Gypsum rotary kiln is a mechanical equipment that converts natural gypsum ore into plaster of paris through high-temperature treatment. When the gypsum is heated to 150°C to 160°C in the rotary kiln, the crystallized water evaporates and the gypsum is converted into semi-hydrated gypsum, which is the same as gypsum. The temperature inside the rotary kiln is uniform and the finished product is of high quality. Modern gypsum rotary kilns are equipped with efficient heat recovery systems, which have significant energy saving effects and reduce energy consumption by about 20%. At the same time, the automated control system improves production stability and efficiency.
Efficient Gypsum Calcination Solution
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The gypsum rotary kiln is processed with high-precision CNC machine tools, and the tolerance is controlled within ±0.5 mm to ensure high quality of the components. Use high temperature resistant alloy steel to withstand operating temperatures of 1600°C. The modular design simplifies installation and maintenance, the intelligent control system adjusts production parameters in real time, the heat recovery efficiency is as high as 90%, and the energy saving is significant.
Tongli gypsum rotary kiln adopts automated welding technology to ensure consistent welding quality and high strength. Using high-precision welding equipment, the strength of welded joints usually reaches 420 MPa; through ultrasonic and X-ray inspection after welding, the integrity and reliability of each welded joint are ensured.
Key components of the gypsum rotary kiln, such as the lining, are heated at 1050°C and rapidly cooled. The hardness is increased to HV 600, and the wear resistance is increased by 40%. This heat treatment process significantly improves component durability and toughness, reduces maintenance requirements, and enhances reliability under long-term high-temperature operation.
Tongli gypsum rotary kiln adopts high-precision machining technology to ensure the high quality and precise fit of each component. During the manufacturing process, the processing tolerance of the key components of the kiln body and lining is controlled within ±0.5 mm. This high-precision manufacturing ensures the stability and operating efficiency of the equipment.
xxxxxxx | Capacity (t/h) | Motor Model: | Gearbox Model | Input Moisture (%) | Fuel Coal Calorific Value (kcal) | Output Moisture (%) |
φ1.2x10 | 2.5-3 | M160M-6 → 7.5 | ZQ350Ⅱ-25 | 25±5 | ≥5500 | ≤13 |
φ1.5x14 | 7-9 | Y180L-6 → 15 | ZQ400Ⅱ-31.5 | 25±5 | ≥5500 | ≤13 |
φ1.5x18 | 9.5-12 | Y180L-6 → 15 | ZQ400Ⅱ-31.5 | 27±5 | ≥5500 | ≤13 |
φ1.8x14 | 12-15 | Y200L-6 → 18.5 | ZQ400Ⅱ-31.5 | 25±5 | ≥5500 | ≤13 |
φ1.8x18 | 14-18 | Y200L1-6 → 18.5 | ZQ400Ⅱ-31.5 | 27±5 | ≥5500 | ≤13 |
φ2.0x18 | 18-22 | Y200L2-6 → 22 | ZQ50Ⅱ-31.5 | 25±5 | ≥5500 | ≤13 |
φ2.0x20 | 18-23 | Y200L2-6 → 22 | ZQ50Ⅱ-31.5 | 30±5 | ≥5500 | ≤13 |
φ2.2x18 | 21-25 | Y200L2-6 → 22 | ZQ65Ⅱ-31.5 | 27±5 | ≥5500 | ≤13 |
φ2.2x20 | 22-25 | Y225M-6 → 30 | ZQ65Ⅱ-31.5 | 30±5 | ≥5500 | ≤13 |
φ2.4x20 | 25-29 | Y225M-6 → 30 | ZQ75Ⅱ-31.5 | 27±5 | ≥5500 | ≤13 |
φ2.4x22 | 26-30 | Y225M-6 → 30 | ZQ75Ⅱ-31.5 | 30±5 | ≥5500 | ≤13 |
φ2.6x20 | 28-33 | Y250M-6 → 37 | ZQ85Ⅱ-31.5 | 25±5 | ≥5500 | ≤13 |
φ2.6x24 | 29-35 | Y250M-6 → 37 | ZQ85Ⅱ-31.5 | 30±5 | ≥5500 | ≤13 |
φ3.0x20 | 45-50 | Y280S-6 → 45 | ZQ100Ⅱ-31.5 | 25±5 | ≥5500 | ≤13 |
Gypsum is a widely used mineral consisting mainly of calcium sulfate dihydrate (CaSO₄·2H₂O). Its applications include building materials (such as gypsum board), medicine (such as plaster bandages), and agriculture (such as soil conditioners). Gypsum has a hardness of about 2 (Mohs hardness), which is softer than ordinary stone.
Gypsum rotary kilns are used to calcine natural gypsum into hemihydrate gypsum (CaSO₄·0.5H₂O), a process that is essential for producing high-quality gypsum for construction and industrial use. The main benefits of the calcination process include:
Removal of crystal water: The crystal water (about 20%) in gypsum is removed by heating, converting it into hemihydrate gypsum, which is suitable for further processing. The calcination temperature is controlled in the range of 120°C to 160°C.
Improved physical properties: The calcined hemihydrate gypsum has better workability and stability, and can harden quickly and form a strong material after drying.
Improve production efficiency: The continuous operation mode of the rotary kiln can handle large quantities of gypsum raw materials
Reduce the feed rate of the rotary kiln, reduce the supply of primary air, and increase the kiln body speed to prevent the red kiln phenomenon and kiln body damage. Keep the ingredients stable, ensure the matching of wind, coal and materials, and avoid incorrect operating procedures to reduce the shedding of the kiln skin caused by uneven heating.
Use thermal insulation materials for spraying, use thermal insulation materials made of lightweight hollow microspheres, add anti-cracking fiber chopped strands, and spray with a spray gun to reduce heat loss.
In addition, use thermal insulation materials for insulation, such as silicon plate materials, which have light, heat-insulating and fire-resistant properties, and effectively reduce heat loss. Select high-quality fuels, select coal with good heat energy and less loss, and ensure that the moisture content and particle size of the coal meet the process requirements.
Otherwise, feed accurately and appropriately, control the amount of coal fed, do a good job of sealing everywhere, strengthen management, avoid air leakage, and reduce heat loss.
The kiln head is usually equipped with a sealing device and a burner. The sealing device can effectively prevent heat loss and outside air from entering. Generally, high-quality high-temperature resistant sealing materials are used to ensure that the sealing effect reaches more than 95%. The burner is a key device for providing heat source. The diameter of its nozzle varies according to the specifications of the kiln body. For example, for a rotary kiln with a diameter of about 3 meters, the diameter of the burner nozzle is usually about 0.5 meters.
The sealing device at the end of the kiln is equally important to ensure the stability of the air pressure in the kiln. The supporting wheel device is generally composed of multiple supporting wheels, each of which can be up to about 1 meter in diameter and bears the weight of the rotating cylinder. The wheel blocking device prevents the cylinder from moving up and down, and is usually set at a certain distance. The rotating cylinder is the core component, with a length of up to tens of meters and a diameter ranging from a few meters to more than ten meters according to production needs.
The coal injection pipe device is responsible for accurately injecting fuel, and its length is generally about 2 meters to ensure that the fuel is fully burned. In addition, some gypsum rotary kilns are also equipped with auxiliary equipment such as vertical preheaters and vertical coolers to improve production efficiency.
Improving the production efficiency of gypsum rotary kilns can be achieved in many ways:
Optimize the combustion system: ensure that the burner nozzle is reasonably designed, select high-efficiency fuels, and adjust the ratio of fuel to air to ensure full combustion. A combustion control system can be used to monitor temperature, gas composition and other data in real time to ensure maximum heat utilization.
Use a preheater: Use a preheater to preheat the raw materials before the gypsum enters the rotary kiln. This can reduce the heating burden in the kiln, improve calcination efficiency, and reduce fuel consumption.
Improve the uniformity of raw materials: ensure uniform feeding and consistent particle size to avoid uneven calcination caused by large differences in raw material particle size. Gypsum with uniform particle size can complete calcination faster and more evenly, shortening the production cycle.
Improve kiln design: Choose the appropriate kiln length and diameter, and use lightweight, efficient refractory and insulation materials to reduce heat loss and improve thermal efficiency. Appropriate kiln design can balance production efficiency and energy consumption.
Gypsum is primarily used for producing wallboard and plaster, making it essential in construction and agriculture.
Clay varieties like kaolin, bentonite, and fireclay offer versatility in different industrial applications like ceramics and cement production.
Limestone is used in cement production and acts as a fluxing agent in various industrial processes like steelmaking.
Dolomite, a magnesium-rich limestone, is used in the production of refractory materials and as a flux in steel production.
Fly ash is a byproduct from burning coal, used as a supplementary cementitious material for enhancing concrete properties.
Shale is a sedimentary rock used in brick manufacturing and as a raw material for cement production, offering low thermal expansion.
Bentonite clay is highly absorbent and used in drilling, foundry, and as a binder in various industrial applications.
Slate is used in roofing, flooring, and as a raw material for producing cement and other construction materials.
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