12

5.6. Nose Ring Cooling

The nose ring is cooled by a high capacity fan.

5.6.1. Nose Ring Cooling Function

FONS TECHNOLOGY INTERNATIONAL Page 13

FONS TECHNOLOGY INTERNATIONAL Page 14

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