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| Application Practice of Integrated Online Surfacing Repair Process for Spalling and Pitting Crater Defects of Rotary Kiln Support Rollers |
| Yang Fei, Liu Yunpeng
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| China Resources Cement (Heqing) Co., Ltd. , Dali Yunnan 671500, China |
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Abstract Spalling and pitting crater defects on rotary kiln support rollers are recurring equipment failures that severely disrupt the continuous and stable operation of cement production lines. Targeting a pitting crater defect with a depth of 40mm and an area of 300cm2 on the support roller of a ?4.0m×60m rotary kiln at a cement plant, this paper develops an integrated online surfacing repair process. A302 stainless steel electrode is selected for the process. The integrated repair workflow covers pre-weld surface treatment, multi-layer temperature-controlled surfacing, and post-weld in-situ turning and grinding. Benefiting from the cold-work hardening effect formed under long-term roller operation, the surface hardness of the repaired area rises from 23.5HRC to 40.5HRC after three months of service, which is close to the hardness of the roller base metal. One year of post-repair operational monitoring data indicates that the roller surface temperature remains steady at 46°C~105°C, and the vibration amplitude of the rotary kiln shell is controlled between 10~55μm. All measured parameters stay within safe limits, and no secondary spalling occurs. Compared with the conventional offline repair method, this online solution cuts the repair duration by approximately 50% and slashes repair costs by roughly 90%, while drastically mitigating production losses caused by shutdowns. Field application verifies that this integrated online repair method delivers both outstanding emergency construction efficiency and reliable long-term service performance, offering a viable technical solution for remediation of identical defects on rotary kiln support rollers.
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Received: 16 January 2026
Published: 24 September 2026
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