Plug In Rotary Kiln
Products Description
The plug in rotary kiln is a highly efficient piece of integrated, modular thermal equipment. Its main novelty is the physical and functional integration of the drying and calcination modules through the use of a rigid, sealed insertable connection structure. This equipment was specifically built to maximize the continuous heat treatment process flow in order to address the systematic technical challenges with traditional split systems, including low thermal efficiency, large floor space, difficult installation, and expensive operating and maintenance costs.
This plug in rotary kiln's technological implementation depends on the core subsystem, which is made up of the insertion and intermediate connection sections.
- ● High-precision standard flanges are used in the middle connection section to create a rigid connection with the drying kiln's head cylinder, guaranteeing the system's alignment accuracy and power transmission stability. This design satisfies frequent disassembly and repair requirements for working conditions.
● As a functional extension component, the insertion section creates a high-temperature material gas-lock channel by precisely extending its end into the interior of the rotary calcining kiln's feeding end through a unique high-temperature sealing structure (using a graphite composite seal or a cylinder-compressed fish-scale seal). This construction ensures that the dried materials are continuously and steadily carried to the calcination section in a closed environment while successfully blocking the reverse cross-flow of high-temperature flue gas inside the calcination kiln, greatly decreasing the system's heat loss.
Through modular design, the full plug in rotary kiln system creates a smooth link between the drying and calcination sections, guaranteeing the system's sealing performance and improving equipment operation reliability.
Products Specification
The feeding apparatus feeds the ingredients into the drying kiln cylinder. Through efficient heat exchange with the heating wall surface and direct contact with high-temperature hot air (which can be done in either co-current or counter-current mode), the material inside the cylinder completes the preheating and dehydration process.
The materials are continually raised and dispersed along the cylinder wall, which is outfitted with a specialized material lifting system, creating a consistent material spreading under the combined influence of gravity and the kiln body's rotation. This guarantees the material dries quickly and evenly, dramatically increases the contact area between the material and the heat medium, and greatly improves the efficiency of heat and mass transfer. The kiln tail releases the dehydrated ingredients.
Important process connection
- An inventive insertable sealed connection device transfers the material straight and continuously to the feeding end of the rotary calcination kiln once it has dried. This apparatus successfully stops the thermal system from interfering with high-temperature flue gas from escaping from the calcination kiln.
- The calcination kiln is a rotary cylinder that is slightly inclined and often designed to be 3 to 3.5 percent. The lifting plates incorporated into the kiln wall continuously raise and disperse the ingredients under the cylinder's rotation, creating a compound motion of axial movement and radial rolling that ensures thorough stirring and mixing.
- A steady, high-temperature flame is created at the kiln head by the fuel that the multi-channel burner injects. In order for the material layer in motion to finish physical and chemical reactions (like decomposition, sintering, and crystal phase transformation) within the predetermined temperature curve, heat is primarily transferred to it via three methods: flame radiation, convection of hot flue gas, and conduction of refractory materials.
- After calcination is complete, the final products are released from the discharge port beneath the kiln head cover and go into the cooling system that follows.
Technical parameters
| Parameter Name | Parameter range | Remarks |
| Kiln body diameter | Φ2.5m - Φ6.0m | It can be customized according to requirements |
| Length of the kiln body | 40m - 95m | It can be customized according to requirements |
| Installation slope | 3.5% - 4% | Adjustable |
| Rotational speed range | 0.25 - 5 rpm | Adjustable speed |
| Working temperature | up to 1600°C | Depending on the lining material |
| Output | 180-10000 t/h | It can be customized according to requirements |
| Driving power | Configure according to specifications | Energy-saving design |
| Applicable fuel | Gas, fuel oil, pulverized coal, etc | A variety of burners are available |
Customized service
We understand that each project is different. Consequently, we provide extensive customisation.
- Size customization: Customize the size of the kiln body to fit your space and production capability.
- Material upgrade: We offer unique alloy and refractory material solutions for materials with high levels of corrosiveness and abrasiveness.
- Process compatibility: Your unique process requirements can be taken into account while designing and integrating the combustion system, temperature control system, supporting dust collection, etc.
Products Advantages
The large concrete foundation and separate supporting steel structure needed for traditional split-type kilns are no longer necessary with this plug in rotary kiln's highly integrated one-piece structure, which can save up to 70% on the cost of civil construction and installation foundation. Rapid production capacity combined with a lower initial investment guarantees a faster investment payback period, greatly increasing the project's economic feasibility and resistance to investment risk.
Our plug in rotary kiln's core modules have been pre-assembled and tested in the factory before being sent, significantly lowering the complexity and unpredictability of on-site building. Only module hoisting, positioning, and interface connection remain when the equipment is delivered to the site, which can enable clients take advantage of market possibilities and cut the project construction time by more than 50%.
The plug in rotary kiln's integrated and small design significantly reduces the amount of floor space that the apparatus takes up. Without requiring further site purchase or industrial expansion, it is especially well-suited for technology transformation or capacity growth projects in current factory regions. In the meantime, this design allows for easy and smooth integration into the current production line and allows for flexible tuning of the feeding and discharging directions based on the current process flow.
The main benefits of the rotary kiln process, like consistent material calcination and consistent quality, are carried over into this plug in rotary kiln apparatus. It effectively eliminates heat leakage, has a high system thermal efficiency, and uses a lot less energy to operate than a standard split system thanks to high-performance insulating materials and modern sealing technology.
Our plug in rotary kiln's humanized and modular design makes maintenance simpler. Downtime can be efficiently reduced by the straightforward daily inspection, maintenance, and component replacement procedures. The inventory cost of spare parts and the strain of subsequent procurement have also been greatly decreased by the widely used generic models and standard parts.
Company Profile
why choose our products
AGICO Cement is a professional engineering organization that provides all-inclusive solutions for the global cement market. With decades of experience, we are specialists in cement plant design, equipment manufacturing, spare parts supply, and EPC project contracting.
Increasing energy efficiency, modernizing industrial lines, and constructing new plants are all included in our comprehensive services. We develop a full range of high-performance cement manufacturing equipment and maintain an effective spare parts supply system to ensure operational stability.We are committed to providing sustainable and efficient industrial solutions to our global clientele.
FAQ
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