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Help CenterRotary Kiln for Phosphate Rock Calcination 500 Tpd
Product Spotlights
Integrated high-efficiency heat exchange and waste heat recovery system fully utilizes exhaust gas heat to preheat feed, significantly reducing coal or gas consumption per unit product, directly lowering production costs.
Strong Adaptability
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1. Introduction
The 500 TPD (Tons Per Day) Rotary Kiln for Phosphate Rock Calcination is a high-capacity, heavy-duty pyro-processing system specifically engineered for the high-temperature thermal treatment of raw phosphate ore. With a robust daily output of 500 tons, this system is a critical asset for the global fertilizer industry, phosphoric acid production plants, and elemental phosphorus chemical complexes. Its primary function is to subject raw phosphate rock to intense thermal treatment, driving off organic impurities, decomposing carbonate fractions, and altering the mineral structure. This crucial process enriches the $P_2O_5$ concentration and significantly improves the rock's reactivity for downstream chemical processing.
2. Working Principle
The calcination of phosphate rock inside the rotary kiln is a continuous, high-temperature thermal process based on an optimized counter-current heat flow design to maximize heat transfer efficiency. The system operates through the following sequential stages:
Material Feeding: Crushed and sized phosphate rock is continuously and metered into the kiln tail (the elevated, cooler end of the slightly inclined, slowly rotating steel cylinder).
Preheating and Devolatilization: As the kiln rotates, internal refractory lifters cascade the phosphate rock through the oncoming hot flue gases. In this zone, residual moisture is evaporated, and organic matter within the rock begins to burn off as temperatures rise.
High-Temperature Calcination: The material enters the primary calcination zone (kiln head area), where it is subjected to temperatures ranging between $900^\circ\text{C}$ and $1100^\circ\text{C}$ driven by a high-momentum multi-fuel burner. This intense heat completely decomposes carbonates into oxides, releases carbon dioxide ($CO_2$), and restructures the phosphate minerals to make them highly soluble and reactive for acidulation.
Cooling & Product Discharge: The red-hot calcined phosphate rock drops from the kiln head into a heavy-duty rotary or grate cooler. Direct or indirect air cooling rapidly lowers the material's temperature, recycling the heated air back into the kiln as secondary combustion air to optimize thermal efficiency.
3. Advantages
High-Throughput Process Optimization: The 500 TPD configuration is a heavy-industry benchmark, engineered to handle large-scale, continuous 24/7 operations. It provides fertilizer manufacturers with a steady, reliable stream of high-purity raw materials required to sustain massive downstream production lines.
Enhanced $P_2O_5$ Recovery and Grade: The continuous tumbling motion ensures that every ore particle undergoes uniform thermal decomposition. This eliminates under-calcined cores, completely removes organic carbon impurities that cause foaming during acid digestion, and maximizes the grade and recovery rate of $P_2O_5$.
Advanced Multi-Fuel Combustion Flexibility: Equipped with a state-of-the-art burner assembly, the system can seamlessly utilize various fuel sources—including pulverized coal, heavy oil, or natural gas—allowing plant operators to adapt to local energy markets and minimize fuel costs.
Maximum Heat Integration: The system captures high-temperature secondary air from the cooling stage and recirculates it to feed the burner. Combined with utilizing the kiln tail's exhaust gases for ore pre-drying, this layout delivers class-leading thermal efficiency and drastically reduces fuel overheads.
Heavy-Duty Structural Reliability and Sealing: Designed to withstand extreme internal temperatures, the kiln features high-tensile steel construction, custom-formulated refractory linings, and premium mechanical fish-scale seals at both ends. This guarantees zero material leakage, low shell distortion, and exceptionally long service lifespans under demanding conditions.
Technical parameters
Model |
Speed (r/min) |
Inclination (%) |
Capacity (t/h) |
Gearbox Model |
Ratio |
Motor Model |
Motor Power (kW) |
Motor Speed (r/min) |
Thrust Roller Type |
Support Count |
Weight (t) |
Φ1.9/1.6x36 |
0.53-1.59 |
4 |
2.5-3 |
JZQ750-1 |
48.58 |
JZT-72-4 |
30 |
1200/400 |
Mechanical |
3 |
53 |
Φ2.1/1.8x36 |
0.5-1.51 |
4 |
4 |
UT2-110 |
163.38 |
JZS-81 |
30/10 |
1410/470 |
-- |
3 |
75 |
Φ1.2x25 |
0.5-1.6 |
3 |
-- |
PM650 |
40.17 |
JZTY71-4 |
22 |
1200/120 |
-- |
3 |
34 |
Φ1.6x32 |
0.158-0.258 |
3 |
-- |
PM750 |
48.57 |
JZJY61-4 |
15 |
1200/120 |
-- |
3 |
46.82 |
Φ1.8x45 |
0.66-1.98 |
4 |
3.5 |
UT2-110 |
163.38 |
JZS-81 |
30/10 |
1410/470 |
-- |
3 |
80 |
Φ2.2x50 |
0.125-1.25 |
3.5 |
4 |
ZS145-11 |
157 |
YCT280-4A |
30 |
1320/132 |
-- |
3 |
130.7 |
Φ2.5x50 |
0.516-1.549 |
3.5 |
5.5 |
ZS165-7 |
99.96 |
YCT355-4A |
55 |
1320/440 |
-- |
3 |
167.5 |
Φ3x48 |
0.3309-3.309 |
3.5 |
35 |
ZL130-14 |
32.11 |
ZSN4-250-21B |
90 |
1000/100 |
-- |
3 |
237 |
Φ3.2x50 |
0.398-3.975 |
3.5 |
50 |
ZL130-16 |
40.85 |
ZSN4-280-11B |
190 |
1500/150 |
-- |
3 |
263 |
Φ3.3x52 |
0.391-3.91 |
3.5 |
50 |
ZSY500-28 |
27.707 |
ZSN4-315-082 |
190 |
1000/100 |
-- |
3 |
280.8 |
Φ4x60 |
0.396-3.96 |
3.5 |
104 |
ZSY630-35.5 |
34.601 |
ZSN4-355-092 |
315 |
1000/100 |
Hydraulic |
3 |
487.5 |
Φ4.2x60 |
0.4165-4.165 |
3.5 |
116 |
ZSY710-35.5 |
35.526 |
ZSN4-355-12 |
420 |
1000/100 |
-- |
3 |
576.1 |
Φ4.3x62 |
0.398-3.98 |
3.5 |
125 |
ZSY710-35.5 |
35.714 |
ZSN4-355-12 |
420 |
1000/100 |
-- |
3 |
598.5 |
Φ4.8x74 |
0.35-4 |
4 |
208 |
JH710C-SW305-40 |
42.226 |
ZSN4-400-092 |
630 |
1500/130 |
-- |
3 |
841 |
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