Rotary kiln

The rotary kiln is the main equipment for calcining cement clinker, and is mainly used in the chemical, metallurgical and other industries. The rotary kiln calcining system equipment has been technologically innovated. The system adopts advanced hydraulic wheel blocking devices at home and abroad, high-precision metering plunger pumps, speed regulating valves and contact stone grinding block sealing devices. In order to improve the degree of automation, a special high-temperature resistant industrial television system is installed at the kiln head of high-temperature industrial equipment such as cement rotary kilns and metallurgical furnaces. The flame combustion state, material turnover and temperature distribution in the kiln are monitored through real-time images, replacing the traditional manual naked eye observation method. The process simulates the fluorescent screen, and the calcining belt uses an infrared scanner to directly reflect the calcining situation of the calcining belt on the computer. These new technologies are intuitive, easy to operate and reliable. The thermal system is stabilized and the equipment operation rate is improved. Compared with equipment of the same specification, the operation rate is increased by 3-5%, the output is increased by 5-10%, and the heat consumption is reduced by 15%.

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Description

Working Principle

1. Structural basis and movement principle
The main body of the rotary kiln is a steel cylinder installed at an angle, which is driven to rotate by a transmission device. After the material enters from the tail of the kiln, it moves along the axial direction of the cylinder under the action of gravity, friction and centrifugal force, while constantly rolling and mixing. This composite movement ensures that the material is heated evenly and prolongs its residence time in the high-temperature zone.
2. Heat source and heat transfer process
The fuel is sprayed into the kiln head and burned, forming a high-temperature flame of 1200-2500℃. Heat is transferred to the material through radiation, convection and conduction:
Radiation heat transfer: The flame radiates directly to the surface of the material, which is the main heat transfer mode in the calcination zone;
Convection heat transfer: The hot air flow contacts and exchanges heat with the surface of the material, especially in the preheating stage;
Conduction heat transfer: The high-temperature kiln wall transfers heat to the contacted material layer and conducts deep into the interior through particle conduction. Before the exhaust gas is discharged from the kiln tail, it exchanges heat with the cold material moving in the opposite direction, which significantly improves the thermal efficiency.
3. Material conversion
The material undergoes three stages of preheating, calcination and cooling in the kiln:
Preheating section: The exhaust gas at the kiln tail preheats the material to above 900℃ to complete dehydration and pre-decomposition;
Calcination section: At a high temperature of 1200-1450℃, the material undergoes a chemical reaction;
Cooling section: The clinker is quickly cooled at the kiln head to avoid excessive crystal growth and recover waste heat.
4. Parameter control
Speed and inclination: determine the material residence time and movement speed, and need to match the feed amount to maintain a stable filling rate;
Combustion control: optimize the flame length and temperature distribution by adjusting the fuel and primary/secondary air ratio;
Temperature monitoring: use thermocouples, infrared scanners, etc. to monitor the temperature field in the kiln in real time to prevent over-burning or under-burning.

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Jiangsu Haijian Co., Ltd

Jiangsu Haijian Co., Ltd was established in 1970 and was restructured into a provincial privately-owned joint-stock company in 2003. The company currently employs over 300 people, with engineering and technical personnel accounting for 25% of the total workforce. It covers an area of 100,000㎡ and has a building area of 55,000㎡. We currently possess vertical lathes ranging from Φ2.5-10m in diameter; gear hobbing machines with Φ2-8m capacity; floor-type lathes with Φ5×16m and Φ7×20m capacities; overhead cranes ranging from 10-150t; plate rolling machines from 30-120; gas annealing furnaces measuring 6.5×6.5×18m; and automatic drying and spraying booths, with a total of 500 units/sets of various equipment.
Jiangsu Haijian Co., Ltd is a professional China Rotary kiln Manufacturers and Rotary kiln Company. We provide professional cement production equipment, industrial solid waste incineration equipment, and professional equipment for mining and metallurgical applications.We are a major manufacturing enterprise, a key backbone enterprise, and a primary export base for cement, power, environmental protection, and metallurgical and mining equipment in China. The company has the legal rights to independently manage the import and export of its products and is legally authorized to undertake general contracting for foreign projects.

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Industry knowledge

As core thermal equipment in the chemical, metallurgical, and building materials industries, rotary kilns transform and purify mineral raw materials through a high-temperature calcination process. In cement production, they convert raw meal into highly reactive cement clinker, increasing the final product's compressive strength by 5-10 MPa. In the metallurgical industry, rotary kilns perform crucial processes such as magnetization roasting of lean iron ore and reduction of laterite nickel ore, achieving nickel recovery rates exceeding 90%. In the chemical industry, their stable temperature control ensures consistent quality for products such as chromium salts and aluminum hydroxide.

The main body of a rotary kiln is an inclined steel cylinder, driven by a transmission. After entering the kiln from the rear, the material moves axially along the cylinder under the influence of gravity, friction, and centrifugal force, while continuously tumbling and agitating. This combined motion ensures uniform heating of the material and prolongs its residence time in the high-temperature zone. Jiangsu Haijian Co., Ltd. is a professional rotary kiln manufacturer and company. We provide professional cement production equipment, industrial solid waste incineration equipment, and specialized mining and metallurgical application equipment. The operating principle of a rotary kiln combines the synergistic effects of mechanical motion and high-temperature chemical reactions. A high-temperature resistant industrial television installed at the kiln head captures flame patterns and material movement in real time. This, combined with infrared scanners, generates thermal images of the calcining zone, which are then transmitted to the DCS control system.

A continuous maintenance system is key to ensuring the long-term operation of the rotary kiln. Refractory material management utilizes 3D laser scanning technology, generating weekly kiln lining thickness distribution maps (accuracy ±3mm). Automatically alerts are issued when the remaining thickness of fired magnesia-alumina spinel bricks is less than 100mm. A vibration-temperature composite sensor is installed on the roller bearings, using spectrum analysis (frequency resolution 1Hz) to proactively identify bearing wear trends. The gear transmission system implements online oil monitoring, triggering maintenance procedures when ferrography indicates a wear particle concentration greater than 15ppm.