In clinker rotary kiln, clinker is opposite to raw material. Clinker refers to sintered ore or pellet produced by the high-temperature agglomeration of the concentrated powder and the ore-rich powder. Clinker can increase yield and reduce the coke ratio. As the increasing demand in industry, the comprehensive utilization value of clinker is also upgrading. How to ensure greater use-value of clinker? Here I recommend rotary kiln for everyone. Clinker rotary kiln is a professional equipment designed according to the characteristics of clinker. The calcination process of clinker includes crushing and pre-homogenization, raw material preparation, homogenization of raw meal, preheating decomposition and clinker burning. Clinker rotary kiln has high calcination quality, less fly ash, high purity, excellent working environment, and low energy consumption.
Clinker rotary kilns main part mainly consists of a cylinder, front roller ring, rear roller ring, gear and stop roller; tow roller, pinion, discharge part, lifting plate, reducer, motor, hot air duct, feed chute and furnace. The clinker rotary kiln can also add gas generators, combustion chambers or supporting hoists, belt conveyors, dosing feeders, cyclone dust collectors, and induced draft fans according to users requirements.
In clinker rotary kiln, the suspension preheating and calcining kiln are collectively referred to as a new clinker rotary kiln. The new clinker rotary kiln has moved the preheating and carbonate decomposition of the clinker powder outside of the kiln while in suspension state. The thermal efficiency is high, which reduces the load on the clinker rotary kiln, and the clinker is not only low in heat consumption from 30to 60 but also further expands the production capacity of the kiln. The clinker rotary kiln is pre-fired well, the temperature in the kiln is high, the clinker cooling rate is fast, and the clinker is with high silicic acid ratio, high saturation ratio and high alumina oxygen ratio, and the clinker strength is high. The clinker rotary kiln feeds the clinker powder directly into the kiln for calcination. The moisture rate of the clinker is generally 1% to 2%, sparking a large amount of heat by drying required for clinker.
The main drive motor in the clinker rotary kiln transmits power to the open gear device through the main reducer. The raw material is needed from the kiln tail. Due to the inclination and slow rotation of the clinker rotary kiln, the raw material has produced a force to roll in a circumferential direction and while the move from a high end to a low end along the axial direction. The raw material in the clinker rotary kiln through decomposition, firing and other processes, discharged from the bottom end of the kiln cylinder into the cooling machine. Fuel is injected into the kiln from the kiln head. After the exhaust gas is exchanged with the material, it is led out from the kiln tail and discharged into the atmosphere by the chimney.
Cement Rotary kiln, is one kind of lime kiln, belongs to building material equipment. The rotary kiln has wide applications, such as metallurgy, chemical industry, cement, refractory materials, lime, environmental protection and other industries.
Cement rotary kiln, also called clinker kiln, can be divided into dry-process cement kiln and wet-process cement kiln according to the cement production technology. Dry-process cement rotary kiln is mainly used to calcine cement clinker. As the core equipment of NSP cement production line, cement rotary kiln is consist of shell, supporting device, transmission device, lubrication device, moving kiln head, sealing device for kiln tail, burning device and etc. dry-process cement rotary kiln has advantages of simple structure, reliable operation and easy to automatic control in the cement production line.
AGICO Cement is one of leading cement plant manufacturers offers cement kiln and other cement equipment, our cement rotary kiln has been widely applied to many cement plant. Based on 60+ years experience and advanced production equipment, we can provide EPC project and custom-designed solution to cement manufacturing.
Cement rotary kiln is a piece of cement equipment with strong durability, also plays a vital role in the cement plant. If you find any problem in the operation, solve it immediately. In general, the maintenance of rotary kiln is a complex process, here are some tips will be helpful.
First of all, check the fire hole of the rotary kiln is closed or not, ensure the close state to avoid too much cold air. Then, check the windshield of the burner at the kiln door is close to the kiln door. If the air leakage is not closed, it should be pushed to the position of close contact with the kiln door. Third, check the door cover of rotary kiln, if there is the phenomenon of positive pressure ash, should inform the central control to adjust properly. Finally, remember to check air leakage or wear out the phenomenon of resistant material, when you find the above problems, promptly inform the relevant leadership to deal with them.
Check the fish scales sealed in the kiln head, and then check the fitting condition of the fish scales in the rotary kiln and friction ring. If there is any bad condition such as non-fitting, the weight should be adjusted by tightening the device to make it fit. If there is too much aggregate in the reliable rotary kiln, the discharging pipe should be adjusted timely. After that, check the wear condition of the friction ring of rotary kiln. If the friction ring is found to be badly worn or worn out, replace it.
Check the cooling air at the kiln head, and then check the friction between kiln head and the kiln door cover. In order to ensure safety, check the oil film contact of the supporting wheel shaft and thrust plate one by one. Check oil level, oil scoop and oil distribution of rotary kiln. Next, check whether there are impurities, water droplets, oil leakage, collision, loosening and other abnormal conditions, if necessary, the temperature can be measured and control.
The service life of rotary kiln is affected by many factors, such as quality, regular maintenance, etc. AGICO CEMENT ensures the quality of the rotary kiln by strict quality control and advanced technology. Besides, regular maintenance can prolong the useful life of your rotary kiln.
Yes, in order to prevent cold air from entering the rotary kiln and smoke dust from spilling out of the cylinder, the rotary kiln is equipped with a reliable sealing device for the inlet end (tail) and an outlet end (head) of the cylinder, ensuring the sealing performance of the rotary kiln.
The cement rotary kiln produced by AGICO has been optimized and added with e dust filter products for environment protection, which is a new type of environmental protection equipment to reduce the environmental pollution caused by industrial production.
Lime rotary kiln has many advantages in the processing of limestone ore, it is also known as the lime kiln, is a professional strong calcining equipment, its main advantage include great production capacity, no noise, low energy consumption and so on. As the main equipment of lime production line, it has very high industrial value, so the demand for the lime rotary kiln is very high, and becomes the ideal equipment for the masses of users in the lime processing.
Aiming at the calcination characteristics of limestone, a new type of cement kiln for active lime has been developed on the basis of absorbing and learning from similar rotary kilns at home and abroad.
The lime rotary kiln produced by AGICO CEMENT has the characteristics of the high utilization rate of raw materials, uniform quality, good quality, large capacity, high turnover rate, and easy operation.
Limestone is fed into the kiln through the chute at the end of the kiln. Due to the tilt and slow rotation of the kiln body, the limestone rolls along the circumference on one side and moves from the end of the kiln to the kiln head on the other side along the axis. The fuel is sprayed into the kiln from the end of the kiln through the burner for combustion, and the heat is transmitted to the limestone by radiation, convection and conduction. After the limestone is calcined into quicklime during the moving process, it is discharged from the end of the kiln, and the high-temperature flue gas enters the dust removal system from the end of the kiln.
According to the fuel, lime kiln is divided into mixed kilns (namely burning solid fuel, coke, coke powder, coal, etc.) and Gas kiln. Gas kilns include blast furnace gas, coke oven gas, calcium carbide tail gas, producer gas, natural gas, etc.
What is a clinker? Cement clinker is made of limestone, clay, and iron, these main raw materials are mixed in proper proportions, burned to partial or total melting, and finished cement is obtained by cooling. Portland cement clinker is mainly containing CaO, SiO2, Al2O3, Fe2O3, in accordance with the appropriate proportion of grinding into fine powder burning to partial melting, calcium silicate as the main mineral composition of the hydraulic cementation material. Among them, calcium silicate mineral is not less than 66%, and the mass ratio of calcium oxide to silicon oxide is not less than 2.0. What is the clinker used for? Cement grinding plant process clinker into the required size, and finished cement is obtained.
What is clinker plant? As we all know, cement production line can be generally divided into three main parts, raw material production, clinker production and finished cement production. Clinker plant is applied to clinker production, we can classify the clinker plant into two parts, preheat and precalcining, burning in the rotary kiln.
AGICO Cement is a cement plant manufacturer with rich experience, and we are specialized in cement plant and cement equipment. Based on rich experience and advanced technology support, our cement equipment and cement plant have been exported to many countries. For your convenience, we will provide a full guide of the clinker plant, lets learn the clinker plant together!
The preheating of raw material and part of precalcining are completed by preheater in cement plant, it plays partial roles of cement rotary kiln, shorten the length of rotary kiln, and remove the heat exchange from rotary kiln to preheater, which fully mix raw meal and hot air from rotary kiln, increase contact area between air and materials, improve the heat exchange efficiency, realize the goals of higher working efficiency and energy-saving.
In a word, the preheater in the cement plant makes full use of waste gas discharged from rotary kiln and precalciner to heat the raw meal and decompose partial carbonate. To maximize the heat exchange efficiency between gas and solid, and realize the high quality, high yield and low consumption of the whole calcination system, it is necessary for cyclone preheater to have three functions: uniform gas-solid dispersion, rapid heat exchange, and efficient separation.
Note: pre-calcining means that set precalciner between preheater and rotary kiln, transfer the decomposition inside rotary kiln into the precalciner, prolong the useful life of rotary kiln and it is good for the large-scale cement production. It is known with the advantages of high quality, high efficiency, low consumption and a series of excellent performance.
Cyclone preheater: preheater in cement plant use suspension preheat to complete the raw meal preheating and partial precalcining. The cyclone preheater reduces the energy consumption of the clinker plant, also reduces the occupied area. For different areas and production capacity, AGICO Cement provides a custom-designed solution to the clinker plant.
After the raw materials are preheated and pre-calcining in the cyclone preheater, the next, the raw meal will be sent into the rotary kiln for the burning of the clinker. In the rotary kiln, the carbonate is further rapidly decomposed and a series of solid reactions occur to produce minerals in cement clinker. As the temperature of the material rises, the mineral will turn into a liquid phase, dissolve in the liquid phase and react to produce a large amount clinker. After the clinker burning, the temperature begins to drop. And then, the high-temperature clinker discharged from the rotary kiln is cooled by the clinker cooler to the temperature that can be accepted by the downstream transportation, cement storage silo, and cement mill, and the sensible heat of the high-temperature clinker is recovered to improve the thermal efficiency and clinker quality.
Cement rotary kiln: rotary kiln is the core equipment of the clinker plant that is used for clinker burning. According to the cement manufacturing process, rotary kiln can be divided into two types, dry-process cement rotary kiln, and wet-process cement rotary kiln. AGICOs cement rotary kiln is popular with advantages of high thermal efficiency, advanced structure, stable and reliable performance, high production capacity and lower energy consumption.
Clinker cooler: the clinker cooler is heat exchange equipment, clinker cooler use air as medium, pass through the high-temperature clinker and cool the cement clinker, at the same time, recovery the waste heat, promote the thermal efficiency. Our cement cooler has advantages of high thermal efficiency, high clinker quality, fast cooling, high operation rate.
Rotary kiln dryer: rotary kiln dryer also called cement dryer, has strong applicability of materials, and simple and reliable operation of cement dryer makes cement dryer wider applications. The cement dryer produced by AGICO has some advantages including strong drying capacity, the long service life of parts, hard to wear, high drying intensity, high working efficiency, easy to operate, energy-saving, advanced structure, etc.
Commonly known as the rotary kiln, the rotary calcining kiln is also called the rotary dryer, belonging to construction equipment. Depending on the materials, the rotary kiln falls into three types: the metallurgy kiln, the lime kiln and the cement kiln.
The cement kiln is mainly used for calcining cement clinker, classifying into the dry method production equipment and the wet type production equipment. Metallurgy kiln is widely used in steel works in the metallurgy industry for magnetizing roasting of poor iron ore; oxidizing roasting of chromium and nickel iron ore; roasting high aluminum vanadium and soil ore pellets in refractory plants; roasting clinker and aluminum hydroxide in aluminum manufacturers and roasting chrome ore and powder in chemical plants. The lime kiln (i.e. the active lime kiln) is used for roasting active lime in steel works and ferroalloy plants and light roasting dolomite.
The cement kilns mainly fall into two types: one is horizontal cylinder device(with gradient) and since it can make gyroscopic motion, it is also called rotary kiln; the other is vertical without rotation (also called the shaft kiln).
The kiln used in wet type production, which produces slurry with water content of 32%-40% from raw materials, is called the Wet Type Rotary Kiln. Due to the liquidity of the slurry, the raw materials are sufficiently mixed, making clinker of high quality, which is the main advantage of wet production.
Contrary to that in the wet type production, the dry type rotary kiln makes raw materials into dry powder, with water content of less than 1%, thus reducing the heat needed for water evaporation. Hollow Type Kiln has high consumption of heat because the exhaust flue gas is of high temperature. The fluidity of dry power is worse than that of the slurry.
The materials to be burnt get into the stove from the higher end of the cylinder. Due to the slope and slow rotation of the cylinder, the materials move around and move from top to bottom along the axis to finish its process. At last, the finished materials get into the cooler through the burner hood. The fuel gets into the kiln through the head of the kiln. The waste gas will be discharged from the end of the kiln after exchanging heat with the materials.
Product Specification m Kilndimensions Motor power kw Total weight t note Diameter m Length m Obliquity % Capacity t/d Rotation speed r/min 2.540 2.5 40 3.5 180 0.44-2.44 55 149.61 ----- 2.550 2.5 50 3 200 0.62-1.86 55 187.37 ----- 2.554 2.5 54 3.5 280 0.48-1.45 55 196.29 outside disassemble kiln 2.742 2.7 42 3.5 320 0.10-1.52 55 198.5 ------ 2.844 2.8 44 3.5 450 0.437-2.18 55 201.58 outside disassemble kiln 3.045 3 45 3.5 500 0.5-2.47 75 210.94 ------ 3.048 3 48 3.5 700 0.6-3.48 100 237 outside disassemble klin 3.060 3 60 3.5 800 0.3-2 100 310 ------ 3.250 3.5 50 4 1000 0.6-3 125 278 disassemble klin 3.352 3.3 52 3.5 1300 0.266-2.66 125 283 kiln with preheater precalcine 3.554 3.5 54 3.5 1500 0.55-3.4 220 363 kiln with prehrater precalcine 3.670 3.6 70 3.5 1800 0.25-1.25 125 419 Generating klin for usimg ofterheat 4.056 4 56 4 2300 0.41-4.07 315 456 klin with prehrater precalcine 4.060 4 60 3.5 2500 0.396-3.96 315 510 klin with prehrater precalcine 4.260 4.2 60 4 2750 0.41-4.07 375 633 klin with prehrater precalcine 4.360 4.3 60 3.5 3200 0.396-3.96 375 583 klin with prehrater precalcine 4.566 4.5 66 3.5 4000 0.41-4.1 560 710.4 klin with prehrater precalcine 4.774 4.7 74 4 4500 0.35-4 630 849 klin with prehrater precalcine 4.874 4.8 74 4 5000 0.396-3.96 630 899 klin with prehrater precalcine 5.074 5 74 4 6000 0.35-4 710 944 klin with prehrater precalcine 5.687 5.6 87 4 8000 Max4.23 800 1265 klin with prehrater precalcine 6.095 6 95 4 10000 Max5 9502 1659 klin with prehrater precalcine
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Cement kiln, just as its name implies, it is known for its capability to deal with cement. It is a device for bedding for dry and wet cement clinker production. Cement kiln can also be widely applied in other sectors like metallurgy, chemical engineering, building refractory, environmental protection, etc. Cement kiln is composed of the barrel, supporting device, a support device with baffle wheels, gearing, active kiln head hood, kiln end sealing device, coal jet pipe device and so on.
Cement rotary kiln turns into micro running under high temperature. The maintain of attachment devices and the level of the thermal system is closely related to cement kilns safety and efficiency. The key points of caring and maintaining gearing are to checking lubrication, running status, dynamic detection and meshing precision between large and small gears. Installation accuracy of supporting device keep rotary kiln safe and smooth. Then, pay attention to the rational distribution of stay wheels bearing weight, layout form of riding wheels, hydraulic gears upstream and downriver pressure and time. The quality of stealing device directly affects the rotary kilns quality of the thermal system and operating cost. In one word, keeping routine maintenance and data analysis benefits the management of devices.
Cement kiln is an important device for the dry and wet cement production line. Cement kiln is mainly formed by barrel, gearing, roller support device, stop wheel support device, kiln lining, kiln tail seal, kiln head hood and fuel plant.
Cement kilns material of internal heating-type directly contacts with flame and smoke. So, the inside wall of kiln is laid by refractory bricks. Head and tail cover lining is made from wear-resisting, casting material. There is a flexible seal between the head and tail-cover and kiln, which prevents a kiln from raising dust and leaking.
Cement kilns material of external heating-type doesnt directly contact with flame and smoke. Heat source exists between heating furnace and kiln, heating material conducting heat through heat resistant steel cylinder wall. The lining of heating furnace is made from refractory fiber, which helps cement kilns energy-saving and cost-reducing.
Cement kiln puts raw material into kiln tail, raw material turning itself into cement clinker after a series of physical and chemical reaction because of kilns tilt placement and its rotary capability. Put cement clinker into the cooling machine after it ejected from kiln head hood. Dry rotary kiln makes the raw material into raw powder, whose water content is less than one percent. The advantage is that it saves more energy than a wet rotary kiln. The disadvantage is that it may happen that ingredient in mixed material is uneven.
Cement kiln turning raw into a slurry, whose water content is from 32 percent to 40 percent. The advantage of a wet rotary kiln is that the good liquidity of slurry makes better evenness leading to a higher quality of clinker.
AGICO is a comprehensive engineering and technology company that integrates cement engineering equipment and general contracting, cement rotary kiln, cement plant design, cement complete equipment export, supply of cement equipment parts, and maintenance of production line. Our technical team mainly comes from domestic first-class design institutes, cement companies, and large professional engineering companies, with very mature cement plant construction, renovation, and expansion experience. There are more than 20 cement plant kiln projects that the company has completed and are under construction, which has been fully affirmed and recognized by the owners.
In terms of supply capacity, we have formed a close strategic partnership with a first-class design institute, which can meet the demand of 10,000 TPD rotary kiln in cement plant and complete sets of cement production line equipment. In addition, we can also provide cement mechanical shaft kilns, dry and wet process cement rotary kilns, and other different types of rotary kilns for cement plants. At present, the companys main cement equipment includes jaw crusher, preheater, cement rotary kiln, grate cooler, cement ball mill, powder separator, dust collector, and supporting electrical control system and related equipment accessories.
It is reported that the Uzbek customer before mainly engaged in oil-related products, due to development needs, began to invest in infrastructure construction. In order to expand the market share and increase profits, it was decided to build a cement plant and purchase a rotary kiln for cement manufacture. Since the project was put into operation in 2019, the entire rotary kiln cement plant has been running well, with a high automation level, convenient equipment operation, and extremely low failure rate.
1. Be familiar with a blueprint of the cement kiln. Comprehend cement rotary kilns concrete parameters, sub-units exact location and basic lines benchmark through the blueprint. Grasp the information about the transport route, working site, tool room, and temporary power supply through the layout chart.
2. Select good cement kiln hoisting equipment and transportation equipment. The device on the cement kiln-production line is generally large size and heavyweight, so the necessary hoisting equipment and transportation equipment should at least be on a broad scale. The selection, usage, maintenance of other tools such as steel wire rope, hemp rope, and the fixture should be in accordance with relevant provision. Fuel, cutter, and welding tools also should be prepared to make sure the success of the installation.
3. Require for professional for cement kiln. Cement rotary kiln has a short construction period and more work high above the ground because process equipment is at height. So, the characteristic of the installation of cement kiln is difficult and dangerous. That requires constructors should have fit bodies, a wide-scale of knowledge, skilled technology, and the ability to adapt to local conditions.
5. Debugging in a cement kiln. After the installation, check whether the technical indicators are qualified or not. Buyers should inspect the whole cement rotary kiln and its subsidiary facilities before any debugging. Details about debugging are below.
Cement rotary kilns refer to cement rotary calcining kilns (sometimes called rotary furnaces). It is a pyroprocessing device used to heat materials to high temperatures in a continuous process. The kiln body is a cylinder vessel with a certain degree of tilt to the horizontal level. Raw materials are fed into the vessel from the upper end and moved to the lower end, being stirred and mixed relying on the inclination and rotation of the kiln. The kiln burner produces a lot of heat by burning fuel. This kind of heat is usually transferred to materials through flame radiation, hot gas convection, kiln brick conduction, etc., which causes the chemical reaction between raw materials and finally forms clinker.
Rotary kilns can be divided into cement kiln, metallurgical and chemical rotary kiln, lime rotary kiln and so on. Cement rotary kilns are used for calcining cement clinker in the cement plant, which can be divided into dry cement kiln and wet cement kiln. Metallurgical and chemical rotary kilns are mainly applied in the metallurgical industry. As for the lime rotary kiln, it is the main equipment for calcining active lime and light burned dolomite used in iron and steel plants, ferroalloy plants, calcium carbide plants, and magnesium metal plants.
The cement rotary kiln is mainly composed of cylinder, supporting device, drive gear, refractory lining, catch-wheel device, kiln head sealing device, kiln tail sealing device, kiln hood, and other components. On the cylinder, there is a large gear ring fixed with a spring plate near the kiln tail, some pinions below are engaged with it, jointly forming the drive gear. In normal operation, the main drive motor will transfer power to this gear device through reducer to run rotary kiln. The raw material usually enters the rotary kiln from the upper end and move slowly to another end along with the chamber as it rotates. In this process, raw materials will be heated by high temperature and then decompose and produce chemical reactions so that their state finally changed. Under normal conditions, the heat source of indirect fired rotary kilns is supplied from the kiln burner outside the kiln. This kind of way protects the integrity of raw materials, while the heat source of the direct-fired rotary kiln is inside the kiln. Besides, the rotation speed and temperature of the cylinder are tightly controlled and changed according to different desire processes and material applications. After the calcination is completed, the clinker will be pre-cooled in the chamber and then be sent into the cooler for further cooling.
AGICO Group is an integrative enterprise group. It is a Chinese company that specialized in manufacturing and exporting cement plants and cement equipment, providing the turnkey project from project design, equipment installation and equipment commissioning to equipment maintenance.