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Help CenterRotary Kiln for Ceramic Material Calcination 200 Tpd
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1. Introduction
The 200 TPD (Tons Per Day) Rotary Kiln for Ceramic Material Calcination is an advanced, high-precision thermal processing system designed for the calcination, sintering, and phase modification of advanced ceramic raw materials (such as bauxite, kaolin clay, alumina, proppants, and synthetic ceramic bodies). With a daily output of 200 tons, this system serves as a crucial production asset for the technical ceramics, refractories, aerospace, and metallurgy industries. Its primary function is to subject raw ceramic minerals to uniform high-temperature profiles, driving off structural moisture, inducing ideal mineral phase alterations (e.g., converting kaolin into mullite), and achieving precise densification and high mechanical strength in the fired grains.
2. Working Principle
The calcination of ceramic materials inside the rotary kiln is a continuous pyro-processing method that utilizes an optimized counter-current heat flow design to ensure slow, controlled thermal ramping and maximum structural stability. The system operates through the following sequential stages:
Material Feeding: Raw, pelleted, or crushed ceramic minerals are continuously and precisely metered into the kiln tail (the elevated, cooler end of the slightly inclined, slowly rotating cylinder).
Drying and Dehydration: As the kiln rotates, specialized internal refractory lifters gently cascade the material through the oncoming hot air stream. In this zone, surface moisture and chemically bound structural water are thoroughly evaporated without shocking the grains.
High-Temperature Calcination & Sintering: The material moves slowly into the primary calcination zone at the kiln head, where a high-momentum burner creates an intense thermal environment ranging between $1100^\circ\text{C}$ and $1450^\circ\text{C}$. Under this precise heat, the ceramic particles undergo solid-state chemical reactions and grain-boundary sintering. This eliminates porous microstructures, increases material density, and locks in the desired crystalline phase.
Cooling & Product Discharge: The white-hot calcined ceramic aggregates drop from the kiln head into a high-efficiency rotary or grate cooler. Rapid, controlled air cooling quickly lowers the product temperature to prevent thermal cracking, while reclaiming the ambient heat as secondary combustion air for the kiln.
3. Advantages
Flawless Phase Control and Crystal Uniformity: Advanced automation systems and multi-stage fuel-air ratio controls allow operators to maintain a tight temperature profile within $\pm5^\circ\text{C}$ across the sintering zone. This ensures uniform phase conversion, eliminating under-fired cores and over-sintered glassy phases to yield highly consistent ceramic products.
Optimized Capacity for Custom & High-End Formulations: The 200 TPD throughput capacity provides the ideal "sweet spot" for technical ceramic and refractory manufacturers. It offers excellent operational flexibility to run distinct batches of high-purity material or specialized formulations without the massive operational overhead of larger systems.
Abrasion-Resistant and Ultra-High Refractory Lining: Ceramic materials are highly abrasive and require extreme heat. The kiln shell is lined with custom-formulated, high-purity corundum-mullite or high-alumina bricks capable of withstanding continuous $1450^\circ\text{C}$ operation while fiercely resisting mechanical wear and chemical attack.
Superior Fuel Economy and Thermal Loop Integration: The kiln utilizes a highly self-sustaining thermal design. High-temperature exhaust gas from the kiln tail is redirected to a pre-drying flash system, while heat from the cooler feeds the primary burner. This localized loop cuts external fuel consumption (natural gas, liquefied gas, or oil) by up to $20\%$.
Robust Sealing and Dust-Free Operation: Fine ceramic powders pose strict environmental and mechanical wear hazards. The kiln integrates heavy-duty, flexible mechanical fish-scale seals at both ends, backed by a pulse-jet baghouse system. This guarantees a $99.9\%$ fine particulate recovery rate, preventing material waste and ensuring compliance with clean emissions regulations.
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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