ROTARY KILN

ROTARY KILN

Agenda
 Rotary kiln
 Types of kilns
 Two base and Three base kiln
 Components in kiln
 Kiln Inspection
 Types of kilns
 Shaft kilns (Counter current)
 Annular kilns
 Regenerative kilns
 Rotary kilns
Shaft kiln
 Types of kilns
 Wet process
 Dry process
 Wet Process
Advantages:
 when slurry dried in the kiln, it forms
granular crumble which is ideal for
subsequent heating in kiln.
 Wet process
Disadvantages:
 Larger kiln was used for a given clinker
output.
 When slurry was introduced in the kiln, a
large amount of extra fuel was used in
evaporating the water.
 Rotary kiln
 Rotary kiln is a pyroprocessing device
used to raise material to a high
temperature (calcination) in a continuous
process.
 Slope angle 3.5 to 4 %
 Rotates around 4 rpm
 Calcination
 Calcination is thermal treatment process
applied to ores and other solid materials in
order to bring about a thermal
decomposition, phase transition.
 The chemical reaction is
CaCO3 +heat→ CaO + CO2 (g)
 What really happens in a kiln?
 Evaporating free water, at temperatures up to
100 C
 Removal of adsorbed water in clay materials,
100 to 300 C
 Removal of chemically bound water 450 to 900
 Calcination of carbonate materials 700 to 850 C
 Formation of Ca2SiO2, aluminates and ferrites
800 to1250 C
 Formation of liquid phase melt, >1250 C
 What really happens in a kiln?
(Contd.)
 Formation of Ca3SiiO2 at1330 to 1450 C
 Cooling of clinker to solidify liquid phase
1300 to 1240 C
 Final clinker microstructure frozen in
clinker <1200 C
 Clinker cooled in cooler 1250 – 100 C
 Kiln operational parameters
 Material Residence Time (t):
t = 1.77xLxOxF/(pxDxn)
Where,
t = residence time, min
L= kiln length, meters
p= kiln slope, degrees
D= kiln diameter, meters
n= kiln speed, rpm
O= Angle of repose (40 degrees)
F= Constriction factor
 Kiln operational parameters
 kiln degree of fill
- Range of 5 to 17 percent.
 kiln slope
 ROTARY KILN

Three support kilns

Two support kilns

Three Base kiln
2 Base Kiln
FLS 2-base kiln Dimensions
13 x D inside lining
6.8 x D 3.6 x D
2.3 x D

øD
FLS 3-base kiln
17 x D inside lining
6.4 x D 2xD
1.3 x D 5.3 x D

øD

PR E
 Rotary kiln - Various components
 Kiln shell
 Kiln tyres / live rings
 Tyre supporting blocks/Attachments
 Support rollers
 Support bearings
 Base frames
 Thrust device
 Kiln drive
 Refractory lining
 Lamella seal
ROTARY KILN

Kiln shell
 Kiln shell
 Material – Mild steel
 Thickness- 15 to 30 mm
 Refractory Lining
 To Insulate the steel shell from the high
temperatures inside the kiln.
 To Protect it from the corrosive properties of the
process materials.
 The thickness of lining is up to 180 to 300 mm.
 Maintains temperature drop of 1000 C between
its hot and cold faces.
 The shell temperature is to be maintained below
350 C
 ROTARY KILN

Kiln tyre / Attachment

Tangential tyre suspension
Tangential tyre suspension
 Tangential tyre suspension
Features:
 Low ovality (0.15%)
 Longer lining life
 No risk for kiln shell constrictions
 No wear between tyre and kiln shell
Self aligning kiln supports
Self aligning kiln supports
Self aligning kiln supports
(Traditional supports)
Self aligning kiln supports
 Self aligning supports
 Ensures equal load distribution across the
full width of the supporting rollers and the
tyres.
 Capable of withstanding higher specific
loads.
 Designed for the pressure of 550 N/mm2
compared with pressure of 440 N/mm2 for
traditional supports.
ROTAX – 2 kiln drive
(Friction drive)
Hydraulic friction drive
Electro- Mechanical friction drive
Friction drive
Girth gear drive
Kiln drive station
Kiln outlet lamella seal
Kiln outlet lamella seal
Kiln inlet lamella seal
Kiln inlet lamella seal
 ROTAX-2 Vs Three base kilns
 Kiln shell – Same as that of three base
kilns less one support
 Tyre supporting blocks – Tangentially
fixed in the shell
 Support rollers – Same as that of three
base kiln except the drive rollers for the
kiln drive
 Support bearings – same as that of three
base kiln
 ROTAX-2 Vs Three base kilns
 Base frames – Self-aligning supports
 Kiln foundation – Only two piers
 Kiln drive – Drive through supporting rollers
 Refractory lining – Similar to three base kilns
 Advantages of 2-Base kilns
Lower investment cost
Lower maintenance cost
Lower operating cost
 Kiln Inspection
 Kiln Axis
 Kiln shell ovality
 Axial balance
 Kiln crank
 Kiln drive
 Kiln shell profile Analysis
 Benefits
 Increases the life time of refractory lining
and expensive kiln components
 Reduces the risk of unscheduled
stoppages
Thank you