الافران الحرارية الدوارة لانتاج الكربون النشط والاسمنت والجير والبيلليت

ROTARY KILN

How Rotary Kilns Work

Rotary kilns are used to heat solids to the point where a chemical reaction or physical change takes place
.
They work by holding the material to be processed at a specified temperature for a precise amount of time
.
Temperatures and retention times are determined through creating temperature profiles, based on thorough chemical and thermal analyses of the material

A rotary kiln is comprised of a rotating cylinder (called the drum), sized specifically to meet the temperature and retention time requirements of the material to be processed
.
The kiln is set at a slight angle, in order to allow gravity to assist in moving material through the rotating cylinder

Rotary kilns can be either of

the direct-fired type
,
or

the indirect-fired type (sometimes referred to as a calciner)
.
In a direct-fired kiln
,
a process gas is fed through the drum, processing the material via direct contact.
In an indirect-fired kiln
,
material is processed in an inert environment,
and is heated through contact with the shell of the kiln, which is heated from the outside to maintain an inert environment

Rotary Kiln Construction



indirect-fired kiln

A variety of drive assembly arrangements are available: chain
sprocket
,
gear drive
,
friction drive
,
direct drive assembly

THE COMPONENTS

Chain & Sprocket
:
A chain and sprocket arrangement works much like a bicycle;
there is a large sprocket wrapping around the rotary drum with a chain on it that goes to the reducer and motor
.
The spinning motor turns a gear box, which spins a small sprocket that is attached by the chain to the large sprocket wrapping around the rotary drum
.
Chain and sprocket drive setups are reserved for small rotary kilns, running up to 75 horsepower
.
This type of arrangement is not suitable for larger kilns running above 75 horsepower, but is ideal for smaller jobs, as it is cost-effective, and easy to run

Gear Drive

:
The gear drive is best for heavy-duty applications running above 75 horsepower.
Similar to the chain and sprocket drive, instead of a sprocket wrapped around the girth of the drum
,
this drive has an actual gear around the drum
.
This gear meshes with a small gear drive, which rotates it.
This type of drive is more costly, but operates and wears better in heavy-duty applications

Friction Drive

Friction drive assemblies are reserved for small applications requiring low horsepower.
This is commonly seen with drums around 6’ and under
.
With a friction drive, two of the four trunnion wheels are connected by one shaft and driven by a shaft mounted reducer and motor arrangement

Direct Drive

Direct drive assemblies are used in small to medium sized drums, with motors up to 75 horsepower
.
In this design, a shaft is mounted to a solid, discharge end plate at the outlet of the kiln.
The motor and reducer are either directly connected to this shaft with a coupling, or a shaft mount arrangement



Riding Rings

The riding rings provide a surface for the kiln load to be distributed

Thrust Rollers

Thrust rollers prevent the drum from drifting or moving horizontally by pushing against the riding rings

Trunnion Wheels

The trunnion wheels act as the cradle for the rotating drum shell
.
They ensure smooth and concentric rotation during operation.
They also act as a wear piece, because they are easier and less costly to replace than the riding ring itself
.
The wheels are mounted to steel support bases with sealed roller bearings.
Support rollers bear the weight of the drum

Discharge Breeching

The discharge breeching serves two purposes
:
one purpose is to provide a place for product to exit the kiln, so it can move on to subsequent processing
;
the second purpose is to mount the kiln burner in a counter-current system




Product Discharge

The product discharge area is where product exits the kiln
.
Typically, the product will then move on to cooling or subsequent processing if needed

Exhaust Gas System

The exhaust gas system is typically much larger when working with a direct-fired kiln.
Here, exhaust gases and any small particulates exit the system and typically go through exhaust gas treatment to remove contaminants before being discharged into the environment.
The exhaust gas system on a kiln often requires an afterburner and heat exchanger or quench tower to cool the gases before they enter the bag filter

Refractory

Refractory serves the purpose of insulating and protecting the shell of the drum from the high temperatures within, and also minimizing heat loss
.
Many types of refractory are available, and refractory layers can be customized to suit the unique application
.
Burner

The burner of a rotary kiln supplies the energy required by the process.
Instead of utilizing a combustion chamber, typically the burner on a kiln is mounted on the discharge end housing

Burners can be designed to accommodate a variety of fuel sources, from natural gas, to propane, diesel, and other common fuel sources
.
Choosing the appropriate burner for a rotary kiln is integral to ensuring efficient processing

Raw Material Feed

The raw material feed, or feed chute, is where feedstock enters the drum.
This is typically carried out using a feed screw or chute and is often made from a more heat-resistant alloy
.
This area must be designed to be robust and to lessen the opportunity for build-up to occur

Air Seal

The seal connects the stationary breeching to the rotating drum, and helps to prevent the escape of process gas from the system, as well as prevents air from leaking in
.
Holding the appropriate temperature within a rotary kiln is what allows the desired chemical reaction to occur
.
Sustaining that temperature, however, can be difficult if the right seal is not chosen
.
Shell

Direct-fired kilns are typically made out of carbon steel.
Indirect-fired kilns, however, must be more resistant to high temperatures, and are therefore made out of a more heat-resistant alloy

List

Procedures

Equipment List

Equipment component list

Specification

Unit

Quantity

Origin


1 Stock Tank 5CBM set 1




daily totally capacity wood activated cabron 5MT /DAY.

monthly capacity 150MT.

based on ASTM Iodine value 1000mg/g,MB value 190ml/0.1g

daily totally need wood charcoal 18-20MT.


24hour running .

totally need workers 3 people per shift ,per day 2 or 3shift.

water consumption : 30-40MT per day .


Rotary Main body system


100MT

Loading :1*40 OT container

1.Weight bridge


Raw material storage

16 meter long 1

1.
Project design: wood charcoal based AC will be around 5MT per day. Monthly 150MT
wood charcoal To Activated Carbon Rotary Kiln Factory Project
2.Rotary kiln line

6.
Feeding Equpment
2 Declining feeding Bucket elevator set 1
3
Feeding speed quantity control equipment
set 1
4 Blower with motor set 2KW set 1
5 air flow mete 1000-7000CBM/H set 2
6 Operation platform 4sqm set 1
7
Cylinder body Manganese steel code:345r min 18mm thickness
2.5m. Dia. X 18m pc 1
8 Belting leather 2.9M pc 2
9 towing launch pc 4
10 Base for towing launch pc 2
11 gear ring cast steel code:235b 3.3m pc 1
12 Front seal cover
Manganese steel code:345r
pc 1
13 Back seal pc 1
14 connection elbow for boiler pc 1
15 Fire-resistant graphite gaskets pc 10
16 Insulating Firebrick high AL type ton 15
17 Hard Firebrick about 15000pcs ton 50
18
Fire cement,fire mud and filling materials
bags 10
19 decelerator RATE:59：1, 450# RATE:59：1 set 1
20 small gear pc 1
21 speed regulator 11KW set 1
22 Steam jet stainless 310S pc 400
23 Steam pipe stainless 310S ø40、ø50、ø25 ton 1
24 High temperature ruber pipe ø40、ø50、ø25 pc 450
25 valves and fittings ø40、ø50、ø25 pc 50
26 fireresistant S.S pipe ø30、ø50 KG 500
27 fireresistant S.S sheet δ4 KG 200
28 pressure meter 0.8Mpa pc 20
29 revolving joint ø50 pc 2
30 Raw AC output Tank
Manganese steel code:345r 50*50*50cm
pc 1
31 Screw Cooling Discharger pc 1
32 Rotary water cooling machine
dia=80cm ,longth=3meter
set 1
33 thermocouple 1200oC pc 10
34 wireless temperature pickup set 3
35
Fireresistant temperature correction wire
m 100
36 Steam boiler
capacity 2MT，pressure 0.6Mpa
set 1
37 Pre-heating water tank 3CBM set 1
38 Draft fan & Motor 7.5KW set 1
39 Water softting System
rate:4ton/hour dia0.5*1.3(h)m
set 1
40 Suppling Pump 5.5KW set 2
41 Steam-distributing cylinder set 1
42 valves and fittings set 1