Scribd Logo
Upload

Welcome to Scribd!

  • 384 views

    Bogiflex KGD20 - For Plant

    Uploaded by

    Anonymous PVXBGg9T
    The document introduces the Bogiflex kiln drive, developed by Holcim and CMD to address issues with existing kiln drives like low speed and impacts of thermal expansion. The Bogiflex aims to allow higher kiln speeds up to 4.5 rpm and will be tested in 2007 at the San Sebastian plant. It features a floating gearbox supported by spring plates that maintains optimal gear meshing. The Bogiflex is designed for kilns between 4.0-4.6m and could increase capacities by up to 10%. It costs approximately 600k Euros to install and replaces the need for regular girth gear replacements.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd

    Bogiflex KGD20 - For Plant

    Uploaded by

    Anonymous PVXBGg9T
    384 views13 pages
    The document introduces the Bogiflex kiln drive, developed by Holcim and CMD to address issues with existing kiln drives like low speed and impacts of thermal expansion. The Bogiflex aims to allow higher kiln speeds up to 4.5 rpm and will be tested in 2007 at the San Sebastian plant. It features a floating gearbox supported by spring plates that maintains optimal gear meshing. The Bogiflex is designed for kilns between 4.0-4.6m and could increase capacities by up to 10%. It costs approximately 600k Euros to install and replaces the need for regular girth gear replacements.

    Original Description:

    Bogilex funcionamiento

    Original Title

    Bogiflex KGD20_for Plant

    Copyright

    © © All Rights Reserved

    Available Formats

    PPT, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The document introduces the Bogiflex kiln drive, developed by Holcim and CMD to address issues with existing kiln drives like low speed and impacts of thermal expansion. The Bogiflex aims to allow higher kiln speeds up to 4.5 rpm and will be tested in 2007 at the San Sebastian plant. It features a floating gearbox supported by spring plates that maintains optimal gear meshing. The Bogiflex is designed for kilns between 4.0-4.6m and could increase capacities by up to 10%. It costs approximately 600k Euros to install and replaces the need for regular girth gear replacements.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    384 views13 pages

    Bogiflex KGD20 - For Plant

    Uploaded by

    Anonymous PVXBGg9T
    The document introduces the Bogiflex kiln drive, developed by Holcim and CMD to address issues with existing kiln drives like low speed and impacts of thermal expansion. The Bogiflex aims to allow higher kiln speeds up to 4.5 rpm and will be tested in 2007 at the San Sebastian plant. It features a floating gearbox supported by spring plates that maintains optimal gear meshing. The Bogiflex is designed for kilns between 4.0-4.6m and could increase capacities by up to 10%. It costs approximately 600k Euros to install and replaces the need for regular girth gear replacements.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 13

    Introduction to the Bogiflex drive:

    Kiln Gear Drive 20


    HGRS/MER
    General information about the Bogiflex
    Holcim has developed a project together with CMD to
    make the Bogiflex kiln drive reliable
    The Bogiflex should solve the current following issues:
    Low kiln speed (new max speed 4,5 rpm)
    Impact of the process conditions (thermal expansion)
    Impact of the kiln deformation
    Natural frequency in the drive
    Poor lubrication of the girth gear
    The first Bogiflex drive will be tested in 2007 at the San
    Sebastian plant
    At that stage of the project, the design of the Bogiflex
    should be the same for all kilns with a inner shell
    diameter between 4.0 m up to 4,6 m.
    Overview 2
    Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
    Bogiflex_KGD20.ppt
    Bogiflex displacements: The meshing on the girth
    gear is optimum and constant
    Axial Radial

    How is it working? 3
    Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
    Bogiflex_KGD20.ppt
    Bogiflex: Main components
    Spring plates
    Girth gear
    Bogi-pinion
    Torque arm
    Primary gearbox
    Baring unit
    Lubrication unit
    Housing & Sealing

    New technologies

    4
    Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
    Bogiflex_KGD20.ppt
    Design approach (must be confirmed)
    Single motor (420 kW, 1000 rpm)
    with VFD
    Girth gear and pinion:
    340/23 teeth, module 20, helix angle = 0,
    pressure angle=20
    T shape girth gear (almost identical):
    adjustment of the web height
    Spring plates set
    Floating gear set: 560HD
    72/30 teeth, module 11, helix angle = 0
    Standard Reducer:
    Ermaster R2HC40 with a speed ratio of 7.15
    Universal joint and reaction arm
    Two lubrication units and one baring
    unit
    Comparison with SB Could be different 5
    Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
    Bogiflex_KGD20.ppt
    Design approach: pre-requisite data
    Operating values (Power(kW) and associated kiln speed
    (rpm)):
    During stable condition
    During high filling degree operation: ring(s) in kiln
    Temperature (average, max) at:
    The girth gear meshing
    The close tire and rollers
    The shell underneath the girth gear
    Drawings of the kiln with the shell thickness and tires,
    the present drive, the pier (with cross section)
    Axial moving range of the kiln

    6
    Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
    Bogiflex_KGD20.ppt
    General figures (must be confirmed)
    New kiln capacities
    3.9 rpm at 50 Hz
    4.6 rpm at 60 Hz (power calculated with the B. Saxer
    formula)
    The production rate is increasing proportionaly to the
    speed until the kiln speed is the bottleneck of the line
    Cost approach:
    Bogiflex KGD20 incl. CMD supervision and inspections (3
    years): ~600 kEuro
    New motor with VFD: ~110 kEuro (250 Euro/kW)
    Monitoring of the KGD20: ~30 kEuro
    Foundation modification and steelwork (local): ~40 kEuro
    Erection cost: same as a girth gear replacement
    Erection time: ~2 weeks in the critical path of the shutdown

    7
    Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
    Bogiflex_KGD20.ppt
    The new type of spring plates has better
    performance

    8
    Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
    Bogiflex_KGD20.ppt
    New housing design to avoid oil leakage

    9
    Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
    Bogiflex_KGD20.ppt
    The floating gearbox follows all the movements of
    the girth gear
    girth gear

    internal roller

    bearing 1

    LS pinion

    U joint

    concentric
    roller
    primary drive
    wheel
    bearing 4

    bearing 2

    concentric roller bearing 3

    primary drive
    pinion

    10
    Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
    Bogiflex_KGD20.ppt
    The position of the reaction arm is always pushing
    the pinion against the girth gear
    Torque arm Rollers on the pinion (rings) support the load, keep the tip-to-root
    Force Pushing effect clearance constant and drive the position of the floating gear set

    Girth gear / pinion

    Meshing reaction of the


    wheel to the pinion

    Position of the torque arm

    11
    Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
    Bogiflex_KGD20.ppt
    Axial displacement
    Cardan keeps distance between the pinion and the reducer
    The bogi-pinion follows the girth gear and displaces the floating
    gearbox
    The floating gearbox moves on its pinion

    12
    Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
    Bogiflex_KGD20.ppt
    Application Overview
    Power of PC4, PC5 and PC6 kilns related to the shell diameter
    Installed Power Calculated power 4.5 rpm Power (Installed Power) Power (Calculated power 4.5 rpm)
    2'800

    2'600

    2'400 SMALL MEDIUM


    KGD 20 ?KGD 26?
    2'200

    2'000

    1'800 ~10'000 t/d


    1'600
    kW

    1'400
    ~8'000 t/d
    1'200

    1'000
    ~6'000 t/d
    800

    600 ~4'500 t/d


    400
    ~2'500 t/d
    200

    0
    3.6 3.8 4 4.2 4.4 4.6 4.8 5 5.2 5.4 5.6 5.8 6 6.2 6.4 6.6
    13
    Holcim Group Support Presentation of the Bogiflex KGD20 16.10.2017/MER/AND
    Bogiflex_KGD20.ppt

    You might also like