Project Background

The customer is a domestic cement group with multiple 5000t/d new dry-process cement production lines. Sudden failures of the rotary kiln support roller bearings had previously caused several unplanned kiln shutdowns, each resulting in losses exceeding RMB 1 million.

Problem Diagnosis

Support roller bearing operating temperatures were too high (alarming above 70℃)
Abnormal bearing wear with irregular replacement cycles
Coarse lubrication management, lacking a scientific maintenance plan

Solution

Bearing Upgrade: The original standard spherical roller bearings were upgraded to enhanced products with optimized internal clearance design.

Monitoring System: An online temperature and vibration monitoring system was installed to track bearing operating conditions in real time.

Lubrication Optimization: A scientific lubrication plan was developed, including oil selection, regreasing intervals, and grease quantity standards.

Regular Inspections: A mechanism for periodic inspections by technical experts was established to identify and eliminate hidden hazards in advance.

Results

Zero unplanned kiln shutdowns over two years of implementation
Bearing operating temperature stabilized below 50℃
Bearing service life extended to more than 3 years
Annual maintenance costs reduced by RMB 2 million