Turnkey Calcination Rotary Kiln Project Cement Clinker Rotary Kiln Furnace

Cost of turnkey calcination rotary kiln project for cement clinker

1.Product Introduction Calcination Rotary Kiln

The Turnkey Cement Clinker Calcination Rotary Kiln Project provides a comprehensive one-stop solution from initial design to final commissioning. The scope includes the rotary kiln shell, preheater, cooler, combustion system, electrical control units, and environmental protection equipment. Systems are customized based on capacity requirements, with typical specifications covering 180 to 10,000 tons per day (tpd), supporting various process routes such as New Suspension Preheater (NSP) dry process or wet process. The project is implemented by a professional engineering team to ensure technical realization and high-efficiency operation.

2.Application Calcination Rotary Kiln

• Cement Manufacturing: Serving as the core "calcination" stage in the "two-grinding and one-firing" process, responsible for the conversion of raw meal into clinker.
• Co-processing: Utilizing high-temperature environments to dispose of hazardous waste and sludge, achieving detoxification and resource recovery.
• Metallurgy & Chemicals: Used for magnetizing roasting of lean iron ores, oxidative roasting of ferrochrome/nickel ores, and calcination of aluminum hydroxide.
• Environmental Engineering: Utilizing the alkaline atmosphere to fix heavy metals and minimize dioxin formation, supporting green production initiatives.

3.Working Principle Calcination Rotary Kiln

• Material Flow: Homogenized raw meal enters the cyclone preheater, where it exchanges heat with high-temperature flue gas from the kiln tail. After partial decomposition, it enters the rotary kiln. The kiln body is inclined (3.5%–6%) and rotates slowly; material moves from the tail to the head, passing through drying, preheating, decomposition, sintering, and cooling stages.

• High-Temperature Calcination: Pulverized coal or gas is injected from the kiln head, creating a flame temperature of 1,700°C–1,800°C. The material partially melts at approximately 1,450°C, forming clinker minerals primarily composed of calcium silicates.

• Heat Recovery: High-temperature clinker enters the grate cooler. Cold air cools the clinker and is then recirculated as "secondary air" back into the kiln to support combustion, significantly boosting thermal efficiency.

• Gas Dynamics: Flue gas exits from the kiln tail and is directed to a Waste Heat Recovery (WHR) boiler for power generation or used for raw material drying, achieving cascaded energy utilization.

4.Advantages Calcination Rotary Kiln

• High Thermal Efficiency: Equipped with five-stage cyclone preheaters or shaft preheaters, the system boasts high heat recovery rates; the dry process energy consumption is significantly lower than the wet process.

• Operational Stability: The kiln body is supported by rollers and guided by thrust rollers to control axial movement. The primary and auxiliary drive systems ensure the kiln continues to rotate slowly during power outages to prevent thermal deformation.

• Environmental Synergy: The alkaline environment fixes acidic gases like $SO_2$ and $Cl$. The long residence time at high temperatures (>35 minutes) ensures thorough decomposition of organic matter, with a Destruction and Removal Efficiency (DRE) of 99.99%.

• Fuel Versatility: Capable of using pulverized coal, natural gas, biomass, or even waste-derived fuels (RDF) to lower operational costs.

• Advanced Automation: Integrated PLC control systems enable precise regulation of temperature, rotational speed, and feed rates, enhancing product quality consistency.

5.Technical Specifications

6.Our Solutions