Product category:
Maintenance Services
News Release from: Corus Northern Engineering Services | Subject: Lafarge Cauldon works
Edited by the Processingtalk Editorial
Team on 18 June 2008
Supply of kiln support roller shaft at
Lafarge
Corus Northern Engineering Services has successfully manufactured and installed a kiln support roller assembly on the 58m long rotary kiln, at the heart of the Lafarge Cement's Cauldon works
Over the last two years, CNES has now manufactured and refurbished more than one million pounds worth of kiln support roller shaft assemblies for all the major UK-based cement manufacturers, but this is the first time that CNES has been involved in the actual installation work in the cement industry Cauldon Works has production capacity to manufacture up to one million tonnes of cement each year and is increasing the use of waste-derived fuels as part of its drive for increased sustainability in operations
This article was originally published on Processingtalk on 2 Oct 2006 at 8.00am (UK)
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The Works uses a combination of traditional fossil fuels - coal and petroleum coke - with tyre chips and Processed Sewage Pellets.
It is also permitted to use Recovered Fuel Oil (RFO) and has recently been given a permit to evaluate Solid Recovered Fuel (SRF), which, it is estimated, could reduce its carbon dioxide emissions by around 17,000 tonnes each year.
One of the existing kiln support roller shafts at the Works needed replacing as it was badly worn.
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This roller shaft is one of six that supports the kiln.
The rollers themselves weigh between 8 and 9 tonnes each and have a typical operating life of around five years.
Lafarge decided to replace the worn roller shaft at the next available plant shutdown, which was in February 2008.
However, due to the height and accessibility of the unit under the kiln, Lafarge decided to outsource this work to an experienced contractor, who would be responsible for removing the old roller and installing the complete new roller shaft assembly.
Stephen Haywood, Project Engineer at CNES commented: "We have a very close working relationship with Lafarge and this, coupled with the CNES vast experience in heavy lifting, removal and installation work, resulted in Lafarge inviting us to tender for the installation work, as well as the manufacturing of the replacement roller shaft.
We beat off fierce competition to secure the contract".
The removal and installation work took five days to complete.
First, in order to remove the existing damaged roller shaft, CNES engineers had to jack up one end of the kiln that the roller was supporting.
This was carried out using two, 150-tonne hydraulic jacks and the roller removed in a two-day time frame.
This process involved moving it out from its position on skates using lifting slings and lifting beams, connecting to chain hoists and lowering it 8m to a sunken floor.
The roller was finally removed from site for scrapping and recycling the steel.
Fitting the new roller was effectively a reversal of the removal procedure.
The new roller shaft was manufactured at Corus Process Engineering at Workington.
The rotary kiln was then lowered back onto the new roller shaft ready for commissioning by the Lafarge engineering team.
In total, CNES engineers spent around eight days on site changing the rollers over.
As well as the removal and installation work, CNES manufactured the replacement roller shaft assembly.
CNES Scunthorpe manufactured the shaft and then machined it to suit the roller at Corus Process Engineering in Workington.
Alan Holgate, Estimating Engineer at CNES commented: "For Lafarge at Cauldon, we manufactured the forged steel shaft at Scunthorpe, while the roller forging was delivered to CPE Workington.
Engineers at Workington machined the inside diameter of the roller, for Scunthorpe to machine the shaft to just one thousandth of an inch larger than the roller bore.
The shaft was shipped to Workington, where the roller was placed in an oven to expand the bore before it was dropped onto the shaft to cool down to a tight fit.
Once this had taken place, the main diameter of the roller was machined in a large lathe to the required dimensions and concentricity, before final inspection and despatch to Lafarge".
Lafarge Cement is part of the Lafarge Group, the world leader in building materials, with top-ranking positions in all of its businesses: Cement, Aggregates and Concrete, and Gypsum.
The Cauldon Works has capacity to manufacture up to one million tonnes of cement each year and distributes this to customers in the Midlands and the Northern Home Counties. Request a free brochure from Corus Northern Engineering Services ...
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