Description

Rotary kiln belongs to building material equipment and is wildly used in nonferrous metallurgy industry, ferrous metallurgy industry, chemical industry, cement industry, refractory material industry, lime industry, environmental protection industry.

According to the different materials processing, rotary kiln can be divided into cement kiln, metallurgy chemical kiln, lime kiln, ceramic kiln, zinc oxide kiln. Cement kiln is mainly used to calcine cement clinker, and it is divided into two kinds: dry process cement kiln and wet process cement kiln. Metallurgy chemical kiln is mainly used for poor iron ore magnetizing roasting in steel factory. Oxidation roasting of chromium and nickel ore. It is also used for extracting of tin and lead by chlorination volatilization roasting, for refractory plant roasting high alumina bauxite and aluminum plant roasting clinker, aluminum hydroxide and for chemical plants roasting chrome ore and chrome ore powder. Lime kiln is used for roasting acive lime and light burned dolomite used in iron and steel plant, ferroalloy plant and calcium carbide plant. Ceramic kiln is used for calcination and manufacture of various ceramic of materials bauxite, clay, yellow mud, river sludge, fly ash, shale, coal gangue, municipal solid waste, biological sludge. The Zinc Oxide kiln is used for mixing the zinc charge and the coking coal in proportion to produce Zinc Oxide.

In addition, in the chemical industry, rotary kiln can produce calcined soda, phosphate and barium sulfide. In the environmental protection, rotary kiln has been widely used in incineration of hazardous waste and sludge. 

The rotary kiln is mainly composed of a kiln body, a transmission device, a supporting device, a gear wheel device, a kiln head sealing device, a kiln tail sealing device and a kiln head cover.

Technology Data of NSP cement rotary kiln
Specification	Inclination	Capacity	Speed	Motor Model	Power(kw)	Weight(t)	Notice
(m)	%	(t/d)	(r/min)
φ1.6x20	4	10	0.14-1.64	JZT362-4	17	45.9
φ1.8x18	4	12	0.08-1.04	JZT371-4	22	51.2
φ1.9/1.6x36	4	72	0.3-1.76	YCT280-4A	30	62.9
Φ2.5/2.2x50	3.5	96	0.5-1.55	YCT315-4A	55	154.9
Φ2.8/2.5x55	3.5	132	0.5-1.55	Z2-92	75	210
Φ3/2.5x60	3.5	168	0.5-1.8	ZSN4-225-11	75	429.5
Φ3.0x48	3.5	840	0.43-3.62	ZSN4-250-11B	110	241
φ3.2x50	3.5	1200	0.36-3.57	ZSN4-250-091B	160	259
φ3.3x52	3.3	1320	0.398-3.975	ZSN4-250-11B	190	243
φ3.5x52	3.5	1500	0.36-3.51	ZSN4-315-082	190	318
φ3.95x56	3.5	2000	0.6-3.3	ZSN4-315-072	250	418
φ4x60	3.5	2500	0.396-3.96	ZSN4-355-092	315	497
Φ4.2x60	3.5	2800	0.4165-4.165	ZSN4-355-12	420	576.1
Φ4.3x62	3.5	3000	0.398-3.98	ZSN4-355-12	420	598.5
Φ4.8x74	3.5	5000	0.35-4	ZSN4-400-092	630	841

Technology Data of Metallurgical kiln
Specification(m)	Capacity(t/d)	Motor Model	Power(kw)	Main reducer model	Speed ratio	Weight(t)	Notice
φ1.8x26	72	JZT2-72-4	30	JZQ750-1-Ⅰ	48.57	66
φ1.9/1.6x39	72	JZT2-72-4	30	JZQ750-1-Ⅰ	48.57	66
φ1.9x36	84	YCT315-4A	37	ZS110-5-Ⅲ	78.19	85.9
φ2.2x45	98.4	JZT82-6	55	ZA125	93.93	104
φ2.5x40	160	Z2--92	40	ZS125-2-Ⅰ	134.9	143
φ2.5x45	170	JTZ82-4	45	ZS125-4-Ⅰ	69.71	148
φ2.5x50	180	ZT3-72-4	30	ZS145-9-Ⅴ	122.8	173
φ2.5x60	168	YCT355-4B	75	ZS165-7-Ⅱ	99.96	222	Bauxite calcined kiln
φ3x48	360-480	YCT355-4B	75	ZS145-7-Ⅱ	100.4	170.6
φ3.1/2.5x78	216-240	Z4-225-31	75	ZS165-2-Ⅱ	57.17	268
φ3x48	700	ZSN4-280-21B	110	MSY56-28-Ⅱ	28	244	Kiln decomposition
φ3x100.94	450	ZSN4-280-21B	90	NZS995-90-Ⅵ-L	90	526	Multi cylinder cooling
φ3.2x50	1000	ZSN4-280-21B	160	MSY56-28-Ⅱ	28	252.4	Kiln decomposi
φ3.2x52	600	ZSN4-280-21B	125	ZSY1110-71BL	71.54	275	Preheater kiln
φ3.3x52	1000	ZSN4-280-11B	125	NZS995-40-Ⅵ-BR	40	283	Kiln decomposition
φ3.5x52.5	1400	Z2-112	180	ZS177	79.22	360	Kiln decomposition
φ3.5x54	1500	ZSN4-3156-092	220	ZSY500-40-Ⅴ	40	368	Kiln decomposition
φ3.6x70	490	ZSN4-280-11B	125	ZS177-5-Ⅱ	79.2	419	Waste heat power generation kiln
φ3.95x56	2000	Z4-280-32BTH	250	ZSY560-40-Ⅰ	40	417	Kiln decomposition
Φ4x28	90	ZSN4-280-21B	160	ZSY500-71-Ⅳ	71	300
φ4x60m	2500	ZSN4-355-09Z	315	ZSY630-35.5-Ⅰ	34.6	523	Kiln decomposition
φ4.2x60m	2800	ZSN4-355-12	420	ZSY710-35.5-Ⅰ	35.5	---	Kiln decomposition
φ4.3x60m	3000	ZSN4-355-12	375	ZSY710-40	40	553	Kiln decomposition
φ4.8x75m	5000	ZSN4-400-92	630	JH710-40	42	841	Kiln decomposition

 

Technology Data of Lime kiln

Capacity（t/d）

150

200

250

300

350

400

500

600

750

800

1000

Product

Active lime

Active lime

Active lime

Active lime

Active lime

Active lime

Active lime

Active lime

Active lime

Active lime

Active lime

Rotary kiln

Specification(m)

Φ2.5×40

Φ2.8×40

Φ3×46

Φ3.3×50

Φ3.5×54

Φ3.6×54

Φ3.8×58

Φ4×60/Φ4.2×60

Φ4.3×62

Φ4.3×64/Φ4.5×63

Φ4.8×68/Φ4.9×70

combustion temperature

1300

1300

1300

1300

1300

1300

1300

1300

1300

1300

1300

Fuel

Gas and

Gas and

Gas and

Gas and

Gas and

Gas and

Gas and

Gas and

Gas and

Gas and

Gas and

pulverized coal

pulverized coal

pulverized coal

pulverized coal

pulverized coal

pulverized coal

pulverized coal

pulverized coal

pulverized coal

pulverized coal

pulverized coal

Heat consumption

5016

5016

5016

5016

5016

4932

4932

4932

4932

4932

4932

（KJ/KgCaO）

Principle

Rotary kiln is a cylinder with a certain degree of slope which is in 3 ~ 3.5%, with the rotation of the kiln to promote the material mixing and contacting in rotary kiln. A large amount of heat is generated by the combustion of the fuel and the heat is transferred to the material by means of the flame radiation, the convection of hot air and the transmission of the kiln brick. The forward movement of the material depends on the inclination of the kiln barrel and the rotation of the kiln.

The raw material enter into the cylinder body from the tail of the kiln to be calcined at high temperature. Due to the tilting kiln body and the slow rotation, the material produces a complex movement which moves along the circumferential direction and moves along the axial direction from the high end to the low end. The raw materials are decomposed, sintered and cooled down in the rotary kiln then clinker discharged from low-end into cooling machine. The fuel is sprayed from the kiln head, the combustion is carried out in the kiln to heat the raw material into clinker. The hot air produced in the process of heat exchange with the material enter into the kiln tail system from the kiln feed and finally it is discharged into the atmosphere.

Advantage

Our company is committed to the application of modern design theory and methods for many years to develop energy-saving rotary kiln. So our rotary kiln has unique characters in the process design and mechanical equipment manufacturing. such as:

i. Adopting new heat insulation material to reduce heat loss.

ii. At the end of the kiln head, a new type of compound scale is used to make the air leakage coefficient less than 10%, at the same time to meet the environmental protection requirements.

iii. Lime kiln is usually made up of a larger diameter and shorter kiln body, which is supported by two gears. Therefore, it not only reduces the amplitude of the upper and the lower range of the kiln body and prolongs the cycle of the inner ring of the kiln but also reduces the transmission power and reduces the energy consumption.

Maintenance

i. Checking regulations

During the operation of the kiln, the wear parts and th e low precision of the equipment will affect the operating rate, so the user must maintain and replace the wear parts regularly. Under the principle of preventive maintenance, maintenance plan shall be prepared in advance. At present, the main method is small-scale maintenance and medium-sized maintenance usually in the empty stop lining. Medium-sized repair should be carried out in stop the kiln lining in the 2-3 times and rotation device should be checked after lining work, but should be checked in the short term (such as 8 - 12 hours) as soon as possible. Overhaul repair is longer(such as 10-20 days), during this time the user should replace wear parts and adjust all units(such as the replacement of the tube section, ring gear, wheel, roller and other important parts, find the kiln center line).

The standard for the repair and replacement of the main wear parts of rotary kiln is as follows:

1.The tooth thickness of the drive gear is worn by 30%, or the tooth edge has a non recoverable damage.

2.Cracks and local deformation of the segment of the kiln barrel.

3.The 20% wear of tyre section and the surface is worn into tapered, polygonal, and partially penetrated cracks.

4.Roller wear by 20% or wheel rim thickness wear 25%; the rim is worn into tapered or other alien shape; or the rim has a through crack. When the roller and gear wheel are replaced, the relevant lining must be renewed or replaced as well.

ii. Maintenance regulations

1. Each part of the gear wheel and the transmission system must be checked once an hour, and the abnormal sound, vibration and overheating should be handled promptly.

2.Check whether contact and wear between the tyre and roller is uniform, and there is no excessive force and surface operation.

3.Identify the gap and wear according to the relative displacement between the wheel and the plate in a turn; and pay attention to the crack in backing welding and add lubrication into friction surface between tyre and block.

4.Check the transmission base and the supporting device of the anchor bolts and fixed bolts once a time, the loose part should be tightened immediately.

5. Observing whether the foundation has the phenomenon of vibration and sinking.

6.Observe whether the kiln tail sail and kiln head seal is good, whether the wear is serious.

7.Check the wheel bearing shell temperature and lubrication condition once an hour and observe whether the gap between the thrust ring and the lining is in a normal state.

8. Regularly check the auxiliary transmission device, auxiliary drive should start without clutch once a week to ensure that the main power supply can be activated when the sudden interruption.

9.Check cylinder temperature regularly. Especially the burning zone and the middle block temperature near the cylinder wheel should be maintained below 380℃; it is allowed to reach 410℃ only in case of accident; it is illegal operation if the user continue to operate in temperature more than 415℃.

Wear part list

No.	Name	Material
1	Kiln tail seal	0Cr18Ni9
2	Kiln head seal	0Cr18Ni9
3	Rotary kiln pinion	34CrNi3Mo
4	Liner shell	ZA303/ZCuAl10Fe3
5	Couplings (all levels)	ZG45#