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Riding Rings, Trunnions, and Thrust Rollers: Supporting a Rotary Drum

A rotary drum rests on a handful of rolling contacts: steel riding rings on the shell, a pair of trunnion rollers under each ring, and thrust rollers that stop the inclined drum from running downhill. UTEC Industrial designs, engineers, machines, fabricates, and installs custom material handling systems for aerospace and heavy industry from its Spokane Valley, WA facility, integrating Allen-Bradley PLC and motion control with in-house CNC machining, heat treating, and stress relief. This article follows the load from the shell into the foundation: how it divides between stations and rollers, why the ring-to-roller contact is so highly stressed, how thrust and float are controlled, what the bearings and lubrication face in continuous service, and how the supports are sensed and maintained. The published mechanical data used here come from cement and mineral kilns, so the figures below are kiln examples; a biomass dryer runs under different conditions and takes its own numbers from its designer.

What does each part of a rotary drum's support system do?​

The process side of a dryer is covered in how a rotary drum dryer works; this article covers the structure that carries the shell, and flights and residence time are covered in the flight design article. The literature uses several names for the same parts:

  • Riding ring. Also called a tire or tyre, and a "bandage" in some translated papers. A heavy steel ring around the shell that transfers the drum's weight to the rollers.
  • Trunnion roller. Also called a support roller, carrying roller, or trunnion wheel. Each support station has two, one either side of the drum's bottom centerline, each running on its own shaft and bearings.
  • Thrust roller. A roller that resists the axial force that tries to move the inclined drum along its own axis.
  • Base and bearings. The frame, bearing housings, and foundation under each roller pair, which fix where the roller axes sit.

In the kiln studies of Shrubchenko and co-workers, each support is a tyre fixed on the shell and two support rollers on rolling bearings, and the published roller and tyre dimensions for kiln stations are listed in kiln, clinker, and aggregate handling in cement plants. The requirement this article builds on is geometric: the roller axes must lie in one plane at the drum's inclination, because a roller out of that plane bends the drum axis and overloads individual supports. Holtec's kiln guideline adds the thrust roller, and describes the modern trend as a hydraulically operated thrust roller that floats the kiln (Shrubchenko et al. 2015, p. 195; Dalela et al., §6.4).

How is a drum's weight shared between support stations and rollers?​

A long drum sits on several support stations, and each station's share of the weight is carried by two rollers pushing up at an angle. Two kiln sources show the scale.

FAG's design example for a cement-kiln support roller describes kilns that can run 150 m (about 490 ft) or more in length with support rollers at intervals of about 30 m (98 ft). For a kiln 4.4 m (14.4 ft) in outside diameter, each support roller is 1.6 m (63 in) in diameter and 0.8 m (31.5 in) wide and carries a radial load of 2,400 kN (about 540,000 lbf) and a thrust load of 700 kN (about 157,000 lbf). The example's operating data list a speed of 5 min⁻¹, and the roller and its housing together weigh 13 t.

The angle between the rollers matters as much as the weight. Shrubchenko and co-workers give the angle between the lines from the tyre center to the two roller centers as 60 to 65°. The same authors note that the two rollers are set at equal distances either side of the drum's vertical axis so that they share the weight equally. A simple statics check shows the effect of the angle. Take a station load W, assume the two rollers share it equally, and ignore the drum's small inclination. Each roller reaction R is then:

R = W ÷ (2 × cos(α ÷ 2))

  • At α = 60°: R = W ÷ (2 × 0.866) = 0.577 W per roller.
  • At α = 65°: R = W ÷ (2 × 0.843) = 0.593 W per roller.

Each roller therefore carries more than half the station load, because it pushes partly sideways as well as up. As engineering reasoning, the equal-share assumption is the weak one: Holtec's kiln guideline notes that with a warped shell not all tyres are in contact with the support rollers, so roller loading is not uniform. The bearings under each roller carry that roller's reaction, not the station's share of drum weight (FAG Publ. No. WL 00 200/5 EA, design example 96; Shrubchenko et al. 2015, p. 195; Dalela et al., §4).

Why is the contact between riding ring and roller the most highly stressed point?​

Each roller reaction from the previous answer passes through a narrow strip where two convex steel surfaces meet. That line contact is governed by Hertz theory, and the strip is far narrower than the ring face.

Shchetinin and co-workers work a Hertz example for a kiln tyre that shows how narrow, for a tyre removed from the drum and resting on the rolls of a machining stand under its own weight:

  • The tyre. A tyre mass of 56,000 kg (about 123,000 lb), with a boundary force of 280,000 N (about 63,000 lbf) derived from that weight.
  • The geometry. A tyre radius of 3,050 mm (about 120 in) on a roll radius of 1,700 mm (about 67 in).
  • The result. A contact half-width of about 1.2 mm, so the load crosses a band roughly 2.4 mm (under 0.1 in) wide across the face.

In their formula the half-width grows only with the square root of the pressure term p = F/S, which, as engineering reasoning, is why the band stays narrow. The Hertz stress figures, the minimum contact-patch length, and the effect of crossed roller axes that Shrubchenko and co-workers published for kilns are summarized in the cement-plant article linked above.

Bowen and Saxer's analysis of 125 kiln riding rings, summarized in the dryer anatomy article, adds that Hertzian pressure must be regarded as the most significant load factor on the ring because it produces stresses slightly below the surface as well as at it. As engineering reasoning, the running surface alone then does not show the full stress state (Shchetinin et al. 2018, §2; Shrubchenko et al. 2015, pp. 196 and 201; Bowen and Saxer 1985).

What defines a drum's alignment, and how does misalignment reach the roller bearings?​

The Hertz example above assumes that ring and roller touch along their full face and that each roller carries its designed share. Both assumptions depend on alignment, and both kiln sources locate the drum axis at the tyres.

  • The axis. Holtec's kiln guideline treats a kiln as aligned when the rotating centers of the shell at the tyres, joined together, form a straight line in both the horizontal and vertical planes. Kovanič and co-workers, working from a terrestrial laser scan of a kiln during shutdown, likewise take the centers of the carrier tyres as the kiln's longitudinal axis, and analyze shell deformation and ovality on sections cut perpendicular to it.
  • Shell warp. The same guideline notes that a warped shell leaves tyres off their rollers and the roller loads uneven, and lists disturbed kiln alignment among the consequences of warp.
  • Common plane. The roller axes have to lie in one plane at the drum's inclination, and a roller out of that plane overloads individual supports.

Misalignment does not stop at the rolling contact. Timken's engineering manual states that accurate shaft-to-housing alignment is critical for bearing performance, that as misalignment increases under moderate to heavy loads, high contact stresses can be generated at the edges of contact, and it carries a separate misalignment life factor in its life calculation. The spherical roller bearings in the FAG and SKF kiln examples are self-aligning: Timken sets their misalignment factor at 1.0 and allows 0.5 to 1.25° of misalignment depending on the bearing series, with life reduced beyond those limits. In engineering terms, the two bearing housings on each trunnion-roller shaft still have to stay within that allowance. How the worn profiles then progress between ring and roller is covered in riding ring and trunnion wheel wear in rotary kilns (Dalela et al., §4 and §5; Kovanič et al. 2020; Shrubchenko et al. 2015, p. 195; Timken 2024, p. 54).

How do thrust rollers and roller skew control a drum's axial float?​

A drum mounted at an inclination carries an axial component of its weight, and the drum also shifts axially in service, which the support bearings see as thrust. Something has to take that axial force and keep the rings on their rollers.

The kiln sources describe three ways the axial force is taken:

  • Bearing thrust. In FAG's cement-kiln example, each support roller carries 700 kN of thrust alongside its 2,400 kN radial load. The two spherical roller bearings on each roller shaft are mounted in a floating arrangement, in which the shaft can shift relative to the housing within a defined axial clearance, and the spherical roller bearings also take the thrust that comes from kiln displacement.
  • Roller skew. In engineering terms, turning a support roller's axis slightly out of parallel makes it push the drum axially as the drum turns. Holtec's guideline warns that excessive or wrong skew may create heavy thrust on the bearings and at times vibration, and that the rollers should be skewed to take the thrust equally.
  • Thrust roller. Holtec describes the modern kiln trend as parallel support rollers with a hydraulically operated thrust roller to float the kiln, but prefers careful, controlled skewing to avoid full-time loading of the thrust roller.

None of the sources consulted gives thrust-roller load ratings, hydraulic settings, or skew angles; those belong to the drum's designer. Axial movement of the riding rings themselves along the shell, sometimes called walking or migration, is a related effect covered on the kiln wear page linked above (FAG Publ. No. WL 00 200/5 EA, design example 96; Dalela et al., §6.4; Shrubchenko et al. 2015, p. 195).

What is the difference between a floating and a welded-in riding ring?​

A floating riding ring is not fixed to the shell. It sits loose over pads or chairs fixed to the shell, with a small clearance, so that the hot shell can expand inside it. A welded-in ring is part of the shell structure.

Holtec's guideline sets out how a floating ring behaves on a cement kiln:

  • Creep. Because the ring bore is slightly larger than the shell over its chairs, the ring and shell move relative to each other on every revolution. Holtec defines this creep per revolution as U = π × (Do − do), the difference in circumference between the undeformed ring bore Do and the undeformed shell outside diameter over the chairs do. The tyre clearance S is the gap at the vertical diameter of the loaded, slightly elliptical ring; theoretically U = π × S, but in practice U = 2S.
  • Recommended clearance. For proper floating, the guideline recommends 3 to 4 mm (about 0.12 to 0.16 in) of clearance, or 6 to 8 mm (about 0.24 to 0.31 in) of creep.
  • Measurement. With loose tyres, the guideline calls monitoring creep and clearance important. Both can be read from a pointer-and-plate device; creep alone can be found by marking the ring and shell and measuring the offset.
  • Correction. Clearance is restored with shims or thicker chairs, and the method depends on whether the chairs are bolted or welded. The guideline also recommends graphite or copper lubricant between the tyre bottom and the chairs to reduce chair wear and the risk of seizure.

Welded-in rings trade those problems for others. Shchetinin and co-workers report that long service indicated relatively low reliability of floating tyres and complexity in their mounting, service, and repair, so operating drums are being modernized with welded-in tyres, which have a more complex design and are less practical and more expensive to manufacture. The authors' department developed its own on-site conversion method, so their paper supports the distinction rather than a verdict. For a biomass dryer, the clearance values above are a kiln reference, not a dryer specification (Dalela et al., §3.1, §3.2, §3.4 and §6.4; Shchetinin et al. 2018, §1).

Why are start-up and cool-down the hardest periods for the supports?​

In the kiln sources, the supports' thermal problems arise mainly during transients such as heating and cooling, when shell and rings are at different temperatures.

Two kiln sources describe the mechanism from different sides:

  • Clearance loss. Holtec's guideline warns that when the shell under a floating ring is overheated, or heated rapidly during start-up, the clearance reduces and can reach zero, and further heating constricts the shell. It states that typically the shell-to-tyre temperature difference must not exceed 150 °C (270 °F), and that above it a fan should cool the shell through the gap between chairs.
  • Peak stress at the ring. Guillin-Estrada and co-workers modeled an industrial-scale ferronickel rotary kiln during preheating and found the maximum von Mises stress, 121 MPa (about 17,500 psi), at the wheel (tyre) position in the hot region of the refractory, against 30 to 60 MPa (about 4,400 to 8,700 psi) in the shell. Their study starts from the observation that rotary kilns are prone to mechanical failure made worse by thermal effects, mainly during transients such as preheating and cooling.

Dryers see their own temperature band. NREL reports inlet gas temperatures to rotary biomass dryers of 450 to 2,000 °F (232 to 1,093 °C) and outlet temperatures of 160 to 230 °F (71 to 110 °C), so the kiln stresses above are not dryer values. As engineering reasoning, the mechanism carries over: a hot shell inside a cooler ring loses clearance, and heating rate is a variable the start-up sequence controls (Dalela et al., §3.3; Guillin-Estrada et al. 2022; Amos 1998, §3.1).

What bearings carry a trunnion roller, and how is their life judged for 24/7 service?​

In engineering terms, a support roller turns under load for as long as the drum runs, so its bearing life is judged in running hours.

FAG's cement-kiln example shows one rolling-bearing arrangement. Each roller shaft runs in two spherical roller bearings with a dynamic load rating of 6,200 kN each, in split plummer-block housings on a common grey-iron base, in the floating arrangement described above. The calculated life factor gives a nominal rating life of 100,000 h, which the example judges adequate. The shaft is machined to an n6 fit and the housing to H7, the bearings are greased with a lithium-soap EP grease, and the roller side is sealed with felt strips and grease-packed labyrinths.

Timken's engineering manual sets out what that life figure means:

  • Definition. Bearing life is the time or number of revolutions until a fatigue spall of 6 mm² (0.01 in²) develops. The rating life L10 is the life that 90% of a group of identical bearings will complete or exceed.
  • Equation. L10 = (C ÷ Pr)^e × (10⁶ ÷ (60 × n)) hours, where C is the dynamic rating, Pr the equivalent load, n the speed in rpm, and e = 10/3 for roller bearings.
  • Adjusted life. The ABMA expanded form, Lna = a1 × a2 × a3 × L10, adjusts the rating life with life-adjustment factors. Timken's own expanded equation splits the adjustment into further factors, one of which is the misalignment factor discussed above.

In continuous service a year is 8,760 h, so a 100,000 h rating life is about 11.4 years of running, and one in ten bearings is expected to spall before then. Some kilns run their rollers in plain (sliding) bearings instead. McQueen and van Arkel's case study of a 76 m (about 250 ft) expanded-clay kiln on eight support-roller units describes the operator replacing a first set of its plain-bearing units with rolling-bearing units, each a hardened 1,500 mm (59 in) roller on two 500 mm (19.7 in) bore spherical roller bearings with centralized lubrication, and attributes a saving of up to 10% in energy to the operator (FAG Publ. No. WL 00 200/5 EA, design example 96; Timken 2024, pp. 48-49; McQueen and van Arkel 2011).

What has to be lubricated at a drum support, and what goes wrong if it is not?​

A drum support has three kinds of friction point: the rolling contact between ring and roller, the sliding contact between a floating ring and its chairs, and the roller and thrust-roller bearings. Each needs a different treatment.

Klüber Lubrication's cement-industry guide lists the riding ring and the lamellar seal among the frequently lubricated friction points on a rotary kiln. It states that solid lubricants have to enter the contact area to prevent metal-to-metal wear, and notes that the suspensions must be mixed well before use because the oil might ignite if carrier oil and solid lubricants are not homogenised. The guide notes that the riding-ring lubricant is applied through spray equipment for occupational safety. Support-roller and thrust-roller bearings are grease- or oil-lubricated.

The sources describe the lubrication at each point:

  • Rolling bearings. FAG's kiln example uses lithium-soap EP grease, sealed at the roller side with felt strips and grease-packed labyrinths.
  • Plain bearings. In McQueen and van Arkel's case study, the plant manager explains that after a roller is replaced the sliding bearings must be aligned absolutely perfectly, or they can heat up the lubricant and ignite. That safety issue was the operator's main reason for moving to rolling-bearing units with centralized lubrication.
  • Chairs. Holtec's graphite or copper lubricant between tyre and chairs, noted above, reduces chair wear and the risk of seizure.

Wherever a dryer uses the same ring, chair, and bearing arrangement, the same friction points exist (Klüber Lubrication 2016, pp. 21-22; FAG Publ. No. WL 00 200/5 EA, design example 96; McQueen and van Arkel 2011; Dalela et al., §6.4).

What must be right when riding rings and trunnion rollers are machined and fitted?​

The support works only if parts machined separately meet in the geometry the design assumed. As engineering reasoning, the requirements below are fits and relative positions rather than single dimensions, and each ties back to a failure mode above.

  • Shaft and housing fits. FAG's example specifies an n6 fit on the roller shaft and H7 in the split bearing housing. Žiga and Kačmarčik identify the shrink fit between shaft and roller as one of the sources of stress in the roller, so that interference is a stress input as well as a retention feature.
  • A common base. The same example mounts both plummer blocks of a roller on one grey-iron base. In engineering terms, machining the two housing seats to one base helps hold the shaft-to-housing alignment that Timken's manual calls critical for bearing performance, within the misalignment the bearings accept.
  • Bearing arrangement. The floating arrangement depends on a defined axial clearance within which the shaft can shift relative to the housing, so that clearance is set at assembly, not left to chance.
  • Ring bore and pads. On a floating ring, the ring bore and the outside of the shell pads or chairs set the running clearance, the quantity Holtec's guideline keeps at 3 to 4 mm on kilns. On a welded-in ring, Shchetinin and co-workers note a more complex design that is less practical and more expensive to manufacture.

Face-width practice, contact-patch length, and the in-place turning and grinding of worn faces are covered in the cement-plant article linked earlier, and the hardness differential between ring and roller on the kiln wear page. On the wood-chip and biomass drum dryers for Weyerhaeuser, Westec designed the dryers and UTEC Industrial fabricated drum shells, riding rings, trunnion rollers, and drive gear components (FAG Publ. No. WL 00 200/5 EA, design example 96; Žiga and Kačmarčik 2017; Timken 2024, p. 54; Dalela et al., §3.2; Shchetinin et al. 2018, §1).

What sensing and controls watch a drum's supports while it runs?​

In engineering terms, the controls' job at the supports is to measure the quantities the kiln sources describe changing, and to act on the few that can be acted on automatically.

Each quantity below comes from a failure mode described earlier:

  • Ring creep and clearance. Holtec's guideline measures creep and clearance on floating tyres and gives U = 2S in practice. As engineering reasoning, a pointer-and-plate reading can be logged and trended, and a steady fall in creep is an early sign of clearance loss.
  • Shell-to-ring temperature. The same guideline typically limits the shell-to-tyre temperature difference to 150 °C on kilns, with fan cooling between the chairs, and says continuous creep monitoring can be installed with an alarm that starts the cooling automatically when creep falls below the recommended limit. A PLC can run that logic from the measured creep and temperatures, and the start-up sequence can limit heating rate.
  • Bearing temperature. In McQueen and van Arkel's case study, misalignment in the sliding bearings caused two roller fires, and overheating sometimes took a week to detect. As engineering reasoning, bearing temperature is a direct input for an alarm and a trip.
  • Thrust and vibration. Holtec ties wrong skew to heavy bearing thrust and at times vibration. As engineering reasoning, axial position at the thrust roller and vibration at the roller bearings then show whether thrust is shared as intended.
  • Lubrication. Centralized lubrication, as fitted in the case study, can give the controls a flow or cycle signal to confirm.

In an Allen-Bradley Logix 5000 controller, tasks can be configured as continuous, periodic, or event, and a periodic task executes automatically at a preconfigured interval, so these slow-changing inputs can be scanned at a fixed interval. The drive and fan outputs fall under IEC 60204-1:2016, which applies to the electrical equipment of machines not portable by hand while working. Stamboliska, Rusiński, and Moczko's book on proactive condition monitoring of low-speed machines includes a chapter of case studies. UTEC Industrial, a Rockwell Automation Recognized System Integrator, builds Allen-Bradley ControlLogix and CompactLogix control with VFD drives in UL 508A panels (Dalela et al., §3.2, §3.3 and §6.4; McQueen and van Arkel 2011; Rockwell Automation 1756-RM094N-EN-P-2025; IEC 60204-1:2016; Stamboliska et al. 2015).

How are support rollers adjusted, realigned, and made safe for maintenance?​

As engineering reasoning, the supports are tuned in service rather than set once, because rings and rollers wear and the shell changes shape.

Holtec's guideline describes skew adjustment on a cement kiln as a slow, stepwise process: rollers are moved from neutral in steps of 0.13 to 0.26 mm (about 0.005 to 0.010 in), with a wait of about 4 hours between steps, and the aim is to share the thrust equally among the rollers. Three further maintenance points come from the other sources:

  • Realignment after replacement. In McQueen and van Arkel's case study, the plant manager says plain (sliding) support bearings must be aligned absolutely perfectly after a roller is replaced, for the safety reason given above.
  • Cold survey. Kovanič and co-workers derive kiln geometry from a terrestrial laser scan during shutdown and take the tyre centers as the axis; their analytical point-cloud segmentation agreed with manual processing to a root-mean-square deviation of up to 2 mm. Cold alignment by total station, the method Mogilny and Sholomitskii analyze, is summarized in the cement-plant article.
  • Energy isolation. OSHA 29 CFR 1910.147 defines push buttons, selector switches, and other control-circuit-type devices as not energy-isolating devices, and 1910.147(d)(5)(i) requires stored or residual energy to be relieved, disconnected, restrained, and otherwise rendered safe after lockout. As engineering reasoning, a drum with an off-center material bed can roll when its drive is released, so work on a roller or bearing begins with the drum restrained, not just stopped (Dalela et al., §6.4; McQueen and van Arkel 2011; Mogilny and Sholomitskii 2017; Kovanič et al. 2020; OSHA 29 CFR 1910.147-1989).

Where do a drum's supports sit in the design-to-monitoring chain?​

A drum support is decided at the start of the chain and paid for at the end. Following it through design → engineering → parts machining → fabrication → assembly → weld fatigue → stress relief → drives → controls → tuning → monitoring:

  • Design and engineering. The drum's designer sets the number of stations, their spacing, the ring type, and the roller loads. On a dryer, that is the dryer vendor's process and mechanical design.
  • Parts machining. Ring bores and faces, roller faces, shaft fits, and bearing bases are machined so the fit, clearance, and common-plane requirements above can be met.
  • Fabrication and assembly. The shell, pads or chairs, and ring attachments are fabricated and fitted, and the roller axes are set in one plane.
  • Weld fatigue and stress relief. Weld quality and residual stress in the shell, the pads or chairs, and the roller bases are fixed at fabrication, before the drum ever turns. Stress relief of large weldments before machining is covered in the Related Articles.
  • Drives. ANSI/AGMA 6014-B15 provides a method to determine the power rating of open and semi-enclosed spur and helical gear sets for grinding mills, kilns, coolers, and dryers; its foreword records that the earlier A06 edition added annex discussion of new-equipment installation and alignment.
  • Controls, tuning, and monitoring. The sensing, skew adjustment, and surveys described above help keep the supports at the geometry the design assumed.

UTEC Industrial states that it has built dryer drums up to 80 tons and 125 ft long. As engineering reasoning, at that scale an error at any link, from an out-of-plane roller base to an unmonitored bearing, can show up later as ring wear, bearing distress, or a drum that will not stay on its rollers (ANSI/AGMA 6014-B15; Shrubchenko et al. 2015, p. 195).

Related Articles

References​

  • Shrubchenko IV, Hurtasenko AV, Sharapov RR, Duyun TA, Shchetinin NA (2015). "Investigation of Characteristics of Contact Bandages and Support Rollers of Rotating Technological Drums." Modern Applied Science, 9(1), 195-203. DOI 10.5539/mas.v9n1p195
  • Dalela GC, Goyal R, Kumar K. Mechanical Stability of Cement Rotary Kilns to Prevent Brick Lining Failure. Holtec Consulting Private Limited, New Delhi (undated web documentation, accessed September 2026).
  • FAG Publ. No. WL 00 200/5 EA: The Design of Rolling Bearing Mountings: Design Examples covering Machines, Vehicles and Equipment, part 6/8. FAG OEM und Handel AG (undated web documentation, accessed September 2026).
  • Shchetinin NA, Duganova EV, Golubenko NV, Novikov IA, Korneev AS (2018). "Study of strain-stress behavior when reconstructing rotary kiln tyres from floating to welded-in type." IOP Conference Series: Materials Science and Engineering, 327, 042104. DOI 10.1088/1757-899X/327/4/042104
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  • Klüber Lubrication B142001002: Reliable and efficient cement production. Speciality lubricants meeting the highest requirements, Edition 06.16. Klüber Lubrication, 2016.
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  • Rockwell Automation 1756-RM094N-EN-P-2025: Logix 5000 Controllers Design Considerations. Rockwell Automation, 2025.
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