The process of a rotary kiln involves the following steps:
1. Material Feed: The process feedstock is fed into the upper end of the cylindrical vessel of the kiln. This material can be in the form of powders, granulates, suspensions, or green bodies.
2. Rotation: The kiln is inclined slightly from the horizontal and is rotated slowly about its longitudinal axis. The rotation allows the solid reactants to work their way down the tube. The speed and angle of rotation determine the retention time of the material in the kiln.
3. Heating: The material inside the kiln is heated to extremely high temperatures, typically ranging from 800 to 2,200°F. This heating can be achieved through direct contact with a process gas or through indirect heating from outside the kiln. The temperature and retention time are predetermined based on a thorough chemical and thermal analysis.
4. Reaction: As the material moves down the kiln, it may undergo a certain amount of stirring and mixing. The high temperatures in the kiln cause chemical reactions or physical changes to occur in the material. These reactions can include processes such as calcination, thermal desorption, organic combustion, sintering/induration, reduction, heat setting, and more.
5. Gas Flow: Hot gases pass along the kiln, either in the same direction as the material (co-current) or in the opposite direction (counter-current). The gas flow can be generated in an external furnace or by a flame inside the kiln. The gas flow helps to transfer heat to the material and aids in the reaction process.
6. Discharge: The processed material gradually moves down toward the lower end of the kiln. Once the material reaches the desired level of processing, it is discharged from the kiln.
The rotary kiln is a versatile thermal processing equipment used in various industries. Its design and operation can be customized to suit different materials and processes. The components of a rotary kiln include the shell, refractory lining, support tyres (riding rings) and rollers, drive gear, and internal heat exchangers. These components work together to ensure efficient and controlled thermal treatment of the material.
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