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Help CenterRotary Kiln for Nickel Slag Recycling 500 Tpd
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Product Introduction
The 500 TPD (Tons Per Day) Nickel Slag Recycling Rotary Kiln is a cutting-edge, heavy-duty industrial pyrometallurgical system designed for the sustainable recovery of valuable metals from nickel smelting by-products. Nickel slag contains significant amounts of residual nickel, cobalt, and high-grade iron oxides, making it a highly lucrative source for resource reclamation.
This 500 TPD rotary kiln system is specifically engineered for reduction roasting, sulfidizing modification, or magnetic separation pre-treatment of nickel slag. By subjecting the slag to controlled high-temperature processing, the kiln enables metallurgical plants to extract precious ferronickel alloys and iron concentrates, transforming industrial environmental liabilities into high-value raw materials.
Working Principle
The operation of the 500 TPD nickel slag recycling rotary kiln relies on high-temperature phase reconstruction and localized reduction chemistry:
Material Blending and Feeding: Sized nickel slag is mixed with targeted reducing agents (such as pulverized coal or petroleum coke) and necessary fluxing materials. This blended mixture is continuously and uniformly fed into the kiln from the higher end, known as the kiln tail.
Tumbling and Thermodynamic Transport: The kiln shell is installed at an incline of 3.5 percent to 4 percent and rotates slowly under the power of a variable-frequency drive. As the kiln turns, the dense nickel slag mixture tumbles along the refractory lining, ensuring maximum exposure to the counter-current hot gases while gravity slowly advances the material toward the lower end, known as the kiln head.
Reduction and Phase Aggregation: Advanced multi-fuel burners at the kiln head generate an intense heating zone, maintaining internal process temperatures between 1150 and 1350 degrees Celsius. Inside this highly controlled reducing atmosphere, the nickel and iron oxides embedded in the slag silicate matrix are reduced. The microscopic nickel and iron particles aggregate and grow into larger, distinct metallic grains.
Discharge and Downstream Recovery: The thermally treated slag mixture is discharged from the lower end of the kiln and directed into a cooling system. After cooling, the modified slag undergoes crushing, grinding, and multi-stage magnetic separation or flotation to cleanly separate the valuable ferronickel concentrate from the final inert tailings.
Product Features
High Metallurgical Recovery Rate: The kiln provides an exceptionally stable and uniform thermal environment. This optimal heat distribution ensures high metallization rates, maximizing the transformation of bound nickel and iron into easily recoverable magnetic phases.
Advanced Resistance to Molten Slag Chemical Attack: Nickel slag typically has a high iron-to-silica ratio, making it highly corrosive to equipment linings at elevated temperatures. The interior of this kiln utilizes premium-grade, chemically inert magnesia-chrome or chrome-alumina refractory brick linings designed to withstand aggressive liquid slag erosion and thermal shock.
Precise Atmospheric Controls for Reducing Environments: To prevent over-reduction or premature melting of the slag, the system features sophisticated air-to-fuel ratio controls and secondary air injection ports. This allows operators to maintain the exact reducing atmosphere required for efficient metal grain growth.
Heavy Duty Mechanical Design: Given the high bulk density and abrasive nature of nickel slag, the kiln is engineered with massive structural margins. It features forged alloy steel riding rings, heavy dual-roller support assemblies, and a high-torque main drive system equipped with an auxiliary backup drive to handle heavy loads safely.
Excellent Environmental Compliance and Sealing: The processing of nickel slag can release sulfurous gases and fine particulate matter. The kiln head and tail are equipped with advanced double-enclosed scale or labyrinth seals to completely prevent fugitive emissions, working seamlessly with downstream gas cleaning and desulfurization plants.
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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