Calcining and roasting is an intense process that involves high temperatures, heavy loads and significant thermal stresses. Finding the right rotary kilns that will consistently withstand the pressure is the key to running an efficient and profitable operation. When unproven processes are required or calcinations of unusual materials are desired, FLSmidth can help with an excellent Research and Development Group and with well-equipped pilot plant facilities, including a 0. Also available are crushing and grinding machines, muffle furnaces, a complete wet and dry chemical lab, and other facilities to support this activity. For more information, call or email the FLSmidth office nearest you. Your safe and durable rotary kiln solutions Get consistent results and sustainable productivity with rotary kilns that are precision engineered to keep your operation running safely and smoothly.
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Increase your energy efficiency with our innovative graphite seal that works on any kiln — any size, any manufacturer. We deliver a module that is designed to integrate with your existing casing and cooling mantle with no modification required.
Much of the Kiln Graphite Seal Module is pre-assembled in our workshop, which means easy installation and less downtime for you. It also allows us to deliver top quality, ensuring the straightness of the flanges.
Our modular frame includes locking plates, distance spacers and guide blocks. Together, they guide and secure the position of the graphite blocks to maintain a tight rotary kiln seal. Unlike other block seals on the market, our Carbon Graphite Kiln Seal uses a staggered arrangement with two rows of graphite blocks held in place by a wire rope system. Our design lets the graphite blocks move independently with the radial movement of the kiln without getting damaged or stuck.
And locking plates installed on the rear flange keep false air from entering the rotary kiln system. If you choose, the Graphite Kiln Seal can be delivered with a heat-resistant shovel arrangement.
This will collect any back spillage and return it to the kiln. How does it work? The casing, hopping, and ducting act as a material buffer. They guide the excess raw meal to a bin, or to a conveyer system. Meanwhile, the hopper comes with a sloping plate that helps stop dust build-up on the graphite kiln seal. And a slide plate installed at the bottom of the hopper delivers accumulated material to disposal, or to the conveying system if you prefer.
Our Kiln Graphite Seal works on any rotary kiln, not just the kilns we manufacture ourselves. A quick visual inspection will let you know if maintenance is required. You can even change the graphite seal blocks without cooling down the kiln completely. The graphite blocks are self-lubricating, so there is less wear and tear. In fact, the expected wear on the blocks is mm per year, which means a good long lifetime. Two types of Kiln Graphite Seals are available; both are designed to maintain optimal kiln operating conditions and minimise energy loss.
The Kiln Inlet Seal provides an interface between the kiln and preheater, while the Kiln Outlet Seal creates an interface between the kiln and the cooler. Key Benefits Optimise operation pressure stability Reduce release of hot gasses and dust Flexible design adapts to any size kiln Easy installation with minimal downtime.
Keep false air out, hot gas in with our innovative Graphite Kiln Seal This innovative Graphite Rotary Kiln Sealing System can make any existing kiln more efficient by optimising pressure stability and reducing the release of hot gasses and dust particles.
Its modular frame allows for pre-assembly, which means fast, easy installation with minimal downtime. Module pre-assembled in the workshop Much of the Kiln Graphite Seal Module is pre-assembled in our workshop, which means easy installation and less downtime for you. Staggered arrangement with two rows of blocks Unlike other block seals on the market, our Carbon Graphite Kiln Seal uses a staggered arrangement with two rows of graphite blocks held in place by a wire rope system.
Optional shovel arrangement If you choose, the Graphite Kiln Seal can be delivered with a heat-resistant shovel arrangement. Retrofitting rotary kiln seals Our Kiln Graphite Seal works on any rotary kiln, not just the kilns we manufacture ourselves.
The typical installation takes about 7 to 10 days. Easy, predictable maintenance A quick visual inspection will let you know if maintenance is required. Fast, easy installation of an efficient graphite seal to fit any kiln.
Cut down on energy consumption By optimising your kiln performance and keeping out false air, the Graphite Kiln Seal will reduce ID fan consumption by optimising the operation pressure stability. Quick installation with pre-made modules The Graphite Kiln Seal works on any rotary kiln, not just ones manufactured by us. And because we pre-build most of the module in our workshop, installation is quick with limited downtime. Our kiln seals use carbon graphite in staggered blocks held by wire rope Two types of Kiln Graphite Seals are available; both are designed to maintain optimal kiln operating conditions and minimise energy loss.
Efficient seal against the outer air casing Both of these highly efficient kiln seals use carbon graphite to create a staggered arrangement of overlapping blocks, held in place by a wire rope system. This creates an efficient seal against the outer air casing. The graphite blocks move independently with the radial movement of the kiln. Locking plates on the rear flange is one of our key design features. They keep false air from entering the kiln system. An inlet seal casing handles back spillage.
It directs it to the hopper so it can be collected and disposed of. Pre-assemble modules for installation We pre-assemble each module before installation, and we thoroughly inspect the geometrical tolerances of the flanges in our workshop. That helps us ensure the highest quality standards. When it comes to maintenance, the wire rope system and modular frame allow quick replacement of the graphite blocks. Special distanced spacers mean there is no need to dismount the flanges.
Meanwhile, the wire rope system includes counterweights and independent rope systems that cover each row of graphite blocks. The ropes grip the graphite blocks tightly in place, but they also allow for movement caused by kiln runout, ovality, and expansion. Each wire rope is designed to run for a full production campaign, but we have also designed an extra preventative measure.
Download our latest brochure and find out more about the Kiln Graphite Seal Learn more. Precast Kiln Outlet Sectors. Kiln services. Emissions compliance. Build a new cement plant. Stories from FLSmidth. Behind the scenes of MissionZero: What, why and how? Wear panels triple service life and slash costs and downtime. Stay updated on your industry. Get newsletter. Please select your area s of interest: Cement. Please select your cement topic s of interest: Discover Stay up to date on all the latest industry trends and developments.
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Our Precast Outlet Sectors simplify maintenance, avoid costly downtime
Achieving high kiln availability is essential to the competitiveness and profitability of your entire plant. You need to identify the root causes of kiln failure and eliminate problems before a breakdown occurs. To keep your kiln at optimal health throughout its lifetime, we recommend our key kiln services: hot kiln alignment, and reconditioning of tyres and rollers. How can you get the best out of your kiln and keep production maximised?
Your safe and durable rotary kiln solutions
Our concept means you can choose to have a second set of outlet sectors ready for replacement, drastically reducing replacement time. Our system consists of permanent sectors bolted directly to the kiln shell plus one set of hanging sectors that are precast before installation. That can save up to two days. And during the installation of the sectors the kiln is available for turning. That means installation and maintenance is more flexible. You can even manufacture your own replacement casings in your facility or at a local refractory supplier. Make them according to your own schedule, to avoid warehousing costs.
Rotary kilns for cement plants: FLSmidth is the international market leader
Process conditions in the cement and minerals industries can be very harsh. Strong and powerful equipment is required to operate in this kind of environment. Handling the temperature and dust load, however, is a simple enough engineering task. All of our pyroprocess equipment is designed to handle these conditions. The real challenge comes when gas condenses in the raw material, which can happen if high concentrations of volatiles occur in the process.
Our low-maintenance 3-base kiln has the longest lifespan available
This 7-day kiln process and operation course will take place at your plant or a local off-site facility, covering all major theoretical issues within your pyro technology. The goal is to enable the course participants to make operational decisions about your pyro systems. This 7-day course offers classroom instruction from our FLSmidth kiln specialists and case studies based on real situations at different kiln installations. Operational training will occur though use of our advanced simulator.