Refractory Solutions for Roasting kiln
Rotary Kiln Lining System
Contact us:
Tel/WhatsApp:0086-18905335290
Email:luming@lm-kiln.com
A Roasting Kiln is a type of thermal processing equipment used to heat ores, concentrates, powders, or other solid materials to high temperatures in order to induce physical or chemical changes. It is widely used in metallurgy, building materials, chemical, and environmental protection industries. Its main function is to provide controlled heating so that materials undergo dehydration, oxidation, reduction, decomposition, or phase transformation, achieving the desired product properties or composition.The Common Types are Rotary Kiln,Shaft Kiln,Tunnel Kiln,Fluidized Bed Roasting Furnace and Multi-Hearth Furnace.The rotary kiln is the most common type of roasting kiln.Rotary Roasting Kiln is Cylindrical, rotating, and slightly inclined, allowing materials to move slowly forward inside the cylinder.It Suitable for roasting metallic ores (such as bauxite, nickel ore, chromite, iron ore) and producing active lime.
Our Proprietary Core Technology for Ferronickel Rotary Kiln
Our Shandong Luming New Materials Technology Co., LTD has specialized in refractory materials for various types of rotary kilns for over twenty years. To address the drawbacks of traditional masonry techniques, we developed an innovative "brick-and-mortar hybrid masonry process" (Patent No.: 201010130626.6).
This construction technology has been officially included in China's national《Furnace Construction Manual》.
This masonry process innovatively combines the advantages of refractory brick laying and castable monolithic pouring, while effectively overcoming the limitations of both conventional methods.
Standardized refractory material design schemes have also been developed for different types of kilns.With field applications in over 100 rotary kilns and continuous iterative upgrades, this solution reliably meets diverse customer requirements.
The first-generation technology prioritized operational safety and efficiency, delivering secure and long-lasting rotary kiln refractories that significantly reduced maintenance frequency while maximizing equipment uptime.
The second-generation system integrates low-thermal-conductivity materials to achieve 30% reduction in kiln shell temperature and over 10% energy savings while maintaining the safety and longevity advantages. This breakthrough directly supports clients' energy conservation, emission reduction, and green production initiatives.
The current third-generation masonry technology and products utilize nanomaterials, achieving safety, longevity, energy efficiency, and environmental sustainability while further reducing the thickness of refractory materials, offering significant advantages in lightweight design.
How we do for Rotary Roasting Kiln?
Our Lining Installation Process----1.Marking
Marking equally spaced lines according to the calculated number of precast brick rows
Our Lining Installation Process----2.Installing Bricks According to the Marked Lines
Precast refractory bricks are arranged axially (front-to-back) along the rotary kiln, and fixed to the kiln shell by welding anchor hooks.
Our Lining Installation Process-----3.Completion of Precast Refractory Brick Installation
Image of Completed Welding of All Precast Refractory Bricks in Rotary Kiln
Our Lining Installation Process----4. Welding Anchor Hooks Between Precast Refractory Bricks
Welding anchor hooks between precast refractory bricks to provide fixed support for the castable material poured between them.
Our Lining Installation Process-----5.Laying Insulation Materials
After welding the anchor hooks between the precast refractory bricks, lay the insulation materials
Our Lining Installation Process------ 6. Casting Castable Refractory Between Precast Bricks
After the insulation materials have been fully laid, proceed with casting castable refractory in the casting zones.
Photos During Masonry and After Full Completion
Our Product Portfolio--Rotary Kiln and Auxiliary Equipment:
General roasting rotary kiln:
Pyrometallurgical alumina ; Alumina extraction from high-alumina coal fly ash; Reduction roasting of limonite,siderite:
|
Item |
LM-MA85 |
LM-GN15 |
LM-MS65 |
LM-MS45 |
LM-D35 |
|
|
AL2O3 % ≥ |
70 |
45 |
60 |
40 |
30 |
|
|
MgO(SiC) % ≥ |
15 |
/ |
(8) |
(8) |
||
|
Bulk Density(g/m3) |
2.85 |
2.30 |
2.55 |
2.40 |
2.20 |
|
|
Apparent Porosity % ≤ |
15 |
15 |
||||
|
Compressive Strength(MPa)≥ |
110℃X24h |
60 |
50 |
60 |
50 |
40 |
|
1100℃X3h |
80 |
70 |
60 |
60 |
||
|
1350℃X3h |
80 |
90 |
/ |
/ |
||
|
Modulus of Rupture(MPa)≥ |
110℃X24h |
6 |
8 |
8 |
6 |
6 |
|
1100℃X3h |
10 |
10 |
10 |
8 |
||
|
1350℃X3h |
12 |
12 |
/ |
/ |
||
|
Linear change rate, 1350℃x3h, % ± |
0.5 |
0.3 |
0.5 |
0.5 |
0.5 |
|
|
Operating environment and application range |
Rotary kiln for pyrometallurgical alumina calcination; Calcination section of the rotary kiln for alumina extraction from high-alumina fly ash |
Calcination Section of Pyrometallurgical Alumina Rotary Kiln; Low-temperature section for alumina extraction from high-alumina fly ash. |
Calcining zone of rotary kiln for reduction roasting of limonite, siderite, and pyrite |
Low-temperature zone of the rotary kiln for reduction and roasting of limonite, siderite, and pyrite |
kiln hood of a rotary kiln used for the reduction and roasting of limonite, siderite, and pyrite |
|
Usage Results of our Roasting Kiln:
Compared to Traditional Small Brick Masonry Process:
1.Cylinder temperature reduced by more than 30%
2.Fuel cost savings exceeding 10%
3.Completely eliminates brick dropping issues
4.Total refractory weight of the kiln body reduced by 10%, resulting in electricity savings of 10%
5.After 6 months of operation, the refractory cost is effectively equivalent to free usage
Alternative Solution ---All-Precast Refractory Brick Solution for Winter Construction in Extremely Cold Areas:
1.No casting zones required; castable refractory is unnecessary
2.Formed precast bricks are assembled by splicing and welded installation
3.Excellent thermal insulation performance
4.Secure and reliable fixation with no risk of brick loosening or dropping
Front-to-back welded assembly enables rapid splicing and high construction efficiency
Our Main Applications:
1.Metallurgical & Nonferrous Industry:Standard Pelletizing Rotary Kiln,Ferronickel Rotary Kiln,Ferromanganese rotary kiln,Vanadium-Titanium Rotary Kiln, Ferrochrome Rotary Kiln,Alumina Rotary Kiln,Magnesium Metal Rotary Kiln,Zinc Recovery Rotary Kiln,Iron Ore Roasting-Reduction Rotary Kiln,etc.
2.Building industry:Lime Rotary Kiln,Dolomite Calcining Kiln
3.New Energy Industry: Lepidolite Rotary Kiln,Spodumene Conversion Kiln
4.Environmental protection industry: Hazardous Waste Rotary Kiln,Hazardous Waste Rotary Kiln,Sodium Pyrophosphate Thermal Oxidizer,Sodium Pyrophosphate Thermal Oxidizer
5.Coke Oven Door Brick,Coke Dry Quenching Castable Refractory
Our Quality Management
Our company strictly adheres to national and industry standards for refractory materials in design, production, and inspection. We also comply with international standards specified by clients to meet customized requirements.Based on the principles of safety, reliability, and cost-effectiveness, we have established a comprehensive quality management system and inspection and testing system.Our internal quality control standards encompass all critical aspects: Raw material qualification,Production process monitoring, Key control point management, Equipment maintenance & inspection,Full-process quality testing & evaluation, Closed-loop quality feedback & improvement.We implement strict raw material quality control, conducting batch-by-batch inspection with full documentation to ensure consistent material compliance.During the production process, strict quality control is enforced, with every process detail rigorously monitored and inspected. A comprehensive quality management and accountability system is implemented to ensure the overall product quality is flawless.Deploy qualified and experienced project managers and professional construction teams to carry out meticulous construction, ensuring construction quality and progress, and guaranteeing timely completion with high quality and quantity.
Advanced Physical and Chemical Experimental Testing Equipment and Standardized Physico-Chemical Laboratory
CORPORATE ENVIRONMENT AND FACILITIES
Fully Automated Castable Refractory Production Line in Workshop 1
Precast Production Site in Workshop 1
Special Refractory Production and Firing Workshop Site
7 × 52m³ Shuttle Kilns in Special Refractory Workshop
75m Firing Tunnel Kiln in Special Refractory Workshop
Fully Automatic Glaze Spraying Equipment
Our service:
1.Personalized customization solutions:
Based on client requirements, we conduct multi-dimensional analysis covering: Usage Pain Points,Cost Control, Service Life,Energy Saving & Emission Reduction, Project Timeline,etc;We design configuration plans for different budgets and provide detailed product technical specifications and user instructions to ensure customers have a comprehensive understanding of the product;Provide customers with comprehensive end-to-end solutions including consultation, design, production, construction, after-sales service, maintenance and upkeep.
2.Technical Support & Training:
We Provide 24/7 customer service, ready to accept customer inquiries and feedback at any time.Based on customer needs, we can organize regular or occasional technical training sessions on product usage and maintenance to improve customers' ability to use and maintain the products.
3.High-efficiency supply and logistics solutions:
Flexible production mechanism, with adaptable production scheduling to maximize fulfillment of customer delivery requirements.Tiered Delivery Time Management: We provide customized logistics solutions tailored to client requirements, ensuring on-time arrival to meet diverse delivery needs.
4.Customized Packaging Solutions:
All delivered goods are packaged in strict compliance with the buyer's requirements as well as relevant national and industry standards.Shaped products such as refractory bricks and precast blocks are typically packaged on wooden pallets, wrapped with stretch film for sealing, and secured with plastic-steel strapping.Unshaped refractory materials are packaged in 25-50kg plastic bags, with additional outer protection using bulk bags.Our company provides customized packaging solutions including containers, wooden cases, metal boxes, and moisture-proof marine packaging, fully compliant with both local regulations and corporate requirements in your market.
5.After-sales Service & Continuous Improvement:
We provide complimentary technical consulting services to promptly address any issues encountered during product use.During the warranty period, any quality defects caused by our materials or workmanship will be remedied through free repair, replacement or improvement.During project operation, we systematically collect and analyze user feedback to promptly identify and rectify deficiencies, thereby continuously improving product and service quality while enhancing performance and energy efficiency.Continuously improve the quality management system and production processes to enhance both product and service quality and operational efficiency.
Our Construction Showcase
Some overseas project
steel plant
Rotary kiln major overhaul
Rotary kiln Construction
coke oven
Custom Refractory Materials
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