A rotary kiln is a continuous process designed specifically for drying, calcining, processing, or sintering bulk materials.
Schad services Rotary Kilns used in various industrial markets such as:
- Cement
- Lime
- Incineration
- Iron and Steel
- Mineral Processing
- Combustion Systems
The rotary kiln heated chamber is a long horizontal tube that is rotated with one end slightly elevated. The bulk material is continuously fed into the elevated end of the tube and cascades down the length of the tube by the tube’s continuous rotation. The bulk material exits the tube at the other end and falls into a collection hopper. Depending on the required operating temperature of the rotary kiln, the tube material will either be a high temperature metal alloy or ceramic composition.
These units typically operate at high temperatures (close to 3000°F for some applications) under very dynamic conditions. Not only do these units have large unsupported spans between piers, but they also rotate. This creates a dynamic situation with potential for sagging, flexing and egging of the shell during operation. These movements can impart enough stress into the refractory system to cause the lining to catastrophically fail. In addition, exposure to atmospheric conditions including heat, cold, rain, etc. stresses the refractory lining. Many applications can also be very corrosive to the refractory, the steel shell and components, or both. Schad has helped customers maintain and improve their refractory lining systems in these units since 1942.
Schad has successfully performed work in rotary kilns since 1942.
Over the years, we have acquired the people, experience, equipment and processes to be a leader in rotary kiln demolition and refractory installation. We have our own experienced engineering specialists and draftsmen to prepare detailed construction drawings for each project. In addition to our engineering capabilities, we maintain across our branches a large resource of highly skilled bricklayers and field laborers experienced in the process from tear-out to heat-up.
The following information is required to determine the tube OD, tube ID, tube length, tube rotation speed, the tube inclination angle, and the tube material:
- Production rate (pounds per hour)
- Bulk density of the feed material
- Angle of repose of the feed material
- Maximum temperature
- Length of time a the maximum temperature
Schad has specialized equipment that allows us to be more productive and to outperform our competition.
- Schad maintains various designed kiln rigs for brick installations, either custom designed by us or commercially purchased, to ensure that we have the right equipment for the job.
- For castables, we design our own forms and have specialized material handling and installation equipment. This includes conventional gunite rigs, refractory material pumps, spray rigs, etc.; all designed for high production and safe operation.
Full turnkey capability
From planning through engineering, procurement and execution of the work, Schad has the complete team to help customers get units back into production in a safe and timely manner that maximizes reliability and minimizes long term maintenance costs.