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          Cement Rotary Kiln

          Rotary Kiln,Cement Rotary Kiln,Cement Kiln

          ZTIC developed large new dry process cement rotary kiln product with cement research and design institutes in Tianjin, Nanjing and Hefei by using domestic advanced technology, and the product can match 3000~10000t/d large new dry process cement production line. The company has a first-rate rotary kiln development, research and design team, perfect test and inspection means and excellent large rotary kiln manufacturing equipment and manufacturing technology, and has formed a complete technology and production system integrating rotary kiln design, manufacture, install and debugging service.

          Cement Rotary Kiln

          • Application Industry
            Cement Plant, Steel Mill, Chemical Plant & Incinerator
          • Output
            180~10000 t/d

          Rotary Kiln Processes

          With the arrival of rotary kilns, cement manufacturing processes became sharply defined according to the form in which the raw materials are fed to the kiln. Raw materials were either ground with addition of water, to form a slurry containing typically 30-45% water, or they were ground dry, to form a powder or "raw meal".

          • In the Wet Process, the kiln system is fed with liquid slurry, the water then being evaporated in the kiln.
          • In the Semi-Wet Process, raw material is prepared as a slurry, but a substantial proportion (50-80%) of the water is mechanically removed, usually by filtration, and the resulting "filter cake" is fed to the kiln system.
          • In the Dry Process, the kiln system is fed with dry raw meal powder.
          • In the Semi-Dry Process, a limited amount of water (10-15%) is added to dry raw meal so that it can be nodulised, and the damp nodules are fed to the kiln system.

          ZTIC Cement rotary kiln technical characteristics:
             
          ● Kiln body is made of high quality composed of carbon steel or alloy steel plate and automatic welding;
              ● Tyre、Support Roller、
          Open gear adopts alloy cast steel;
              ● 
          Sliding bearing with large gap not scraping tile bearing;                
              ● Transmission device adopts hard tooth surface reducer, flexible diaphragm coupling, dc motor;
              ● Adopts hydraulic gear wheel;
              ● 
          Preheater scales were used respectively to veiw of kiln head, and cylinder pressure tight seal;    
              ● 
          A slow drive device.

          Wet process kilns

          The original rotary cement kilns were called 'wet process' kilns. In their basic form they were relatively simple compared with modern developments. The raw meal was supplied at ambient temperature in the form of a slurry.

          A wet process kiln may be up to 200m long and 6m in diameter. It has to be long because a lot of water has to be evaporated and the process of heat transfer is not very efficient.

          The slurry may contain about 40% water. This takes a lot of energy to evaporate and various developments of the wet process were aimed at reducing the water content of the raw meal. An example of this is the 'filter press' (imagine a musical accordion 10-20 metres long and several metres across) - such adaptions were described as 'semi-wet' processes.

          The wet process has survived for over a century because many raw materials are suited to blending as a slurry. Also, for many years, it was technically difficult to get dry powders to blend adequately.

          Quite a few wet process kilns are still in operation, usually now with higher-tech bits bolted on. However, new cement kilns are of the 'dry process' type.

          Dry process kilns

          In a modern works, the blended raw material enters the kiln via the pre-heater tower. Here, hot gases from the kiln, and probably the cooled clinker at the far end of the kiln, are used to heat the raw meal. As a result, the raw meal is already hot before it enters the kiln.

          The dry process is much more thermally efficient than the wet process.

          Firstly, and most obviously, this is because the meal is a dry powder and there is little or no water that has to be evaporated.

          Secondly, and less obviously, the process of transferring heat is much more efficient in a dry process kiln.

          An integral part of the process is a heat exchanger called a 'suspension preheater'. This is a tower with a series of cyclones in which fast-moving hot gases keep the meal powder suspended in air. All the time, the meal gets hotter and the gas gets cooler until the meal is at almost the same temperature as the gas.

          The basic dry process system consists of the kiln and a suspension preheater. The raw materials, limestone and shale for example, are ground finely and blended to produce the raw meal. The raw meal is fed in at the top of the preheater tower and passes through the series of cyclones in the tower. Hot gas from the kiln and, often, hot air from the clinker cooler are blown through the cyclones. Heat is transferred efficiently from the hot gases to the raw meal.

          The heating process is efficient because the meal particles have a very high surface area in relation to their size and because of the large difference in temperature between the hot gas and the cooler meal. Typically, 30%-40% of the meal is decarbonated before entering the kiln.

          A development of this process is the 'precalciner' kiln. Most new cement plant is of this type. The principle is similar to that of the dry process preheater system but with the major addition of another burner, or precalciner. With the additional heat, about 85%-95% of the meal is decarbonated before it enters the kiln.

          In addition to these distinctions, a further category has emerged in the last 40 years: Precalciner Kilns, in which a proportion of the kiln fuel is burned in a static preheater before the feed enters the rotary kiln.

          1. Cement Rotary Kiln Introduction
          Rotary kiln is rotary forging kiln for short, which is one of building material equipment. It is divided into cement kiln, metallurgy and chemical kiln and lime kiln as per the different material treatment. Cement kiln is applied to carline cement clinker, which has two types,dry-type cement production kiln and wet-type cement production kiln. Metallurgy and chemical kiln is mainly used to magnetizing roast lean iron ore, oxidation roast the nickel chromium iron ore in the steel and iron plant. It is also used to roast bauxite chamotte in the refactory plant and chamotte, aluminium hydroxide in alumimium plant,crome ore in the Chemical plant. Lime kiln is use to roast active lime and soft-burned dolomite in steel plant and iron alloy plant.The cement kiln burns rawmix to produce clinker, which is then ground to make cement.

          The cement kiln is the heart of the cement making process: this is today almost a cliché, but was not always quite so true. In the modern cement plant, the kiln is the most expensive and technically complex part of the plant, and because it must be run all the time (unlike other sections of the plant) it effectively defines the output capacity of the plant. It stands out also in that, unlike the other processes involved, the “pyroprocessing” stage of cement manufacture is absolutely unique to the industry, and has devoted to it a complex and specialized multi-disciplinary technology all its own.

          Because of this, the cement kiln scarcely needs to be considered under the general category of “kilns”. In addition to its uniqueness, it also stands out among pyroprocessing equipment as by far the most economically significant world-wide. The blast furnace for iron production produces less than half the tonnage produced by cement kilns, although it runs ahead in terms of fuel usage. In terms of CO2 production, Portland cement kilns – when using limestone as a raw material – are by far the largest industrial manufacturing source. The taming of these emissions is likely to further increase the sophistication of the kiln design.

          2. Cement Rotary Kiln Features
          Rotary kiln is originally and widely applied to cement production, which is called the heart of cement plant. In the production of building material, Rotary kiln is used to calcine clay lime stone and cement clinker. In the production of refractory material, the kiln is used to calcine the material to extend of stable dimension, enough strength for machine-shaping.

          Rotary kiln is rotary forging kiln for short, which is one of building material equipment. It is divided into cement kiln, metallurgy and chemical kiln and lime kiln as per the different material treatment. Cement kiln is applied to carline cement clinker, which has two types, dry-type cement production kiln and wet-type cement production kiln. Metallurgy and chemical kiln is mainly used to magnetizing roast lean iron ore, oxidation roast the nickel chromium iron ore in the steel and iron plant. It is also used to roast bauxite chamotte in the refactory plant and chamotte, aluminium hydroxide in alumimium plant,crome ore in the Chemical plant. Lime kiln is use to roast active lime and soft-burned dolomite in steel plant and iron alloy plant

          Rotary kiln is one branch of rotary kiln system adopted in the steel and iron pellet with the extinguish design and structure. It is mainly composed of rotary parts, support parts, conveying parts, kiln head cover, kiln head and tail seal, combustion device. The ore, concentrate is sintered and calcined through rotary kiln. For example, aluminum hydroxide is calcined into alumina by the kiln in the aluminum production; Pellet ore for blast furnace is produced in the kiln in iron manufacturing. Iron ore is reduced directly through SL/RN process or Krupp process; Tin and lead can be refined through the kiln by chloridizing volatilization method .

          In addition, there is over twenty years of history to burn the hazardous waste through rotary kiln in developed country with concern of environment. The hazardous waste can be not only reduced in quantity and risk level but also can be consumed as fuel to save energy.

          3. Cement Rotary Kiln Specification

          Product specifications(m) Kiln dimensions Capacity(t/d) Rotation speed(r/min) Motor power(kw) Total weight(t)
          Diameter(m) Length(m) Obliquity(%)
          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 3.5 204 0.48-1.45 55 196.29
          Φ2.7×42 2.7 42 3.5 320 0.10-1.52 55 198.5
          Φ2.8×44 2.8 44 3.5 400 0.437-2.18 55 201.58
          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
          Φ3.0×60 3 60 3.5 300 0.3-2 100 310
          Φ3.2×50 3.2 50 4 1000 0.6-3 125 278
          Φ3.3×52 3.3 52 3.5 1300 0.266-2.66 125 283
          Φ3.5×54 3.5 54 3.5 1500 0.55-3.4 220 363
          Φ3.6×70 3.6 70 3.5 1800 0.25-1.25 125 419
          Φ4.0×56 4 56 4 2300 0.41-4.07 315 456
          Φ4.0×60 4 60 3.5 2500 0.396-3.96 315 510
          Φ4.2×60 4.2 60 4 2750 0.4-3.98 375 633
          Φ4.3×60 4.3 60 3.5 3200 0.396-3.96 375 583
          Φ4.5×66 4.5 66 3.5 4000 0.41-4.1 560 710.4
          Φ4.7×74 4.7 74 4 4500 0.35-4 630 849
          Φ4.8×74 4.8 74 4 5000 0.396-3.96 630 899
          Φ5.0×74 5 74 4 6000 0.35-4 710 944
          Φ5.6×87 5.6 87 4 8000 Max4.23 800 1265
          Φ6.0×95 6 95 4 10000 Max5 950×2 1659