Sludge incineration kiln is a special equipment for sludge treatment. Its principle is to use high temperature to process and decompose harmful substances in sludge, thereby reducing its pollution probability and protecting the environment. Sludge incineration kiln is widely used in the field of sludge treatment and is one of the most effective equipment for thoroughly disposing of sludge. The sludge incineration kiln can destroy the tissue structure of waste at high temperature, eliminate harmful components, quickly and greatly reduce the volume of waste, and can recycle energy.
Riding Rings(Tyre): The Incineration rotary kiln shell is supported on multiple riding rings usually 2~3, which are attached to the shell with point-welded padding on the inside. The rotary kiln riding rings allow the kiln to rotate smoothly on its axis and help distribute the kiln's weight. The thickness of the plate under the riding ring is increased to facilitate strength of the shell.Girth Gear: The Incineration rotary kiln girth gear is a large gear ring encircling the kiln, usually mounted on the kiln shell. It is driven by a pinion gear, and together they form the primary drive unit to rotate the kiln. Under the girth gear is the spring plate, the function of the spring plate is to reduce heat transfer from the shell to the girth gear to prolong the service life time of the equipment.Supporting Device: Sewage sludge rotary kiln supporting device is composed of the supporting roller and thrust roller, the shaft is a forged object to prolong the service life time of the rotary kiln. One thing features about Tongli Supporting device is all the metal casting are produced by our own, the quality is guaranteed. All the metal casting supporting roller, metal casting thrust roller are machined and heat treated, the performance measure is reliable.
Rotary kiln thrust roller：The thrust roller is a critical part of the rotary kiln system. It serves the purpose of supporting the kiln's weight and maintaining its axial position, ensuring that the kiln remains properly aligned along its axis. The thrust roller is typically positioned on the downhill side of the kiln and is attached to the kiln shell, it consists of a central shaft or journal and a roller assembly.
Rotary kiln pinion: The pinion is an essential part of the rotary kiln drive system, responsible for transmitting rotational motion and torque from the driving mechanism to the rotary kiln itself. It consists of a gear wheel with teeth that mesh with the teeth of a larger gear, often referred to as the "girth gear" or "ring gear." The girth gear is attached to the outer shell of the rotary kiln. When the pinion is rotated by the drive system, it drives the girth gear, causing the rotary kiln to rotate.
Rotary kiln bearing housing: The bearing housing serves as the support structure for the kiln's rotating motion and is responsible for holding and guiding the kiln's trunnion bearings. Trunnion bearings are large, heavy-duty bearings that support the weight of the kiln and allow it to rotate smoothly. These bearings are subject to high loads, extreme temperatures, and potentially harsh environments due to the nature of the processes occurring inside the rotary kiln. The bearing housing provides a stable mounting point for the trunnion bearings and ensures proper alignment of the kiln's rotation. It is typically designed to accommodate the axial and radial forces generated during the rotation of the kiln.
Kiln Shell: The sewage sludge rotary kiln shell is a thick, steel cylindrical structure that provides the necessary strength and rigidity to withstand the high-temperature environment inside the kiln. It also serves as a containment vessel for the materials and gases during the manufacturing process. Inside the kiln shell is the refractory lining usually refractory bricks or sometimes refractory castable. Tongli kiln shell has good sealing performance, the edge of each shell is machined smoothly, enhance the sealing and service life of the rotary drum.
Kiln Hood Cover: The rotary kiln hood is located at the discharge end of the kiln and provides sealing to retain heat and gases. The rotary kiln operates under the negative pressure, therefore Tongli implied SS304 lining plate and ceramic felt both in the front and back end to prevent heat leakage.
Rotary Kiln Transmission device: The transmission device of the rotary kiln is mainly composed of main transmission, auxiliary transmission, mechanical thrust roller/hydraulic thrust roller, motor, gearbox and other components. The unique design of tongli transmission can greatly improve the service life and safety performance of the equipment.
PLC control system: A PLC is a digital computer-based system that is designed to control various industrial processes automatically. In the context of a rotary kiln, a PLC is used to monitor and control parameters such as temperature, rotation speed, air flow, fuel flow, and other critical variables that affect the performance of the kiln and the quality of the products being processed. Usually, the rotary kiln control system is integrated in the whole factory’s plc system, therefore we will provide the on-site cabin and a signal cable to the central plc.
Counter-Current Flow: Tongli rotary kilns are designed with a counter-current flow arrangement. In this design, the raw materials and combustion gases move in opposite directions. The raw material enters from the upper end, while the hot gases and combustion products exit from the lower end. This counter-current flow enhances heat transfer efficiency and reduces energy consumption.
Gradual Heating: The raw materials are gradually heated as they move through the Incineration rotary kiln. This gradual heating is crucial to avoid thermal shocks and to facilitate the complex chemical reactions that convert raw materials into final product.
Finite element analysis: Finite element analysis is adopted during the design of the rotary kiln, make sure all the rotary kiln components girth gear, riding ring(tyre), supporting roller, pinion, shell is well suited for its specific job.
Sealing: Both the inlet and the outlet has a hood cover which improves the sealing effect, integrates labyrinth sealing, ceramic felt sealing, double leaf sealing, ss304 fish scale sealing to remain heat escape inside the kiln.
Filler padding: floating padding are used under the riding ring to strengthen the shell and reduce the heat induction to the riding ring.
Girth gear spring plate: Due to the high temperature of the rotary kiln, Tongli Incineration rotary kiln is equipped with spring plate that is attached in between the girth gear and the shell to ensure smooth rotation and reduce heat transfer.
Girth gear/riding ring: All the metal casting are quality assured, Tongli has its own foundry and from the raw material to the finished product, the quality is reliable.
Quality inspection: Tongli offers magnetic testing and ultrasonic testing, which ensures the quality of all the metal castings and the welding seam.
Lubrication system: Tongli Incineration rotary kiln is equipped with an oil station which lubricates the essential part of the rotary kiln to prolong the service lifetime as well as the smooth operation.
Note: *The diameter is the inner diameter, Weight excludes refractory material.
Modern intelligent processing base integrating R&D, production and sales.
Zhejiang Tongli Heavy Machinery Manufacturing Co., Ltd (Formerly known as Tongxiang Coal&Mining Machinery Factory) established in year 1958 is a member of the Chinese National Building Material Machinery Association. Tongli is on the vendor list of designated production enterprise of the Ministry of Coal Industry. ISO9001、ISO14001、ISO45001 certified, accredited as High-tech & new technology enterprise of Zhejiang Province. With 65+ years of experience, Tongli has earned first class R&D and manufacturing capabilities, dedicated to provide satisfactory manufacturing equipments for global customers.
After years of development, there are more than 650+ sets of heavy machinery manufacturing equipments in our workshop, some of them are as follows:
One of the largest equipment in our factory, the maximum processing diameter is 12 meters, and the maximum processing length can reach 26 meters. This Lathe is specially crafted for processing mega cylinders.
One of the super-large equipment in our factory, the maximum processing height can reach 6 meters, and the maximum processing diameter can reach 12 meters, which ensures that the accuracy of the cylinder flange can reach the required level.
Workbench effective size: 4000*12000mm;
Gantry Width: 4900mm;
Processing height: 4000mm;
Three angled milling heads, square ram;
Load-bearing 350 tons;
CNC system: SIEMENS 840D.
Workbench effective size: 3000*8000mm;
Gantry width: 4100mm;
Spindle speed: 2000RPM
Workbench effective size: 2000*4000mm;
Processing Width: 2800mm;
Processing Height: 1100mm;
Full-CNC milling heads；
Workbench effective size: 4500x5000mm
Processing Length: 14000mm;
Processing Height: 5000mm;
CNC system: SIEMENS 840D.
Workbench effective size: 5000x5000m;
Processing Length: 11000mm;
Processing Height: 6300mm;
Tongli incinerator kilns are designed to be energy efficient, with features like pre-heaters and calciners that recover and reuse waste heat, and ss304 lining and ceramic felt to improve the sealing effect.
Adcanced instrumentation and control systems are employed to monitor and regulate the kiln's operation, ensuring stable and consistent production process.
Tongli held independent intellectual property rights, developed core technologies of mechanical, and electrical systems provide high reliability at all events.
Tongli incineration rotary kiln can handle a wide range of materials with varying size and property, which is suitable for different types of production.
What is the application of calcined sewage sludge?
Calcined sewage sludge, also known as sewage sludge ash (SSA), is the residue obtained after the incineration or thermal treatment of sewage sludge. This process involves heating sewage sludge to high temperatures, which results in the removal of organic matter and water content, leaving behind a solid ash residue. Calcined sewage sludge has several potential applications across different industries:
Construction Materials: Calcined sewage sludge can be used as a partial substitute for cement in the production of construction materials like concrete and cementitious products. It has been found to possess pozzolanic properties, which means it can react with calcium hydroxide to form additional cementitious compounds, thereby improving the strength and durability of the materials.
Soil Amendment: The ash can be applied to agricultural fields as a soil amendment to improve soil structure, water retention, and nutrient availability. It can provide essential minerals and trace elements to the soil, enhancing its fertility and crop productivity.
Waste Stabilization: The thermal treatment of sewage sludge reduces its volume and destroys pathogens and harmful microorganisms, making it suitable for safe disposal in landfills or as a solid waste material.
Adsorbent Materials: Calcined sewage sludge has the potential to be used as an adsorbent material for removing heavy metals and organic pollutants from wastewater. Its porous structure and surface chemistry make it effective in adsorbing contaminants.
Brick Manufacturing: Some research suggests that calcined sewage sludge can be used in brick manufacturing as a partial replacement for clay. This not only reduces the demand for raw materials like clay but also offers a sustainable waste management solution.
Phosphorus Recovery: Phosphorus is a valuable nutrient that can be recovered from calcined sewage sludge and used as a fertilizer. Phosphorus recovery is particularly important due to the limited availability of phosphorus resources and its essential role in agriculture.
Catalyst Support: The ash's porous nature and mineral composition can make it useful as a catalyst support in various chemical processes and industrial applications.
Energy Recovery: The incineration process used to produce calcined sewage sludge ash generates heat energy, which can be harnessed for electricity generation or for heating purposes in the facility itself.
What is the difference between incineration kiln and rotary kiln?
A rotary kiln is primarily used for high-temperature processing of materials. It is widely used in industries such as cement, lime, minerals, and more. Its primary purpose is to carry out processes like calcination, sintering, roasting, and other thermal treatments. In a rotary kiln, the material to be processed is placed on a rotating refractory-lined drum. The material moves through the kiln due to the rotation of the drum, and it is exposed to high temperatures for the desired thermal transformation.
An incineration kiln is specifically designed for the thermal treatment of waste materials, typically with a focus on waste disposal and environmental considerations. It is used to combust waste materials at high temperatures to reduce their volume and convert them into inert residues. In an incineration kiln, waste materials are introduced into a controlled combustion environment, where they are subjected to high temperatures and combustion gases. The process is designed to break down organic materials and reduce waste to ash and gas.
The fundamental difference lies in the purpose of the equipment. Rotary kilns are used for various high-temperature material processing operations, while incineration kilns are specifically designed for waste combustion and disposal.
Rotary kilns process raw materials, minerals, and other materials for various industrial applications. Incineration kilns process waste materials, aiming to reduce waste volume and ensure proper disposal.
Both types of kilns involve high temperatures, but incineration kilns are operated at even higher temperatures to achieve complete combustion of waste materials.
Incineration kilns are subject to strict environmental regulations due to the potential emission of pollutants. Special measures are taken to control emissions, ensure clean combustion, and minimize environmental impact. Rotary kilns also have environmental considerations, but the focus is primarily on optimizing the thermal processes.
What is the difference between rotary kiln and vertical roller mill?
The rotary kiln and vertical roller mill are both essential pieces of equipment in the cement manufacturing process, but they serve different purposes and are used at different stages of the process.
The rotary kiln is a large cylindrical vessel used for calcining raw materials at high temperatures. It's a core component of the cement manufacturing process and is responsible for transforming raw materials, particularly limestone and clay, into clinker. In the rotary kiln, the raw materials are heated to temperatures exceeding 1400°C (2552°F), where chemical reactions occur that result in the formation of clinker nodules. And they need to be ground into a fine powder to produce cement. This final grinding process is often performed using a vertical roller mill. The clinker is mixed with gypsum and possibly other additives to create the final cement product.
Vertical Roller Mill (VRM): The vertical roller mill is a grinding machine that grinds materials into fine powders, after the raw material is crushed by the crusher, it enters the vertical roller mill. It is typically used for grinding raw materials, clinker, and additives in the cement manufacturing process. The VRM operates by applying hydraulic pressure and vertical force to the grinding rollers, which then grind the materials between the rollers and the grinding table. This grinding process results in a fine powder that is later used as a key ingredient in the production of cement which is important for the subsequent chemical reactions in the rotary kiln.