Rotary Kiln Services

OP Engineering Group is a trusted name in the field of Rotary Kiln manufacturing, Girth Gear production, and industrial kiln spare parts supply. We specialize in delivering high-performance, heavy-duty solutions for industries such as cement, sponge iron (DRI), steel, chemical, and mineral processing.

With advanced manufacturing technology and an experienced engineering team, we provide custom-built rotary kiln systems and precision-engineered components designed for long-lasting performance, efficiency, and reliability.

A Rotary Kiln is a large rotating cylindrical furnace used for processing materials at high temperatures. It is one of the most critical machines in thermal industries, ensuring:

• Uniform heating of raw materials
• Controlled chemical reactions
• Continuous production process
• Consistent product quality

It is widely used for calcination, reduction, drying, and thermal processing applications.

At OP Engineering Group, we manufacture rotary kilns as per client-specific requirements:

• Capacity Range: 50 TPD to 900 TPD
• Fuel Options: Coal, Gas, Oil-fired systems
• Design Standards: As per customer drawings (Lurgi, FLSmidth, Metso, etc.)
• Material: High-grade alloy steel & cast steel
• Application-Based Customization Available

Our kilns are designed for continuous heavy-duty industrial operations with minimal maintenance.

We are a leading manufacturer and supplier of Rotary Kiln Girth Gears used in sponge iron plants, cement plants, and rotary coolers.

Importance of Girth Gear

The girth gear is a key component mounted on the kiln shell. It plays a vital role in:

• Transmitting rotational motion
• Ensuring smooth kiln operation
• Handling heavy loads and high temperatures

We manufacture girth gears as per industry standards and client requirements:

• Module: As per specification
• Number of Teeth: Custom-designed
• Material Grades: IS 2708 Grade 2/3, IS 2644 CS 700, Alloy Steel (GS34CrMo4)
• Design Compatibility: POPURI, IPS, ITC, MEC, LURGI & others
• Certification: As per required quality standards

OP Engineering Group provides a complete range of kiln and cooler spare parts:

• Kiln Tyre (Riding Ring)
• Girth Gear
• Pinion Gear (Helical / Spur)
• Support Roller
• Thrust Roller Assembly
• Bearing Housing / Plummer Block
• Labyrinth Rings (Bearing Sleeves)
• Spring Plates & End Covers
• End Plates, Nut Bolts & Washery Pins
• Kiln Shell
• Gear Housing & Drive Components
• Base Frame & Structural Parts

All parts are manufactured with high precision, durability, and strict quality control.

We follow a modern and systematic manufacturing process to ensure top-quality output:

1. Design & Engineering

Customized design using advanced CAD tools based on client requirements.

2. Casting Simulation

Simulation software is used to analyze material behavior, cooling rate, and defect prevention.

3. Casting Process

High-quality sand casting method is used to achieve accurate gear shape and strength.

4. Blanking & Gear Cutting

Initial shaping using processes like:

• Hobbing
• Milling
• Broaching
• Shaping

5. Heat Treatment

Enhancing mechanical properties through:

• Carburizing
• Quenching & Tempering
• Normalizing
• Annealing

6. Gear Machining & Finishing

Precision machining ensures:

• Accurate tooth profile
• Smooth operation
• Long service life

7. Quality Testing & Inspection

• Dimensional inspection
• Hardness testing
• Performance checks

8. Packaging & Delivery

Heavy-duty wooden packaging ensures safe transportation across India and international markets.

• Designed for heavy load and high temperature conditions
• High-strength cast steel construction
• Smooth and efficient power transmission
• Long operational life with low maintenance
• Precision tooth design for vibration-free operation
• Reliable performance in continuous industrial use

Our products are widely used in:

• Sponge Iron (DRI) Plants
• Cement Plants
• Steel & Metallurgical Industries
• Chemical Processing Plants
• Activated Carbon Plants
• Fertilizer Plants
• Sugar & Paper Mills
• Mineral Processing Industries

OP Engineering Group supplies across India including:

• Maharashtra, गुजरात, Karnataka
• Tamil Nadu, Odisha, Jharkhand
• Chhattisgarh, West Bengal, Telangana
• Haryana, Himachal Pradesh & more

We are also expanding our reach in international markets, serving clients with high-quality industrial components globally.

✔ Complete Rotary Kiln Solution (Kiln + Girth Gear + All Spares)
✔ Custom Manufacturing as per client design
✔ Advanced Manufacturing Process (Simulation to Testing)
✔ High-Quality Raw Materials
✔ Competitive Pricing
✔ Timely Delivery & Strong Logistics
✔ Experienced Engineers & Technical Support

OP Engineering Group is your reliable partner for Rotary Kiln systems, Girth Gear manufacturing, and industrial spare parts solutions.

With a strong focus on quality, engineering excellence, and customer satisfaction, we deliver products that ensure maximum efficiency, durability, and productivity.