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Help CenterRotary Kiln for Lime Cement Plant System 500 Tpd
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1. Introduction
The 500 TPD (Tons Per Day) Rotary Kiln for Lime Cement Plant System is a fully integrated, heavy-duty industrial pyro-processing production line designed for the dual-purpose manufacturing of active quicklime and high-strength cement clinker. Engineered as a complete turnkey system, this 500 TPD configuration bridges the gap between raw quarry extraction and finished binder products. It is uniquely optimized for medium-scale building material plants, steelworks flux lines, and chemical complexes, providing a highly automated, structurally synchronized system that guarantees continuous material flow, exceptional thermal efficiency, and flexible product output.
2. Working Principle
This integrated system operates as a continuous, closed-loop thermal circuit, synchronizing mechanical handling, pre-heating, calcination, and cooling. The systematic workflow follows these automated stages:
System Feeding & Vertical Preheating: Raw limestone or homogenized cement raw meal is transported via bucket elevator to the top of a vertical preheater system. High-temperature exhaust gas ($>900^\circ\text{C}$) from the kiln tail is forced upward through the material bed, preheating the raw stone to around $800^\circ\text{C}$ and achieving up to $30\%$ initial decarbonization before the material even touches the kiln.
Rotary Kiln Calcination: Hydraulic pushers continuously feed the preheated material into the kiln tail of the slightly inclined, slowly rotating cylinder. Driven by a multi-channel burner at the kiln head, the material rolls through distinct thermal zones: it is calcined into highly porous active lime ($CaO$) at $1050^\circ\text{C} - 1200^\circ\text{C}$, or sintered into nodular cement clinker at $1350^\circ\text{C} - 1450^\circ\text{C}$.
Vertical/Grate Cooling: The white-hot product drops directly into a high-efficiency vertical cooler (for lime) or grate cooler (for clinker). Cold air is blown through the material bed, rapidly dropping the product temperature to under $80^\circ\text{C}$ for safe conveyor transport, while the air itself absorbs the heat to become highly energized secondary combustion air ($>600^\circ\text{C}$) for the kiln burner.
Exhaust & Dust Filtration: The cooled, clean exhaust gas passing out of the preheater is routed through a multi-cyclone settling chamber and a pulse-jet baghouse system, removing fine particulates before clean air is discharged via the ID fan.
3. Advantages
Turnkey System Synchronization: Unlike standalone units, this complete plant system ensures that the raw material handling, vertical preheater, rotary kiln, and product cooler are perfectly matched in capacity and speed. This eliminates production bottlenecks, minimizes material handling spillages, and streamlines plant commission times.
Dual-Campaign Market Adaptability: The system offers unparalleled market flexibility. Operators can switch production campaigns between metallurgical active lime and cement clinker on a single equipment line, allowing the plant to adapt to fluctuating seasonal demands and maximize annual return on investment.
High-Activity Soft-Burned Yields: The dynamic, continuous tumbling motion inside the rotary kiln, paired with rapid quenching in the cooler, ensures that every particle is uniformly heat-treated. This prevents over-burning, yielding quicklime with exceptionally high activity ($>360\text{ ml}$ water titration) and cement clinker with ultra-low free lime fractions.
Exceptional Fuel & Thermal Efficiency: By utilizing a high-efficiency vertical preheater at the kiln tail and a rapid-heat-reclamation cooler at the kiln head, the system recycles almost all waste heat. This localized thermal loop drastically reduces fuel consumption, whether firing pulverized coal, natural gas, heavy oil, or alternative biomass.
Zero-Waste Environmental Compliance: Equipped with advanced, multi-layer flexible fish-scale mechanical seals at both the kiln head and tail, and backed by a large-scale pulse-jet bag filter system, the plant achieves a $99.9\%$ particulate recovery rate. This guarantees a clean, dust-free industrial environment that meets strict modern emission standards.
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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