Rotary Kiln

High quality clay rotary kiln manufacturer

The clay rotary kiln is an industrial equipment used to calcine clay materials. It is usually 30 to 150 meters long and 2.5 to 6 meters in diameter. The kiln body rotates at a speed of 0.5 to 2 rpm and is inclined at 2.5° to 4°. The temperature inside the kiln is between 1000°C and 1300°C, and the heat source is provided by burning natural gas, coal or heavy oil. The production capacity of Tongli clay rotary kiln is 30 to 150tph, the fuel consumption is 400 to 600 kg of standard coal per ton, and the electricity consumption is 30 to 50 kWh per ton. The initial investment in building a clay rotary kiln production line is about 5 million to 20 million US dollars.

tongli heavy machinery clay rotary kiln main picture

TONGLI Clay rotary kiln

A MACHINE YOU CAN DEPEND ON!

Clay rotary kiln is widely used in the production of building materials due to its high efficiency and energy saving. The clay is heated to 1000-1400℃ by rotating the cylinder to produce high-quality clay bricks or ceramic products. Compared with traditional kilns, the fuel consumption of clay rotary kiln is reduced by about 15% and the production efficiency is increased by 20%. In addition, the automatic control system of the rotary kiln makes the product quality more stable and the operation easier.

High Utilization Rate of Raw Materials

Tongli clay rotary kiln increases raw material utilization by about 10%-15% and reduces losses through precise heating and uniform mixing. The heat recovery system reduces heat loss by 20% and reduces waste. Compared with traditional kilns, the waste of rotary kilns is reduced by about 15%, significantly improving the efficiency of raw material utilization and the economy of production.

High Temperature Stability

Tongli clay rotary kiln exhibits excellent stability in high-temperature environments and can stably withstand temperatures up to 1400°C, with temperature fluctuations of only ±5°C. Using high-temperature resistant materials, its thermal efficiency remains above 90% after 1,000 hours of operation, which is 20% higher than traditional kilns. In addition, its failure rate is about 30% lower than that of traditional kiln

High Production Efficiency

The production efficiency of Tongli clay rotary kiln increased by 20%, mainly due to its continuous production capacity, optimized heat energy utilization and shortened heating time. The high-efficiency heat recovery system increases the heat energy utilization rate by about 20%, shortening the heating time from traditional hours to a few hours. In addition, automated control systems ensure a stable and consistent production process, reducing manual intervention and errors.

xxxxxxxCapacity (t/h)Motor Model:Gearbox ModelInput Moisture (%)Fuel Coal Calorific Value (kcal)Output Moisture (%)
φ1.2x102.5-3M160M-6 → 7.5ZQ350Ⅱ-2525±5≥5500≤13
φ1.5x147-9Y180L-6 → 15ZQ400Ⅱ-31.525±5≥5500≤13
φ1.5x189.5-12Y180L-6 → 15ZQ400Ⅱ-31.527±5≥5500≤13
φ1.8x1412-15Y200L-6 → 18.5ZQ400Ⅱ-31.525±5≥5500≤13
φ1.8x1814-18Y200L1-6 → 18.5ZQ400Ⅱ-31.527±5≥5500≤13
φ2.0x1818-22Y200L2-6 → 22ZQ50Ⅱ-31.525±5≥5500≤13
φ2.0x2018-23Y200L2-6 → 22ZQ50Ⅱ-31.530±5≥5500≤13
φ2.2x1821-25Y200L2-6 → 22ZQ65Ⅱ-31.527±5≥5500≤13
φ2.2x2022-25Y225M-6 → 30ZQ65Ⅱ-31.530±5≥5500≤13
φ2.4x2025-29Y225M-6 → 30ZQ75Ⅱ-31.527±5≥5500≤13
φ2.4x2226-30Y225M-6 → 30ZQ75Ⅱ-31.530±5≥5500≤13
φ2.6x2028-33Y250M-6 → 37ZQ85Ⅱ-31.525±5≥5500≤13
φ2.6x2429-35Y250M-6 → 37ZQ85Ⅱ-31.530±5≥5500≤13
φ3.0x2045-50Y280S-6 → 45ZQ100Ⅱ-31.525±5≥5500≤13

FAQ

1. How long is the production cycle of a clay rotary kiln?

The production cycle of a clay rotary kiln refers to the time required for the material to be heated and sintered in the kiln, which is affected by many factors. Generally, the production cycle of a clay rotary kiln depends on factors such as the type of material, processing temperature, material particle size and kiln design.

For clay bricks, it is usually necessary to sinter at a temperature of 1000°C to 1200°C, and the production cycle is about 24 to 48 hours. Ceramic materials require higher processing temperatures (usually between 1200°C and 1400°C), and their production cycle is generally 36 to 72 hours.

The higher the processing temperature, the longer the sintering time is generally. The particle size of the material will also affect the production cycle. Fine-grained clay materials can usually be sintered in a shorter time, generally 12 to 24 hours, while coarse-grained materials may take longer. The design of the kiln is also crucial. When a larger rotary kiln (such as Φ4.0×60) processes high-temperature ceramics, the production cycle may be as long as 48 hours; while a kiln that processes large quantities of materials (such as Φ6.0×95) may take 72 hours to ensure uniform sintering and high-quality output of the materials.

2.What are the main components of a clay rotary kiln?

The clay rotary kiln is mainly composed of several key components. The kiln body is the core part, and its diameter and length directly affect the processing capacity. The inside of the kiln body is coated with a refractory lining to withstand high temperatures. The kiln head and kiln tail are used for material feeding and discharging, respectively, and are equipped with sealing devices to prevent gas leakage, and temperature and pressure monitoring equipment are also provided.

The burner is used to heat the material inside the kiln body. Different fuel types such as natural gas, coal or heavy oil will affect the design of the burner. For example, a Φ3.0×45 rotary kiln may use coal as fuel, while a Φ4.5×66 rotary kiln may use natural gas to improve combustion efficiency. The cooling system is responsible for quickly reducing the temperature of the material in the kiln body to prevent overheating from affecting product quality. Large rotary kilns such as Φ6.0×95 are usually equipped with efficient cooling systems to meet the needs of rapid cooling.

The transmission device is used to drive the rotary motion of the rotary kiln, including motors, reducers and gear systems. A Φ3.0×60 rotary kiln may require a motor power of 100 kilowatts, while a Φ5.6×87 rotary kiln requires a motor power of 800 kilowatts, which affects the rotation speed and stability of the kiln body. The control system is used to monitor and adjust the operating status of the rotary kiln, including temperature, pressure, speed and fuel supply. Tongli rotary kilns are usually equipped with automated control systems to improve operational accuracy and efficiency.

3. What is clay and why is it necessary to calcine in a rotary kiln?

Clay is a natural material composed of fine mineral particles, mainly containing aluminum silicate minerals such as kaolin, montmorillonite, and illite. Its characteristics include plasticity, formability, and the ability to solidify after drying. It is widely used in the construction and ceramic industries, such as bricks, ceramic products, and flower pots.

4. Why is rotary kiln calcination needed?

Rotary kiln calcination is critical to clay for several reasons: Improved strength and durability: Calcinated clay bricks can reach a strength of 20-30 MPa, compared to the uncalcined raw material, which is typically less than 5 MPa. Chemical reactions during the calcination process form a hard crystalline structure, which improves the strength and durability of the product.

Improved physical properties: Ceramic products calcined at 1200°C can reduce water absorption to less than 5%, while uncalcined ceramics generally absorb water between 15% and 20%. Calcination removes water and organic matter from the clay, increasing the product's density and water resistance. Improved chemical stability: During the calcination process, the aluminosilicate minerals in the clay are transformed into more stable mineral phases, such as mullite and corundum, which are more chemically stable at high temperatures. For example, the chemical stability of calcined kaolin is about 30% higher than that of untreated kaolin.

5. How does calcination improve the chemical stability of clay?

The calcination process significantly improves the chemical stability of clay. This process transforms the aluminum silicate minerals in the clay into more stable mineral phases, such as mullite and corundum, by heating at high temperatures. Mullite and corundum have excellent chemical stability at high temperatures, and their acid and alkali resistance is significantly enhanced. Data show that the chemical stability of calcined kaolin is about 30% higher than that of untreated kaolin.

For example, uncalcined kaolin may degrade in an acidic environment, while calcined kaolin can maintain better stability and durability under the same conditions. During the calcination process, harmful impurities and organic matter in the clay are removed, making the final product show higher corrosion resistance and long-term stability in use. These improvements make calcined clay suitable for applications requiring high chemical stability, such as high-temperature ceramics and refractories.

6. What are the practical applications of calcined clay products?

Calcinated clay products are widely used in many fields due to their improved physical and chemical properties. First, in the construction industry, calcined clay is made into bricks and tiles for building structures and wall materials. For example, the strength of calcined clay bricks is increased to 20-30 MPa, making them suitable for load-bearing walls and exterior walls.

Secondly, in the ceramic industry, calcined clay is used to produce high-quality ceramic products such as porcelain, pottery and sanitary ceramics. The water absorption of ceramics calcined at a high temperature of 1200°C is reduced to less than 5%, ensuring the waterproof performance and durability of the product.

In addition, calcined clay is also used to manufacture refractory materials such as furnace linings and linings of industrial kilns, which can remain stable at high temperatures and withstand extreme conditions. In summary, calcined clay products are widely used in many fields such as construction, ceramics and refractory materials due to their superior strength, stability and durability.

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