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Rotary Kiln

Rotary Kiln

Applied fields: magnetizing roast of lean iron ore in the metallurgical industry; oxidizing roasting of chromium and nickel-iron ore; roasting of high-alumina vanadium ore, clinker and aluminum hydroxide.

product image

Model: Φ2.5×40 m

Power: 55 kw

Capacity

Capacity: 180 t/d

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Model: Φ4.0×56 m

Power: 315 kw

Capacity

Capacity: 2300 t/d

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Model: Φ6.0×95 m

Power: 950×2 kw

Capacity

Capacity: 10000 t/d

  • Small-sized
  • Medium-sized
  • Large-sized
Customizable
online customer service

60s online
customer service

customize solutions

2 days customize
solutions

Factory visiting

Factory
visiting anytime

dispatch the goods

1-10 days dispatch
the goods

installation

One week
of installation

training

2 days of
training

after-sales online

365 days
after-sales online

Project tracking regularly

Project tracking
regularly

provide maintenance plan

2 days provide
maintenance plan

Pre-sale service

Sales service

After-sales service

Tip1: The specific time arrangement depends on the actual situation.    Tip2: Free airport transfer and hotel accommodation.

What is a rotary kiln?

Rotary kiln is a kind of thermal processing equipment for drying, calcining, sintering and pyrolyzing raw materials or wastes to reuse or reduce environmental pollution.

Rotary kilns can be divided into cement kilns and metallurgical chemical kilns according to different materials.

Cement kilns are mainly used for making cement clinker. There are two methods of manufacturing cement clinker: the wet process and the dry process.

Metallurgical chemical kilns are mainly used for the roasting of lean iron ore, chromium, nickel iron ore and hematite, etc.

Design and structures of rotary kiln

Main parts of rotary kiln

stuctures of rotary kiln

image from: http://www.cementmillequipment.com

  • 1.kiln hood
  • 2. cooler chute
  • 3. cylinder
  • 4.transmitter
  • 5. tire
  • 6.large ring gear
  • 7. preheating part
  • 8. back end seal
  • 9. back end chamber
  • 10.motor
  • 11.reducer
  • 12. pinion
  • 13. thrust roller
  • 14. kiln shell

Kiln shell

rotary shell

It is made of mild steel plate, and the longitudinal and circumferential gaps of the barrel are automatically welded.

As you can see, there are two solid tires on the shell, their function is to ensure the rigidity of the cross section and reduce the force on the supporting devices. Because when the rotary kiln runs, the thermal expansion will cause distortion of shell, and installation of the two solid tires ideally solve the problem.

Refractory lining

Refractory lining is important to prolong the longevity of the rotary kiln. Its main function is to prevent the whole body from corroding by chemical reaction between high temperature gas and material.

The refractory can be treated as thermal media because it can absorb part of the heat and transfer it to the material by different conduction and radiation ways. So, refractory material is capable of realizing thermal insulation to protect the whole machine.

After the repeated tests by Fote experts, they find that:

Aluminum-silicon refractory bricks are suitable for cylinder, transmitter, and the entire precalciner kiln firing system.

On the upper transition zone near the firing zone, the material of refractory lining must withstand the flame temperature up to 20000°C and material temperature of 1350~1400°C.

In addition, it also faces the challenge of corrosion caused by sulfur-alkali compounds and clinker liquid. Finally, they found that only alkaline refractory brick can meet the strict requirements.

Insulation and refractory materials

The remarkable characteristics insulating refractory material are high porosity with large diameter and thermal insulation performance. Because of its low volume density and light weight, it is usually applied as a lightweight refractory.

In addition, Fote rotary kiln is equipped with an infrared scanner, which is mainly used to warn of hot spots as early as possible to register whether the refractory material has failed.

The complete driving parts

what is the driving device of a rotary kiln

The complete drive parts consist of main drive and auxiliary drive. The main drive consists of drive reducing gear, open gearing, flexible coupling.

The auxiliary drive includes reducing gear, motor and brake which is used for rotary prevent the kiln body from reversing under the weight of materials and kiln skin after the motor stops.

The auxiliary motor is also equipped with a brake to prevent the kiln body from reversing caused by weight of materials and kiln cover.

The pinion gear engineered by the company experiences the fine process and high-frequency quenching, which enhances the hardness of the tooth up to HRC (40-50). Through this heat treatment, the service life of the pinion can be increased by nearly five times.

Working principle of a rotary kiln

working principles of rotary kilns

  1. 1The raw materials are fed into the kiln body from the high end of the feeder.
  2. 2Due to the inclined rotary kiln and slow rotation, the material not only rolls in the circumferential direction, but also moves from the high end to the low end along the axial direction.
  3. 3The raw materials are preheated and calcined in the kiln.
  4. 4The burned materials are discharged from the lower end of the kiln barrel to enter the next process.

What is a rotary kiln used for?

Calcination

It is the process that heating a material to a certain temperature for chemical dissociation. The method is widely used to calcinating limestone, dolomite for making hydrated lime or cement clinker.

Thermal Desorption

This is another separation process which adopts heat to drive off a volatile component. The most common rotary kiln used in this process is an indirect rotary kiln which is designed according to physical and chemical properties and calcination curve of raw materials.

The most important feature of the indirect rotary kiln is supplying the heat desorption, and material has no contact with the flame.

Thermal desorption is best to process non-metallic minerals like Kaolin, as well as agricultural waste, mineral coatings, sewage sediments.

Organic combustion

When the waste is bulky and difficult to handle, it is processed in the furnace to become ashes which is much less in mass and volume than before. So, organic combustion allows the waste to be deposited more efficiently in the landfill.

Advantages of rotary kilns

The use of rotary kiln technology shows following advantages:

  1. 1The kiln body uses three forms of heating which are calcining, sintering and pyrolyzing to make even heat distribution.
  2. 2The equipment runs smoothly, with low failure rate and high operating rate.
  3. 3It also can ensure high production efficiency, large output, stable product quality and excellent performance.
  4. 4People can effectively and easily control the roasting process by manipulating the hydraulic push rod of the preheater in the lower part of the silo
  5. 5It strictly meet the requirements of environmental protection due to installation of high-efficiency heat exchanger, dust collector, and world-leading seal system.

How much is a rotary kiln system?

The final price of a rotary kiln depends on the production requirements. Fote rotary kiln manufacturer provides you the most reasonable prices according to the follow three different production ranges, and the machine can also be customized according to customer specific requirements.

Small output

small production of rotary kiln worksite

Capacity(t/d): 180-800

Diameter(m): Φ2.5×40-Φ3.0×60

Motor power(kw): 55-100

Total weight(t): 149.61-310

price range(usd): $5000-$95000

Middle- sized production

milldle-sized output of rotary kiln

Capacity(t/d): 1000-3200

Diameter(m): Φ3.2×50-Φ4.3×60

Motor power(kw): 125-375

Total weight(t): 278-583

price range(usd): $100, 000-$130,000

Large output

large output of the rotary kiln worksite

Capacity(t/d): 4000-10000

Diameter(t/d): Φ4.5×66-Φ6.0×95

Motor power(kw): 560-950*2

Total weight(t): 710.4-1659

price range(usd): $150,000-$300,000

Successful customers' cases

Indonesian customers purchased a cement rotary kilnYes! I'm interested.

Our Indonesia client Mr. Cokorda needs to process limestone with production 650 t/h. After on-site survey, and the customer’s output requirements, we recommend him a cement rotary kiln with small diameter.

Diameter: Φ3.0×60

Preheater: Grate, Gas-Suspension

Heating types: direct rotary kiln

Heating method: counter current

Temperature range: 1050-1150℃

Indian customer purchased a metallurgical chemical rotary kiln

Another client is Mr. Makongi from India. He needs to iron ores with output requirement 1000t/h, so he wants to buy a metallurgical chemical kiln. We recommended him the middle-sized model Φ3.2×50.

The working principle of the rotary kiln is removing oxygen from the ore composition through carbon monoxide. Finally, this metallurgical chemical kiln ideally reduced and roasted of hematite-containing materials to produce magnetite.

Diameter: Φ3.2×50

Temperature range: 800-1200℃

Fuel: Crude gas

Coal ash melting point: > 1200°C,

Oxidation degree of crude gas: <15%,

Pressure: 0.1~4MPa

Fote rotary kiln price: Get Latest Price

Parameter

Product 
Specification
(m)
Kiln dimensions Motor 
power
(kw)
Total 
weight
(t)
note
Diameter
(m)
Length
(m)
Obliquity
(%)
Capacity
(t/d)
Rotation 
speed
(r/min)
Φ2.5×40 2.5 40 3.5 180 0.44-2.44 55 149.61

-----

Φ2.5×50 2.5 50 3 200 0.62-1.86 55 187.37 -----
Φ2.5×54 2.5 54 3.5 280 0.48-1.45 55 196.29

outside

disassemble

kiln

Φ2.7×42 2.7 42 3.5 320 0.10-1.52 55 198.5 ------
Φ2.8×44 2.8 44 3.5 450 0.437-2.18 55 201.58

outside

disassemble

kiln

Φ3.0×45 3 45 3.5 500 0.5-2.47 75 210.94 ------
Φ3.0×48 3 48 3.5 700 0.6-3.48 100 237

outside

disassemble

klin

Φ3.0×60 3 60 3.5 800 0.3-2 100 310 ------
Φ3.2×50 3.5 50 4 1000 0.6-3 125 278

disassemble

klin

Φ3.3×52 3.3 52 3.5 1300 0.266-2.66 125 283

kiln with

preheater

precalcine

Φ3.5×54 3.5 54 3.5 1500 0.55-3.4 220 363

kiln with

prehrater

precalcine

Φ3.6×70 3.6 70 3.5 1800 0.25-1.25 125 419

Generating

klin for

usimg ofterheat

Φ4.0×56 4 56 4 2300 0.41-4.07 315 456

klin with

prehrater

precalcine

Φ4.0×60 4 60 3.5 2500 0.396-3.96 315 510

klin with

prehrater

precalcine

Φ4.2×60 4.2 60 4 2750 0.41-4.07 375 633

klin with

prehrater

precalcine

Φ4.3×60 4.3 60 3.5 3200 0.396-3.96 375 583

klin with 

prehrater

precalcine

Φ4.5×66 4.5 66 3.5 4000 0.41-4.1 560 710.4

klin with

prehrater

precalcine

Φ4.7×74 4.7 74 4 4500 0.35-4 630 849

klin with

prehrater

precalcine

Φ4.8×74 4.8 74 4 5000 0.396-3.96 630 899

klin with

prehrater

precalcine

Φ5.0×74 5 74 4 6000 0.35-4 710 944

klin with

prehrater

precalcine

Φ5.6×87 5.6 87 4 8000 Max4.23 800 1265

klin with

prehrater

precalcine

Φ6.0×95 6 95 4 10000 Max5 950×2 1659

klin with

prehrater

precalcine

Product 
Specification
(m)
Capacity
(t/d)
Rotation 
speed
(r/min)
Φ2.5×40 180 0.44-2.44
Φ2.5×50 200 0.62-1.86
Φ2.5×54 280 0.48-1.45
Φ2.7×42 320 0.10-1.52
Φ2.8×44 450 0.437-2.18
Φ3.0×45 500 0.5-2.47
Φ3.0×48 700 0.6-3.48
Φ3.0×60 800 0.3-2
Φ3.2×50 1000 0.6-3
Φ3.3×52 1300 0.266-2.66
Φ3.5×54 1500 0.55-3.4
Φ3.6×70 1800 0.25-1.25
Φ4.0×56 2300 0.41-4.07
Φ4.0×60 2500 0.396-3.96
Φ4.2×60 2750 0.41-4.07
Φ4.3×60 3200 0.396-3.96
Φ4.5×66 4000 0.41-4.1
Φ4.7×74 4500 0.35-4
Φ4.8×74 5000 0.396-3.96
Φ5.0×74 6000 0.35-4
Φ5.6×87 8000 Max4.23
Φ6.0×95 10000 Max5

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