Technical Specifications
- Weight: 0.3–50 tons (customizable)
- Diameter: φ400 mm – φ2000 mm (customizable)
- Materials: ZG230-450, ZG270-500, ZG35, ZG55, ZG35CrMo, ZG42CrMo
- Surface Hardness: HRC 45–55
- Heat Treatment: Normalizing, tempering, quenching + tempering
- Surface Treatment: Medium-frequency or induction quenching
- NDT Methods: UT (ultrasonic), MT (magnetic particle), PT (dye penetrant)
- Machining Tolerance: ISO 6–7
- Application: Cement rotary kilns, lime kilns, rotary dryers, rotary coolers
- Customization: Yes, according to customer drawings
Rotary Kiln Supporting Roller
The rotary kiln support roller (also called the carrier roller, supporting roller, or kiln roller) is a critical load-bearing component of the rotary kiln support system. It is a large cylindrical steel casting positioned underneath the kiln shell. The support roller bears the entire weight of the rotating kiln — including the shell, refractory bricks, internal devices, materials, riding ring, and girth gear — and enables smooth rotation.
The tyre and support rollers work together as a pair. Without strong, properly aligned support rollers, the kiln cannot rotate smoothly, putting the entire production line at risk.
AGICO has been manufacturing rotary kiln support rollers for over 20 years. We supply high-quality support rollers for cement plants, lime kilns, and other rotary processing systems worldwide. Our support rollers are made from high-strength cast steel and are custom-made according to customer drawings and specifications.
Working Principle of Rotary Kiln Support Roller
The support roller is positioned underneath the kiln shell and directly contacts the kiln tyre. As the kiln rotates, the tyre rotates against the support roller. The roller bears the full weight of the rotating kiln — which can be several hundred tons — and transfers it to the foundation below.
A typical rotary kiln has two or three sets of support rollers. Each set usually consists of two rollers positioned under each tyre. Together, they distribute the kiln’s weight evenly and ensure stable rotation.
During operation, the support roller faces three types of stress: compressive stress (from the weight of the kiln), contact stress (from rolling contact with the tire), and thermal stress (from the heat of the kiln). A good support roller must handle all three without cracking or wearing out too quickly.
Types of Support Rollers – By Structure
Solid Roller (Monobloc)
The roller body and shaft are cast or forged as one single piece. This design is simple, strong, and reliable. It has fewer assembly points, which reduces the risk of loosening during operation.
- Best for: Standard cement kilns and most general applications.
- Advantages: High structural integrity, easy to install, and low maintenance.
- Disadvantages: Heavier, more expensive to replace as a whole.
Assembled Roller (Roller Body + Shaft)
The roller body and shaft are manufactured separately and then joined together through hot fitting. The roller body is heated to expand, the shaft is inserted, and after cooling, a tight, secure fit is achieved.
- Best for: Large kilns where replacement cost is a concern.
- Advantages: You can replace only the worn roller body without changing the shaft—saving up to 40% of replacement costs.
- Disadvantages: Requires precise machining and skilled assembly.
Which One Should You Choose?
- For most cement rotary kilns, the solid roller is the most common and reliable choice.
- If you want to reduce long-term spare parts costs, the assembled roller allows partial replacement.
- AGICO’s engineering team can help you select the right structure based on your kiln size, load, and budget.
Rotary Kiln Support Roller Materials
The material of the support roller determines its strength, wear resistance, and service life. AGICO offers the following options:
| Material | Strength | Wear Resistance | Best For |
|---|---|---|---|
| ZG230-450 / ZG270-500 | Medium | Medium | Standard cement kilns, lime kilns |
| ZG35 / ZG55 | High | High | Heavy-duty kilns |
| ZG35CrMo | Very High | High | Heavy-duty, high-temperature kilns |
| ZG42CrMo | Very High | Very High | Heavy-duty, best wear resistance |
How to Choose the Right Material
- For standard cement kilns: ZG230-450 or ZG270-500 offers good strength at a reasonable cost.
- For heavy-duty kilns: ZG35, ZG55, or ZG35CrMo offer higher strength and better wear resistance.
- For the most demanding conditions: ZG42CrMo provides the highest strength, best wear resistance, and excellent impact toughness.
AGICO can also cast support rollers with customer-specified materials.
Advantages of AGICO Cement Kiln Support Roller
Crowned Design – Automatic Alignment
AGICO’s kiln carrier rollers feature a crowned design — the outer surface is slightly curved. This design automatically corrects kiln axis deviation and prevents misalignment wear. It also accommodates thermal expansion and axial movement of the kiln shell during operation. This is a key advantage that sets AGICO apart from ordinary support rollers.
High-Strength Cast Steel – Strong Load-Bearing Capacity
AGICO rotary kiln support rollers are made of high-quality cast steel (ZG230-450 to ZG42CrMo). These materials provide high tensile strength, good impact toughness, and excellent load-bearing capacity. The roller can carry the entire weight of the kiln — up to several hundred tons.
Advanced Heat Treatment – High Surface Hardness
AGICO uses normalizing, tempering, and quenching + tempering heat treatment for all support rollers. The roller surface is also treated with medium-frequency or induction quenching to enhance wear resistance and fatigue strength. Surface hardness reaches HRC 45–55, ensuring long-lasting performance even under heavy loads.
Precision Machining & Modular Design, Easy Maintenance
We use large CNC lathes and other advanced equipment for precision machining. Roller journals and surfaces are machined to tight tolerances (ISO 6–7). The roller, support base, and bearing housing adopt a modular design, enabling quick assembly and disassembly to minimise downtime. The roller seat structure also allows precise axial and inclination adjustment through adjustment bolts.
100% Inspection – No Hidden Defects
Every rotary kiln support roller undergoes non-destructive testing (ultrasonic testing, magnetic particle testing, and dye penetrant testing) to check for cracks, inclusions, and pores. We also use a spectrometer to test the chemical composition of the molten steel.
Custom-Made According to Your Drawings
AGICO can produce support rollers of various sizes, weights, and materials according to customer drawings. We provide individual support rollers or complete support roller assemblies.
Manufacturing Process
AGICO follows a strict manufacturing process to ensure every support roller meets the highest quality standards:
- Drawing confirmation
- Pattern and mold preparation
- Smelting in electric arc furnace
- Molten steel testing (spectrometer)
- Pouring
- Cooling and sand cleaning
- Heat treatment (normalizing, tempering, Q&T)
- Rough machining
- Non-destructive testing (UT, MT, PT)
- Surface hardening (medium-frequency/induction quenching)
- Finishing machining (CNC)
- Dimensional inspection
- Final inspection and packaging
Common Problems & How AGICO Solves Them
Even the best support rollers can encounter problems if not properly designed, manufactured, or maintained. AGICO’s engineering approach prevents these issues through quality materials, precision manufacturing, and correct installation.
| Problem | Root Cause | AGICO Solution |
|---|---|---|
| Surface wear and spalling | Poor material or misalignment | High-quality cast steel + heat treatment for surface hardness ≥ HRC 45 + crowned design to reduce edge stress |
| Cracks on the roller | Casting defects or improper heat treatment | CAE simulation to prevent defects + 100% NDT (UT, MT, PT) to find cracks before delivery |
| Bearing overheating | Poor lubrication, seal failure, or misalignment | Precision machining + proper bearing design + lubrication guide provided |
| Loosening between roller body and shaft | Poor assembly fit or thermal expansion | Hot assembly technology ensures tight fit + proper interference control |
| Uneven wear across roller surface | Kiln axis deviation or tyre misalignment | Crowned design automatically corrects axis deviation + adjustment bolts for precise alignment |
| Short service life | Wrong material choice for the application | AGICO’s engineering team recommends the right material based on your kiln load, temperature, and operating conditions |
With proper maintenance, AGICO support rollers typically last 10–20 years.
FAQ about Rotary Kiln Support Roller
Q1: What is the difference between support roller and thrust roller?
A: The support roller carries the weight of the kiln and allows it to rotate. The thrust roller controls the axial movement of the kiln (keeps it from sliding up or down). They serve different functions.
Q2: What is the service life of an AGICO support roller?
A: With proper maintenance and lubrication, AGICO support rollers typically last 10–20 years. Actual life depends on operating conditions, load, and maintenance.
Q3: What is crowned design and why is it important?
A: Crowned design means the roller surface is slightly curved (not perfectly flat). This allows the roller to automatically correct kiln axis deviation and prevent uneven wear. It also helps accommodate thermal expansion of the kiln shell.
Q4: What type of bearings do your support rollers use?
A: AGICO support rollers typically use rolling bearings for high precision and reliability. We can also design with sliding bearings upon request.
Q5: Can AGICO produce a support roller according to my drawing?
A: Yes. AGICO accepts custom orders based on customer drawings. Just provide us with detailed CAD or PDF drawings.
Q6: What is the lead time for a support roller?
A: Lead time depends on size and specifications. Typically 45–90 days. Contact us for a specific quote.
Q7: Do you supply other rotary kiln spare parts?
A: Yes. AGICO supplies kiln tyres (riding rings), thrust rollers, girth gears, pinions, kiln shells, bearing housings, and sealing devices
