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Rotary Kiln

Rotary kilns are cylindrical, slightly inclined vessels that slowly rotate to move material from the feed end to the discharge end. Hot gases generated inside or outside the kiln heat the material through radiation, conduction, and convection as it moves through the kiln. The kiln is made up of a refractory lined steel shell supported by tyres and rollers, with a burner system and sealing arrangements at the ends. Rotary kilns are used for high-temperature processes like calcination and roasting of ores and other materials.

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Darshan Patel
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475 views7 pages

Rotary Kiln

Rotary kilns are cylindrical, slightly inclined vessels that slowly rotate to move material from the feed end to the discharge end. Hot gases generated inside or outside the kiln heat the material through radiation, conduction, and convection as it moves through the kiln. The kiln is made up of a refractory lined steel shell supported by tyres and rollers, with a burner system and sealing arrangements at the ends. Rotary kilns are used for high-temperature processes like calcination and roasting of ores and other materials.

Uploaded by

Darshan Patel
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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A ROTARY KILN is a Direct Fired, Refractory Lined equipment for high temperature applications

where it is necessary to change the ‘state’ of the material in a continuous process or in batch
type process. Since this process usually requires a long residence time, the length to diameter
ratio is often in excess of 10:1 in a continuous kiln. In most cases an oil or gas burner fires
directly into the discharge end of the unit. The material is heated in three ways - by radiation
from the burner flame, conduction from the refractory lining and convection by contact with
the hot gases. They are also used for roasting a wide variety of ores.

PRINCIPLE

The kiln is a cylindrical vessel, inclined slightly to the horizontal, which is rotated slowly about
its axis. The material to be processed is fed into the upper end of the cylinder. As the kiln
rotates, material gradually moves down towards the lower end, and may undergo a certain
amount of stirring and mixing. Hot gases pass along the kiln, sometimes in the same direction
as the process material (co-current), but usually in the opposite direction (counter-current). The
hot gases may be generated in an external furnace, or may be generated by a flame inside the
kiln. Such a flame is projected from a burner-pipe. The fuel for this may be gas, oil or pulverized
coal. Solids retention time in the kiln is an important factor and is set by proper selection of
diameter, length, speed, slope and the internal design.

CONSTRUCTION

The basic components of a rotary kiln are the


refractory lined shell, support tyres and rollers, drive
gear and burner system. A typical Rotary Kiln is
cylindrical shell, slightly inclined from the horizontal
and supported on two or more tyres, which in rotate
on rollers. One of the tyre is fixed by a set of thrust
rollers to take care of the thrust load during kiln
movement. The drum assembly along with tyres is
rotated by a girth gear/pinion arrangement.

SEALING ARRANGEMENT
To maintain proper control of the volume and the temperature of the gases flowing through
the kiln, it is necessary to limit the leakage of the external cold air in to the kiln where the
rotating shell enter at the feed and discharge hood. Seal rings are provided at both ends
between the hood and shell for this purpose. Various types of seal rings are used which include
spring loaded rubbing type where two finished metal surfaces are in contact under spring
pressure and spring plate type.

TYRES & SUPPORT ROLLERS

Tyres, sometimes called riding rings, usually consist of a single annular


steel casting, machined to a smooth cylindrical surface, which attach
loosely to the kiln shell through wedge arrangements. These require
some ingenuity of design, since the tyre must fit the shell snugly, but
also allow thermal movement. The tyre rides on pairs of steel support
rollers, also machined to a smooth cylindrical surface and set about
half a kiln-diameter apart. The rollers must support the kiln and allow
rotation that is as nearly frictionless as possible. Depend on size and
capacity an additional tyre can be provided with a set of support
rollers. Kilns usually rotate at 0.5 to 2 rpm. The bearings of the support
rollers must be capable of withstanding the large static and live loads involved, and must be
carefully protected from the heat of the kiln and the ingress of dust. In addition to support
rollers, there are usually upper and lower "retaining (or thrust) rollers" bearing against the side
of tyres, that prevent the kiln from slipping off the support rollers.

BEARINGS & DRIVE COMPONENTS

Bearings are uniquely designed for this


application. The most common are the anti-
friction or spherical roller bearings. These
bearings have become standardized and
perform excellently in almost any condition.

Rotary Kilns are normally gear driven through


girth gear mounted over the shell on gear
support base, assembled on a section of the
shell away from the shell end where high temperature is encountered. To compensate the
thermal expansion, the girth gear is mounted on a tangential spring plates attached to the shell.
REFRACTORY LINING

The purpose of the refractory lining is to


insulate the steel shell from the high
temperatures inside the kiln and to
protect it from the corrosive properties of
the process material. It may consist of
refractory bricks or cast refractory
concrete. The refractory selected depends
upon the temperature inside the kiln and
the chemical nature of the material being
processed. Mostly refractory is installed
as solid block to fit in to different areas
tightly in round formation from sliding or falling out. There are many types of bricks in different
composition and have different properties such as insulation value, maximum temperature and
resistance to wear. Areas where brick cannot be used liquid refractor called castables are used
with anchor support. Also provided insulation material under the brick and this extra layer
helps to reduce the heat transfer to the shell. A typical refractory will be capable of maintaining
a temperature drop of 1000°C or more between its hot and cold faces. The shell temperature
needs to be maintained below around 350°C in order to protect the steel from damage and
continuous infrared scanners are used to give early warning of "hot-spots" indicative of
refractory failure.

FIRING SYSTEM

The hot gases may be generated in an external


furnace, Hot Air Generator (HAG), or may be
generated by a flame inside the kiln. Such a flame is
projected from a burner-pipe. The fuel for this may
be gas, oil or pulverized coal. The fuel could be
mixed with air before or in the burner. The flame
temperature is a factor of fuel type, fuel/air ratio
and other burning conditions.
SCRUBBER & DUST COLLECTION

Exhaust gases from an oil fired kiln contain certain


proportion of very fine dust, entrained in the air stream
while in contact with materials being calcined and there may
be undesirable constituents such as sulfur dioxide or
hydrogen chloride. Equipment is installed to scrub these out
before the exhaust gases pass to atmosphere.

A Dust Collector of high efficiency cyclone type is used to


trap the fine dust. Very fine particles which escape the dry
collector may be recovered by means of a wet collector in
the form of a sludge or alternatively by means of Bag Filter.

ROTARY COOLER

ROTARY COOLER is a part of Rotary kiln system used to lower


the temperature of the hot products discharged from the kiln
to a temperature approaching ambient. The Rotary Cooler is
installed beneath the Rotary Kiln and interconnected with the
kiln discharge hood. The construction is similar to Rotary kiln
with a cylindrical shell inclined to the horizontal with tyres,
support rollers, feed hood and driven by girth gear & pinion. A
part of the cooler shell is castable lined to take care of the
shell from the hot discharge.
The Rotary Cooler operates in counter-flow, the hot gases
being substituted by ambient or chilled air, which is in direct
contact with the hot material. For high temperature
applications the material is cooled to a temperature
approaching ambient by continuous water spray over the shell
and operates on the principle of heat transfer through the
rotating cylinder wall which is continuously irrigated by a
series of external water sprays mounted over the unit. The
water is partially evaporated as steam while the excess is
collected from the bottom of the unit and re-circulated. The
material thus cooled is discharged from the other end of the
shell.
ROTARY CARBONISER (KILN) FOR ACTIVATED CARBON UNITS

Rotary carbonisers (kilns) are used in


Activated carbon units for the steam
activation of carbon granules
(charcoal) at a controlled temperature.
The kiln is unique in design with a
spiral wound cooling coil arrangement
fixed over the discharge end of the
shell to lower the product
temperature during the discharge
through cooling coil. The system is
complete with moveable type feed hood for easy maintenance, rubbing type, spring loaded
sealing arrangement at both ends of the carboniser to seal and to control the atmospheric air
entry in to the burning zone through adjustable damper valve provided on the feed hood, Steel
casted girth gear with back-up plate to take-up the expansion during operation, cone at
discharge end for free flow of flue gas through flue gas pipe etc.

APPLICATION

Rotary kilns are used for the calcinations of Titanium dioxide, Illeminate, kaolin, Barium
Carbonate, Magnesium Carbonate, Silica Gel, Lime, Activated Carbon, Vermiculite, Barium
Sulphide, Magnesium Oxide, Petroleum Coke, Clay, Gypsum, Alumina etc.

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