Rotary Kiln Tyre

Shata Machinery owns an independent sand casting workshop and a professional 5000-ton hydraulic ring rolling forging workshop, realizing one-stop integrated production of all types of custom rotary kiln tyres. Our dual-process production model covers all customer demand scenarios, solving the problem of single process limitation of most ordinary manufacturers.
For small and medium-sized kiln equipment with conventional operating conditions, we provide cost-effective cast steel rotary kiln tyres to help customers control procurement costs; for large cement rotary kilns, metallurgical kilns, and hazardous waste treatment kilns with high temperature, heavy load, and continuous operation requirements, we supply high-strength forged rotary kiln tyres with stronger wear resistance, structural stability and longer service life.
We support full-shape customization, whether for standard circular kiln tyres or products with complex special cross-sections. Our integrated production mode realizes consolidated procurement for customers, effectively saving logistics costs, supplier management costs and communication costs, and supporting the simultaneous progress of multiple engineering projects.

Most conventional manufacturers only produce standard rotary kiln tyres with ordinary 42CrMo material, which cannot adapt to harsh operating environments such as ultra-high temperature, super heavy load, severe abrasion, and high-sulfur & high-alkali flue gas in lithium ore calcination and metallurgical kilns. Ordinary materials are prone to pitting corrosion, intergranular spalling and premature abrasion, leading to frequent equipment shutdown and replacement.
Shata Machinery has a professional metallurgical engineer team and dual production lines for forging and casting processes. We develop tailor-made high-temperature and corrosion-resistant kiln riding rings according to customer's actual kiln working conditions, fundamentally solving equipment failure risks caused by improper material selection. Our customized kiln tyres are widely applicable to cement calcination, lime production, lithium ore calcination, metallurgical processing and hazardous waste treatment rotary kilns.
Project Case: We customized high corrosion-resistant rotary kiln tyres for an Australian lithium ore calcination kiln project. The custom special-material tyres have operated stably for 5 years without any surface corrosion or spalling. In contrast, the customer's original 42CrMo standard tyres suffered severe pitting corrosion and failure after only 2.5 years of operation, verifying the superior performance of our customized solutions.

If only a single final ultrasonic inspection is carried out upon completion of rotary kiln tyre manufacturing, microcracks induced by casting segregation and heat treatment stress will be concealed beneath the machined surface, making accurate identification impossible and ultimately leading to unplanned kiln shutdown failures in later operation.
We have established a full-lifecycle non-destructive testing system with mandatory inspections implemented at four critical production stages:

1. Forged/Cast Blank Stage: Conventional ultrasonic testing to detect inherent internal defects including internal shrinkage cavities, massive slag inclusions and penetrating blowholes inside workpieces.
2. Post-Heat Treatment Stage: Full-area Magnetic Particle Testing (MT) combined with Penetrant Testing (PT), focusing on subsurface intergranular microcracks at stress concentration zones. Cracks as narrow as 0.1 mm in width can be detected.
3. Semi-Finish Turning Stage: Full-coverage ultrasonic scanning covering fatigue-prone areas of the tyre such as inner bore, outer circle, both end faces and transition radii, to identify delamination and tiny internal defects exposed during machining.
4. Finished Product Delivery Stage: Recheck via ultrasonic testing to guarantee zero missed defects and defect-free delivery.

All defects are intercepted in advance during preceding processes. Problems will not be discovered after full machining, which would otherwise require complete rework of the whole part. This effectively avoids schedule delays caused by finished product scrapping, secures the agreed delivery time, ensures smooth progress of clients' kiln line projects, and ensures customers kilns with long-term operation and less cracking risks.

Thanks to our factory's large annual shipment volume, we have secured long-term strategic pricing with multiple international logistics providers. Over 90% of our rotary kiln tyre clients opt for our in-house logistics solution, with freight rates at least 26% lower than those offered by clients' own forwarders.
Our partnered logistics team specializes in cross-border transportation for oversized and overweight components. They deliver one-stop full-process management covering all links: deployment of special transport vehicles, out-of-gauge cargo permit applications, ro-ro vessel space reservation, marine cargo lashing & securing, customs clearance documentation, port pickup & delivery, and heavy-lift loading/unloading at remote mining plants and manufacturing sites. Our logistics partners streamline the whole transit process and minimize damage risks for rotary kiln tyres during shipment.
In 2023, we delivered a 5.8-meter-diameter large rotary kiln tyre to a South African client. We fully handled cross-border out-of-gauge traffic permits across multiple transit countries, segmented sea-land transshipment, and coordinated heavy crane unloading at the client's plant. The client highly commended our logistics service, noting that compared with their previous forwarder's plan, transit time was cut by 30% and total logistics costs reduced by 37.7%.