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A high temperature shuttle kiln is a type of industrial furnace used to fire or vitrify materials at high temperatures in a controlled atmosphere. It is primarily used in the ceramics and refractory industries to achieve uniform heating of ceramics such as porcelain, stoneware, and earthenware. There are several types of shuttle kilns, including traditional, semi-continuous, full-continuous, and shuttle buggy kilns.
Traditional shuttle kiln
The traditional shuttle kiln is the oldest type of shuttle kiln, which is circular or oval and built underground or semi-underground. It usually has a number of upward openings called flues, which are the openings used to put ceramics in and out of the kiln. The ground-level flue openings are organized in a grid and usually have a width of about 1m-2m. The number of flues, size, and spacing are determined by the amount of products to be fired in the kiln at one time, the type of kiln, firing schedule, and fuel used. The fire starts from the bottom to the top, so the products in the bottom flues get the most heat. Flue openings are the same as kiln chambers. The upper flue openings receive less heat because they are farther away from the fire. This may make the products in the upper part of the kiln over burnt or not burnt enough. Therefore, to ensure that products in every part of the traditional shuttle kiln get an equal amount of heat, potteries or ceramics are usually arranged in a particular way before firing. Pottery that needs more heat is usually put in the bottom part, while pottery that needs less heat is put in the upper part.
Semi-continous shuttle kiln
The semi-continous shuttle kiln, also known as the semi-cyclic shuttle kiln, is a more modern variation on the traditional shuttle kiln. It works periodically rather than continuously. This means that after firing, cooling, and taking out the products, the kiln has to be prepared for firing again. In the semi-continous shuttle kiln, raw materials are constantly put into the kiln while firing is going on. One kiln usually serves many production lines.
Full-continuous shuttle kiln
In contrast, the full-continous shuttle kiln can be used for continuous production. When everything is settled down, raw materials can be put in all the time, and products can be taken out continuously at the same time.
Shuttle buggy kiln
Another notable variant is the shuttle buggy kiln, which is equipped with a shuttle buggy to transport the product cassettes into and out of the kiln. A shuttle buggy is a vehicle with two parallel rails that correspond to the kiln entrance and is used to transport product cassettes of a specific capacity/size into/from the kiln. The mobility of the shuttle buggy is made possible by an electric motor drive and/or an overhead crane. This enables it to travel the distance required to replace a split cassette of products on a continuous basis so that products can be fired in the kiln without having to stop production to bring a cassette in that is not yet ready.
Capacity
High-temperature shuttle kilns have a generally large capacity. Usually, the capacity is listed in cubic feet or cubic meters. For example, a specific high-temperature shuttle kiln may have a capacity of 50 cubic meters.
Temperature range
The temperature range of high-temperature shuttle kilns can be as low as 800 degrees Celsius. Generally, the temperature can reach 1300 degrees Celsius, and in some cases, they can even reach 1500 degrees Celsius.
Energy consumption
One important parameter of high-temperature shuttle kilns is energy consumption, which may be measured in kilowatts or tons of standard coal. For instance, a specific kiln may have an energy consumption of 1.5 tons of standard coal per day.
Operating system
High-temperature shuttle kilns usually have an advanced operating system that enables automatic control and monitoring of the kilns. For example, the operating system may include functions such as an AI controller, recipe management, and remote monitoring.
Regular inspections
Managers should develop a regular inspection schedule and stick to it. Ensure that all parts of the shuttle kiln are checked regularly, including controllers, sensors, valves, and pipelines, to ensure their normal operation and safety.
Equipment cleaning
High-temperature shuttle kilns often produce a large amount of dust and residue. Regular cleaning of equipment helps to prevent the accumulation of dust and maintain good heat dissipation performance, thereby prolonging the service life of the equipment.
Lubrication
High-temperature shuttle kilns' operating components, such as gears and bearings, should be regularly lubricated to avoid excessive friction and abrasion, ensuring their smooth operation.
Replacement of wearing parts
High-temperature shuttle kilns usually have a large number of wearing parts, like refractory bricks and kilns doors. These parts should be regularly inspected and replaced to maintain the stability and reliability of equipment performance.
Paying attention to abnormal conditions
Managers should pay attention to some abnormal conditions during the operation of the high-temperature shuttle kiln, such as weird noises, abnormalities in temperature and pressure, etc. If any abnormal situation occurs, it should be dealt with in a timely manner to avoid potential safety hazards.
The high temperature shuttle kiln is an industrial furnace with a wealth of applications in several industries that require high-temperature heating, especially for changing the properties of materials. This is evident in the way the unit is used in conjunction with high performance ceramics and pottery in the construction of large batches of high-temperature ceramic tiles, refractories, electrical insulators, sanitary wares, tableware, etc., Kunyang high-temperature shuttle kilns are widely used in the ceramic industry to fire and sinter these ceramics, thereby giving them strength and durability.
Since the shuttle kiln can achieve higher firing temperatures, it is also used to process metallurgical products, e.g., ore, etc. This includes the beneficiation of ore by providing a sustainable way to recycle metal ores to extract valuable metals, thereby improving resource efficiency. In metallurgy, it can also be used for the calcination of limestone, dolomite, etc., ore in the quarry industry. Also, many industries process minerals and soil in the Earth through kilns to produce valuable raw materials for construction and other processes, further emphasizing the versatility of the high-temperature shuttle kiln in processing metallurgical products.
In the chemical industry, the kiln is an essential piece of equipment for high-temperature reactions, e.g., calcination in this industry. Many chemicals undergo a reaction under specific conditions and high temperatures, and the chemical compound's change can also be affected by using a shuttle kiln for sintering, vitrification, and oxidation.
The shuttle kiln boasts the capability of high temperature ramping and holding, as well as the capacity to accommodate a large volume of materials, making it an ideal choice for the heat treatment of metals. Such treatments include processes like annealing, quenching, tempering, and oxidization, as well as the firing of metal-based products like metal ceramics, cermets, composite materials, etc.
Lastly, in the glass industry, shuttle kilns are employed to melt glass and fuse its components. The kiln provides the necessary high temperatures to melt raw materials, and good control of the temperature is needed to ensure the uniformity and quality of the glass products.
When choosing a shuttle kiln, buyers should consider the following:
High-Temperature Requirements
Buyers should look for a kiln capable of withstanding the required temperature. The maximum temperature an industrial shuttle kiln can reach is usually determined by its construction material. For example, the maximum operating temperature of a concrete shuttle kiln is about 1,000 degrees Celsius. On the contrary, high alumina brick kilns can withstand temperatures of up to 1,300 degrees Celsius.
Production Volume
The size of the shuttle kiln has a direct influence on its production volume. High-temperature shuttle kilns can be available in various sizes, from small to large. Large-capacity kilns are suitable for large-scale production because they can process a large amount of product at a time.
Fuel Type
Shuttle kilns are available in different types of fuel, such as gas, electricity, coal, etc. The types of fuel not only affect the operating cost of the kiln but also affect the carbon emission of the enterprise.
Automation Level
With the continuous progress of technology, the automation level of kilns has also been improved. Some kilns provide automatic control systems, which can realize automatic program control, and thus make the temperature and time control of the kilns more accurate.
Q1: Which fuel is mainly used for the high-temperature shuttle kiln?
A1: Generally, coal gas is applied fuel for the shuttle kilns, but based on different requirements, it can also be used with other fuels, such as natural gas, fuel oil, or electricity.
Q2: What materials can be sintered in a high-temperature shuttle kiln?
A2: High-temperature shuttle kilns are mainly used for sintering specific materials, such as ceramics, refractory materials, and some high-temperature materials in metallurgy and chemical industries, such as chemical fertilizers.
Q3: What are the advantages of a high-temperature shuttle kiln?
A3: The high-temperature shuttle kiln has many advantages. For example, it has a large capacity to meet various production needs. In addition, it has good temperature distribution, ensuring uniform sintering of materials. Moreover, it is energy-efficient and can save operating costs. Most high-temperature shuttle kilns are also automated. Operation and control can improve productivity and accuracy.
