Rotary kiln 60m

Types of Rotary Kiln 60m

A controlled amount of oxygen combines with carbon to produce carbon dioxide. The rotary kiln is mostly made up of a rotating cylinder that varies in length and is placed at a slight gradient. Raw materials include clay, marble, and limestone, and they enter the kiln from the higher end. Due to the decline and rotation of the kiln, materials slowly progress toward the lower end.

Rotary kilns are divided into five different categories based on their specific functions and designs.

• Cement Rotary Kiln

  In the cement industry, Cement rotary kilns, which are approximately 4,000 feet long and 20 feet wide, play a pivotal role in producing cement. The basic chemical equation of cement production is that limestone must be calcined to lime in a kiln. In the cement rotary kiln, lime and other materials must be calcined simultaneously. Subsequently, the combination of lime and other chemical components will yield cement. The primary function of the cement rotary kiln is to decompose the cement limestone, which directly affects the composition and quality of the cement. Therefore, the quality of the cement rotary kiln has a decisive impact on a cement factory.

• Chemical Rotary Kiln

  Rotary kilns are used in the chemical industry for various purposes, including the production of active lime, soda calcination, magnesium hydroxide decomposition, and the oxidation of chromium ore. Different types of chemical rotary kilns have been designed to meet the needs of specific chemical processes and product requirements. The rotary kiln used in the chemical industry is typically a long cylinder lined with a refractory material. It consists of a slope and a rotation that helps to thoroughly mix and heat the materials, while the temperature inside the kiln is closely monitored and adjusted.

• Metallurgical Rotary Kiln

  The metallurgical rotary kiln is often referred to as a melting kiln or an oxidation-reduction metallurgical kiln. According to the different separation techniques, metallurgical functions, and chemical principles, the rotary kiln designated for metallurgy is made for different purposes. For instance, zinc extraction and lead extraction from metalliferous ores is often performed in a zinc rotary kiln and lead rotary kiln, respectively. Zinc rotary kilns and lead rotary kilns are designed based on distinct chemical separation processes and separation techniques. The kiln is utilized to produce specific metals from ore materials through reduction or oxidation reactions. These include the rotary kiln for zinc extraction and the rotary kiln for lead extraction, respectively. There are also rotary kilns for sulfide ores that work following different chemical processes and separation means.

• Indirect Fired Rotary Kiln

  An indirect-fired kiln is also called a cooling kiln. In this specific type of kiln, heat is put into or extracted from the material by the means of a shell that is cooled or heated by a certain number of external burners or coolers. An indirect-fired rotary kiln separates itself from other types of rotary kilns that directly fire rotary kilns, where heat is supplied through a fuel that is combusted in the kiln.

• Direct Fired Rotary Kiln

  The Direct Fired Rotary Kiln is the most common type of kiln. It is used for a variety of applications such as calcining, roasting, and heat treatment. In a direct-fired rotary kiln, heat is supplied to the material by a burner that directly fires through a nozzle mix combuster. It combusts the fuel and air together with the powder that passes into the kiln.

Specifications and maintenance of a rotary kiln 60m

Specifications

• Length

  The length of the rotary kiln can have a significant effect on its ability to process materials and the quality of the end products.

• Diameter

  Generally, rotary kilns with larger diameters can handle more substantial volumes of materials, thus boosting production capacity. This results in a higher throughput rate per unit of time. Furthermore, the rotary kiln's larger diameter offers enhanced accessibility to its interior, which simplifies maintenance and repair operations.

• Wash coat

  In order to ensure the product's quality, it is essential to examine the rotary kiln's wash coat regularly. Any signs of damage or deterioration should be promptly repaired to maintain the effectiveness of the wash coat. Additionally, controlling the temperature within the rotary kiln is crucial for the longevity of the wash coat.

• Supporting structure

  Maintenance of the supporting structure of the rotary kiln is essential to ensure its stability and support functionality. Regular inspections should be carried out to check for any signs of damage, such as cracks or deformations, and timely repairs should be made to ensure the supporting structure's integrity.

• Firing system

  When maintaining a rotary kiln's firing system, the first step is to conduct a thorough inspection of the burners. This will help identify any signs of damage or blockages. Any issues detected should be promptly addressed to ensure the proper functioning of the firing system. Additionally, regularly cleaning and maintaining the ignition devices of the burners is equally important.

Maintenance

• Seal

  The rotary kiln's seals should be periodically inspected and maintained as part of the overall maintenance plan. This ensures that the seals remain in good condition, effectively preventing the leakage of dust and gases. Additionally, it helps to protect the equipment and improve its operating efficiency.

• Lubrication

  The components need to be cleaned first, and then the old lubricant is removed. Next, select the appropriate lubricant based on the specific equipment and working environment. During operation, ensure even application of the lubricant to prevent excessive or insufficient lubrication. Regularly inspect and supplement the lubricating oil to maintain its effectiveness.

Scenarios of rotary kiln 60m

• Cement production:

  The cement industry was one of the earliest applications of large 60m rotary kilns. The rotary kiln burns the limestone in the raw meal to calcine and produce cement clinker. Then, the clinker is ground to produce cement. A 60m rotary kiln is a common size for large-scale cement companies.

• Activated carbon production:

  Activated carbon is widely used for air and water purifying and industrial decolorizing. The production of activated carbon typically involves a rotary kiln carbonization step. Therefore, a 60m rotary kiln is perfect for producing a large quantity of activated carbon.

• Magnesium oxide production:

  A 60m rotary kiln is often used to produce magnesium oxide. The kiln rotationally magnesite ore is additionally heated to bring chemical changes, resulting in the formation of magnesium oxide. It is ideal for processing magnesite because of its uniform heating and emissions control.

• Refractory materials:

  Refractory materials are designed to withstand high temperatures and are used in a variety of industries, including steel, cement, glass, and petrochemicals. Rotary kilns can directly heat or calcine raw materials to produce high-temperature-resistant rotary kiln refractories, including fireclay bricks, alumina bricks, and silica-zircon bricks.

• Environmental protection applications:

  Large 60m rotary kilns can also be used for hazardous waste treatment and comprehensive recycling of urban solid waste. Rotary kilns incinerate hazardous wastes, such as medical garbage, waste oils, and solvents, at high temperatures to stabilize harmful components and reduce waste volume.

• Metallurgical processes:

  In metallurgical industries such as iron, copper, zinc, and nickel, 60m rotary kilns can be used to oxidate and reduce metal ores. For example, zinc ore is directly roasted in a 60m rotary kiln. Then, the zinc vaporizes and is captured through condensation systems.

• Siderite direct reduction:

  Large 60m rotary kilns are extensively used in the steel industry to produce iron. Rotary kilns can be employed for the direct reduction of iron ore with low grade. By the application of calcium and carbon as reducing agents, rotary kilns can also be used to reduce the iron ore by coal, oil, or natural gas.

How to Choose a Rotary Kiln 60m

When investing in a rotary kiln, one must consider various things. These include the performance, construction material, flexibility, energy-efficient, sealing technology, control system, and after-sales service.

• Performance: A rotary kiln's overall performance can impact productivity and cost-efficiency. Examine its rotation capacity, thermal efficiency, and waste management system to ensure optimum production and environmental compliance.
• Construction material: The durability and longevity of a rotary furnace highly depend on the construction material. Choose a kiln made from corrosion-resistant and heat-retaining materials. This will help ensure prolonged service life and reduced maintenance costs.
• Flexibility: A rotary kiln that can process diverse materials offers greater production potential. Also, it can adapt to changing market demands. Such a rotary kiln can handle various feedstock, such as biomass, waste, and industrial byproducts.
• Energy efficiency: A rotary furnace consumes a lot of energy. Go for the energy-efficient models to cut down on operating costs. Consider features like waste heat recovery systems and advanced insulation. These will reduce energy consumption and environmental impact.
• Sealing technology: The sealing technology used in a rotary kiln can influence gas tightness and friction. Look for effective and reliable sealing solutions, such as inflatable seals, metal labyrinth seals and roller seals. Such sealing options can minimize leakage, reduce abrasion, and enhance operational safety.
• Advanced control system: A rotary kiln with an automatic control system offers high precision and efficiency. Consider models with computer-based controls, real-time monitoring, and data logging functions. Such features enable centralized management, streamline production processes, and enhance operational efficiency.
• After-sale service: Consider the suppliers' after-sales services and support. Go for suppliers offering maintenance support, spare parts availability, and technical assistance. This ensures timely support and minimizes downtimes.

FAQ

Q1: How long does it take to bake cement in a rotary kiln?

A1: The process of making cement takes about 25-35 minutes per ton of material when moving through the different sections of the kiln, including heating, calcination, and cooling.

Q2: What is the lifetime of a rotary kiln?

A2: The rotary kiln can have more than 20 years of useful life if properly maintained and operational conditions are optimized.

Q3: What is the most important characteristic of a rotary kiln?

A3: The most important characteristic of a rotary kiln is its refractory lining. Thermal insulation is crucial because the kiln operates at extremely high temperatures. Around 2000°C is needed to transform raw materials into cement.