Why It’s Essential to Lubricate Kiln Tires & How To Do It

Considered the workhorse of the industry, the rotary kiln is a complex machine that requires regular care to perform its job well. While many components of a rotary kiln must be serviced regularly, lubrication of kiln tires is an important part of general kiln maintenance.  Not taking care of this massive piece of machinery can result in safety hazards, damaged product, and a disruption in production — risky scenarios that should be avoided at all costs. 

If there’s only one thing you do to keep your kiln in good shape, it should be proper lubrication. In this blog post, we will explain why kiln lubrication matters, how to lubricate kiln tires properly, and the best way to get the job done. 

The Benefits of Lubricating Kiln Tires

Lubrication serves multiple functions for rotary kilns. Not only does it protect machine components from wear and tear, it also reduces wasted time on unscheduled maintenance and high energy costs. With numerous types of tire lubrication products available, deciding which type of product works well for your kiln can be inconvenient and time-consuming. Below are the types of lubrication and their many benefits. 

Solid Bar Lubrication

Known to be one of the best ways to lubricate kiln tires, solid bars are easy to use and require no additional tools or machinery for precise application. Solid bar lubrication between the filler bars or kiln shell and riding rings of a rotary kiln is proven to:

  • Extend the life of wear filler bars
  • Extend shell and refractory service life
  • Reduce scoring of kiln tires, inside bore, riding rings, and stop blocks
  • Reduce weld fractures at filler bar and kiln shell interface
  • Reduce friction and wear
  • Fill microscopic imperfections in contact surfaces

Liquid Spray Lubrication

A sprayable form of kiln tire lubrication is another popular option for staying on top of routine kiln maintenance. This type of lubricant provides quick and accurate application while providing distance between workers and the hazardous environment of the kiln. Similar to the solid bar lube, benefits of using this method to lubricate kiln tires include:

  • Reduced friction, wear, and other surface imperfections
  • Increased lifespan of the tire’s support pads and rotary kiln in general
  • Reduced retainer pressure
  • Reduced scoring of tires, nbore, riding rings, and stop blocks

Kiln Tire Lubrication Methods

Not every rotary kiln is the same, so understanding what maintenance your machine needs will determine the best form of lubricant to use. Products made with poor-quality materials can cause dangerous fire hazards and create toxic fumes, while other products that offer very little lubrication won’t provide the necessary protection against wear and tear. 

Choosing the best product to lubricate kiln tires and other parts may require some research and experimentation. 

Easy Bar Solid Lubricant

The first method is the latest and most effective technology in the industry. Easy Bar is a one-of-a-kind lubricant involving application of a solid bar of lubricant between the filler bars of a rotary kiln. 

The bar melts upon contact and the rolling action of the kiln distributes a solid film, thus forming lubrication to the surface of its filler bars, ring bore, and stop blocks. A thin temperature-resistant film creates a barrier between these moving surfaces, filling in microscopic imperfections and assuring protection from cold welding and galling. Easy Bar lube has an auto-ignition point greater than 1,000 degrees Fahrenheit, protecting workers from dangerous flame ups, blow backs, and other hazards. Better yet, it’s the ideal solution for reducing kiln maintenance and downtime. 

Easy Bar Spray Lubricant

The same powerful formula of the Easy Bar solid lubricant also comes in a liquid form for direct spraying precision. Rotary kilns performing at exceptionally high temperatures may be unsafe to be near for prolonged periods of time. Depending on the industry, a sprayable liquid may likely be a better choice. 

Using a lengthen lance, Easy Bar Spray can be applied from several feet away from the kiln. Resulting in precise application every time. 

Graphite Powder

The last method has been used for many years and consists of mixing graphite powder with a liquid such as water or oil. This solution is then applied between the filler bars, or kiln shell and riding rings, via an air-pressurized spray wand. 

Unfortunately, using graphite powder to lubricate kiln tires isn’t always ideal. Not only is it difficult to maintain the mixture’s consistency between applications, but this method makes it difficult to control the amount of lubricant applied during each application. Applying lubricant to a kiln tire in this manner is also time consuming. Overall, this method does not guarantee tire lubrication is accurately delivered to where it is needed most. Because of the many disadvantages of graphite powder, it is not recommended to lubricate kiln tires. 

How to Apply Easy Bar Lube Products

Both products have been designed for ease of application. Dependent on your kiln, you may prefer to use one lube over the other. Below is how to apply each lube type for proper tire lubrication and kiln maintenance. 

Easy Bar Solid Lube

Installation involves placing a whole bar between the filler bars or pads at the five or seven o’clock positions. This will be done every quarter turn of the kiln as it travels through one full revolution. 

The number of bars used per tire/pier may vary depending upon the operational parameters of a kiln. These parameters will include speed of rotation, temperature, and load of the kiln shell itself. The shell of the kiln should be at or above 125 degrees Fahrenheit when the bar is applied. Standard frequency of application is four bars per tire pier/per week.

Easy Bar Spray

With the applicator gun, Easy Bar Spray should be applied in various spray patterns between the filler bars on the uphill side of the tire. A single coating should also be applied to the sides of the riding ring to reduce wear of the stop blocks and tire. 

On a weekly basis, just 32 ounces per tire is all that is needed to provide superior lubrication and protection against wear and damage. Because no mixing is required prior to use, application time is very minimal. 

Try Easy Bar Lube

Plysious, Humboldt Wedag, Metso, Andritz, and FLSmidth are just a few industry names that use Easy Bar to keep their rotary kilns performing at peak level. The reason? Our products work. 

Everything we guarantee is standard, just one of many reasons why maintenance managers and engineers choose Easy Bar over any other competitor. Reliable kiln operation is not optional, and using Easy Bar shouldn’t be either. Get in touch with us below to try our products for yourself and get a free trial. 

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