As this job involved a cracked tyre it had to be treated as a priority case. The tyre needed replacing with minimum downtime to reduce lost production time as we are well aware that any lost time in this industry can be very costly. The existing shell needed to be supported and cut, to enable removal and replacement of the tyre on that section of the kiln.

A cracked tyre needed replacing.	Support spiders were put in place.	Grayton provided the specialists.

We encountered different challenges on this project - we needed a highly specialised lift to get the tyre into position on site and we had to design specialist lugs to assist with lifting the tyre off.

This project involved the installation of new drive gear into a raw mill. Because the working space was so confined there was no room in the mill building to get a crane inside, so we had to design specialist lifting beams before any work could be started. The lift was very complex and required very detailed studies to be carried out to ensure the safe handling of the two gear parts.

Each half of the drive gear weighed 15 tones and had to be installed to a tolerance of 0.5mm axially and 0.75 mm radially. We only had a 24 day window to install the lifting gear, get the old drive gear off and the new drive gear installed and working.

Cleveland Potash use rotary washers in their manufacturing process and these in turn use lots of water. Potash is highly corrosive so these rotary washers are specifically designed to withstand the highly corrosive nature of the process. For us this just means applying our specialist rotating equipment knowledge as normal, but using equipment made of different materials such as Corten in this case. Another area we work in is that of rotary driers.

These often have more complex internals that move the feed stock around, but again our years of experience gives our customers the peace of mind that when we finish our job they are left with reliable efficient equipment. Celanese Acetate Celanese Acetate manufacture cigarette filters which are made from acetate flake and this involves using both rotary washers and rotary driers in the manufacturing process. However, as this process also involves the use of a lot of acid they are always in need of repair. The equipment is generally hard to work on as they are usually in hard to reach places, inside a building making access extremely difficult. We recommend that regular surveys are carried out on these items of equipment to highlight any work that needs doing to prevent breakdown of equipment and subsequently loss of production time and loss of income.

Celanese Acetate manufacture cigarette filters which are made from acetate flake and this involves using both rotary washers and rotary driers in the manufacturing process.  However, as this process also involves the use of a lot of acid they are always in need of repair.  The equipment is generally hard to work on as they are usually in hard to reach places, inside a building making access extremely difficult.

We recommend that regular surveys are carried out on these items of equipment to highlight any work that needs doing to prevent breakdown of equipment and subsequently loss of production time and loss of income.

Secheur drivers are used to dry the highly abrasive soda ash as part of their process.  We use our rotating equipment skills to ensure that the bearings, rollers and tyres are properly maintained and aligned. 

The skills exhibited by us have led to a long term, lasting relationship providing the client with a high level of reliability.  Brunner Mond also recognise the importance of having a maintenance contract with ourselves to adjust support rollers, tyres and carry out general mechanical overhalls of equipment.