An Innovative Process for Direct Reduction of Cold bound Pellets from Iron Concentrate with a Coal-based Rotary Kiln

Successfully developed an innovative process of direct reduction of cold bound pellets from iron ore concentrate with a coal based rotary kiln, in comparison with the traditional direct reduction of fired oxide pellets in coal based rotary kilns , possesses such advantages as: shorter flowsheet, lower capital investment, greater economic profit, good quality of direct reduced iron. The key technologies , such as the composite binder and corresponding feasible techniques were employed in practice. A mill utilizing this process and with an annual capacity of 50 thousand ton DRI has been put into operation.

Effects of Municipal Sewage Sludge on Fixation of Cr,Ni,Cu,and Zn during Co-processing of Heavy Metal-containing Waste in Cement Kilns

Cement raw meal with MSS and different heavy metals was blended to examine the fixation ratios, chemical species, and cement crystalline phases in clinkers. The results showed that blending MSS could decrease the fixation ratio of Cr, Ni, Cu, and Zn in the produced clinker by 5% to 25%. And Cr, Cu, and Zn were mainly incorporated into clinkers as metal silicates, Ni was mainly solubilized in Mg O to form magnesium nickel oxides, and the transition phases were mainly metal aluminum oxides as indicated by X-ray diffraction. The reduction of fixation ratios was likely attributed to the presence of impure elements, such as sodium and phosphorus in MSS. In addition, high concentrations（eg, 1.7 wt%） of chlorine in MSS led to metal chloride formation that could vaporize Cu, Cr, Ni, and Zn. To summarize, introducing MSS would decrease the fixation ratios of heavy metals due to the presence of impure elements, such as sodium and phosphorus and chlorine.

Increasing Plant Availability by Mechanical Checking of the Cement Rotary Kiln Axis

A periodic check of the cement rotary kiln axis is needed withinthe framework of preventive ma- intenance for maintaining high plantavailability. The fourth generation 'KAS-4' measuring system wasdevel- oped by Wuhan University of Technology in 1999. The system canbe carried out with rotating or stationary kiln plant. The same istrue of the measurement of tire and supporting roller diameters, theclearance of tires, the po- sition of rollers, the machining of tiresand rollers, the slops of roller surfaces, the deflection of gear,the axis of kiln. The system has been applied to the measurement for10 set of cement rotary kiln in China.

Plant Test of Industrial Waste Disposal in a Cement Kiln

Destruction of industrial waste in cement rotary kilns (CRKs) is an alternative technology for the treatment of certain types of industrial waste (IW). In this paper, three typical types of industrial wastes were co-incinerated in the CRK at Beijing Cement Plant to determine the effects of waste disposal (especially solid waste disposal) on the quality of clinker and the concentration of pollutants in air emission. Experimental results show that (1) waste disposal does not affect the quality of clinker and fly ash, and fly ash after the IW disposal can still be used in the cement production, (2) heavy metals from IW are immobilized and stabilized in the clinker and cement, and (3) concentration of pollutants in air emission is far below than the permitted values in the China National Standard-Air Pollutants Emission Standard (GB 16297-1996).

Grate-kiln pelletization of Indian hematite fines and its industrial practice

Indian hematite fines normally have a high iron grade and minor impurities; they are usually used as sinter fines for feeding into a blast furnace. In this work, the grindability properties of two kinds of Indian hematite fines and the roasting behaviors and induration characteristics of pellets made from these fines were revealed through experiments involving dry ball milling and small-scale and pilot-scale tests. In addition, the microstructures of the particles of ground India hematite fines and fired pellets were investigated using optical microscopy. On the basis of the results, a grate-kiln production line with an annual output of 1.2 Mt of oxidized pellets was established in India. This pellet plant operates stably and reliably, further confirming that preparing high-quality pellets with Indian hematite fines pretreated by dry ball milling is an industrially feasible process. © 2017, University of Science and Technology Beijing and Springer-Verlag Berlin Heidelberg.

Influence of MnO_2 Mineralizer on the Crystal Structure,Properties of SiC Kiln Furniture Bonded with Fine Silicon Powder

The properties of SiC kiln furniture bonded with fine silicon powderare related to the bonder’s crystal structure. At high temperature, it will crystallize ina-cristobalite with great bulk effect. MnO2 mineralizer can make a-cristobalite convertto a-tridymite whose bulk effect is small. The crystal structure and its amount were investigated with XRD technique. The influence of different amounts of MnO2 on thecrystal structure and polycrystal transformation, and that of crystal structure on theproperties of kiln furniture were studied. The best proportion of MnO2 added was determined to be 2.0%.

CFD prediction of physical field for multi-air channel pulverized coal burner in rotary kiln

A 3-D numerical simulation with CFX software on physical field of multi-air channel coal burner in rotary kiln was carried out. The effects of various operational and structural parameters on flame feature and temperature distribution were investigated. A thermal measurement was conducted on a rotary kiln (4.5m in diameter, 90m in length) with four-air channel coal burner to determine the boundary conditions and to verify the simulation results. The calculation result shows that the distribution of velocity near burner exit is saddle-like; recirculation zones near nozzle and wall are useful for mixture primary air with coal and high temperature fume. A little central airflow can avoid coal backing up and cool nozzle. Adjusting the ratio of internal airflow to outer airflow is an effective and major means to regulate flame and temperature distribution in sintering region. Large whirlcone angle can intensify disturbution range at flame root to accelerate ignition and mixture. Large coal size can reduce high temperature region and result in coal combusting insufficiently. Too much combustion air will lengthen flame and increase heat loss.

Leaching of iron concentrate separated from kiln slag in zinc hydrometallurgy with hydrochloric acid and its mechanism

It is taken as a novel prospective process to treat iron concentrate from hydrometallurgical zinc kiln slag forcomprehensive utilization of valuable metals by a hydrochloric acid leaching-spray pyrolysis method.The leaching mechanism ofdifferent valuable metals was studied.The results revealed that the leaching rates of Ag,Pb,Cu,Fe,As and Zn were99.91%,99.25%,95.12%,90.15%,87.58%and58.15%,respectively with6mol/L HCl and L/S ratio of10:1at60°C for120min.The actionof SiO2in leaching solution was also studied.The results showed that the precipitation and settlement of SiO2(amorphous)adsorbedpart of metal ions in solution,which greatly inhibited the leaching of Cu,Fe,As and Zn,so it is crucial to control the precipitation ofamorphous SiO2.

Flame image recognition of alumina rotary kiln by artificial neural network and support vector machine methods

Based on the Fourier transform, a new shape descriptor was proposed to represent the flame image. By employing the shape descriptor as the input, the flame image recognition was studied by the methods of the artificial neural network(ANN) and the support vector machine(SVM) respectively. And the recognition experiments were carried out by using flame image data sampled from an alumina rotary kiln to evaluate their effectiveness. The results show that the two recognition methods can achieve good results, which verify the effectiveness of the shape descriptor. The highest recognition rate is 88.83% for SVM and 87.38% for ANN, which means that the performance of the SVM is better than that of the ANN.

Present Synthesizing Situation and Application Mechanism of Hercynite in Cement Kilns

The magnesia -hercynite bricks offer a new lining to rotary cement kiln. They are well adopted and widely used in the high temperature zone of cement kiln, and have obtained good performance at rigorous and severe working conditions. The synthesis of hercynite requires a suitable atmosphere with proper O2 partial pressures which makes sure FeO can stably exist at the synthesizing temperature. Current industrial production of hercynite mainly adopts fused method. The other method, sinte- ring method, is not mature and needs further research. The magnesia - hercynite brick shows high hot toughhess, high adhesion strength to kiln crust, and good corrosion resistance to alkali salt in cement kilns. The mismatching of thermal expansion between magnesia and hercynite can improve the thermal shock resistance of the bricks, but the oxidation of partial Fe^2＋ , the high temperature solution, and low temperature exsolution of transgranular secondary spinel lead to cubical expansion, .formation of more cracks, and poor thermal shock resistance of the bricks.

Mathematical models and expert system for grate-kiln process of iron ore oxide pellet production.Part Ⅱ:Rotary kiln process control

Rotary kiln process for iron ore oxide pellet production is hard to detect and control.Construction of one-dimensional model of temperature field in rotary kiln was described.And the results lay a solid foundation for online control.Establishment of kiln process control expert system was presented,with maximum temperature of pellet and gas temperature at the feed end as control cores,and interval estimate as control strategy.Software was developed and put into application in a pellet plant.The results show that control guidance of this system is accurate and effective.After production application for nearly one year,the compressive strength and first grade rate of pellet are increased by 86 N and 2.54%,respectively,while FeO content is 0.05% lowered.This system can reveal detailed information of real time kiln process,and provide a powerful tool for online control of pellet production.

Mathematic simulation of heat transfer and operating optimization in alumina rotary kiln

Based on the analysis of material motion in the axial direction, heat transfer and mass transport processes in a rotary kiln, and combining with pulverized coal combustion, material pyrogenation, cooling of furnace wall finally, and heat transfer and mass transport equations, the combined heat transfer mathematical model for alumina rotary kiln was built up. According to the in-site real operation parameters, the heat transfer mathematical model was solved numerically for an alumina rotary kiln to predict the temperature profiles of gas and material in the axial direction. The results show that as the excess air coefficient reduces from 1.38 to 1.20, the temperature of the sintering zone increases and the length decreases. However, as the excess air coefficient reduces from 1.20 to 1.10, the temperature of the sintering zone decreases and the length increases. When the mixed coal amount at the end of kiln is reduced from 68.6 kg/t to 62.0 kg/t and the burned coal amount at the head of kiln correspondingly increases from 155.3 kg/t to 161.9 kg/t, the sintering zone temperature increases and the length reduces. The suitable excess air coefficient and mixed coal amount at the end of kiln are recommended for the rotary kiln operation optimization.

Mathematical Model for the Rotary Kiln Process and Its Application

A mathematical model to predict the operation behaviours of the rotary kiln process and to describe the axial distribution of process variables along the length of the reactor has been developed in present work.The model is established based on the principle of mass and heat balance in the system under a steady state with the consideration of kinetic characteristics of the processes.Four examples of the simulation processes in a pi- lot kiln and 3 commercial kilns by using the present mathematical model are given in this paper.The good agreement between the predicted results and the measured data has been obtained.

A New Kind of Eco-Cement Made of Cement Kiln Dust and Granular Blast Furnace Slag

A research project wus conducted to manufacture eco-cement for sustainable development using cement kiln dust（ CKD ） and granular blast furnace slag（ GBFS ）. In the project, the burning process and minerul compositions of CKD dinker were investigated. Different minerulizers such as CaSO4 and CaF2 , sulfur and alkali corttent were coasidered. The strength of CKD and GBFS eco-cement were evaluated. The results indicate the CKD clinker can not only form ordinary cement clinker minerals such as C3 S, C2 S and C4 AF , but also form such high-reuctive minerals as C4 A3 S and C. A7 · CaF2 . The CKD and GBFS eco-cement will have the similar strength to the Portland cement grade 32.5 when blend proportion is properly applied.

Application of the Hand-instrument of Measurement of Tyre Gap and Diameter in Cement Rotary Kiln

This article is concerned with the cement rotary kiln, thehand-instrument of measurements of tyre gap and the outer diameter.The accuracy of measurements of tyre gap and diameter is less than ±1 mm. The hand-instrument wins two patents in China. It has beenapplied to the measurement for 16 sets of cement ro- Tary kiln inChina.

Numerical analysis of behavior of active layer in rotary kilns by discrete element method

The behavior of the active layer of material bed within rotary kilns plays a key role in industrial applications.To obtain its influences on industrial process,different regimes of particle motion have been simulated by discrete element method(DEM) in three dimensions under variant rotation speeds,filling degree,based on the background of induration process of iron ore pellets.The influences of the mentioned factors on the maximum thickness of the active layer and the average velocity of particles have been investigated.The average velocity of particles increases with Froude number following the power function over a wide range,and the maximum thickness rises with increasing rotation speed in a way of logarithm.The influence of the filling degree f on the maximum thickness exhibits a good linearity under two classic regimes,but the increasing of the average velocity of the active layer is limited at f=0.4.This basic research highlights the impact of the active layer within rotary kilns,and lays a good foundation for the further investigation in mixing and heat transfer within the particle bed inside rotary kilns.

Improvement of geotechnical properties of sabkha soil utilizing cement kiln dust

Improvement of properties of weak soils in terms of strength,durability and cost is the key from engineering point of view.The weak soils could be stabilized using mechanical and/or chemical methods.Agents added during chemical stabilization could improve the engineering properties of treated soils.Stabilizers utilized have to satisfy noticeable performance,durability,low price,and can be easily implemented.Since cement kiln dust(CKD) is industrial by-product,it would be a noble task if this waste material could be utilized for stabilization of sabkha soil.This study investigates the feasibility of utilizing CKD for improving the properties of sabkha soil.Soil samples are prepared with 2% cement and 10%,20% or 30% CKD and are tested to determine their unconfined compressive strength(UCS),soaked California bearing ratio(CBR) and durability.Mechanism of stabilization is studied utilizing advanced techniques,such as the scanning electron microscope(SEM),energy dispersive X-ray analysis(EDX),backscattered electron image(BEI) and X-ray diffraction analysis(XRD).It is noted that the sabkha soil mixed with 2% cement and 30% CKD could be used as a sub-base material in rigid pavements.The incorporation of CKD leads to technical and economic benefits.

Modeling of Rotary Kiln in Cement Industry

Cement production is a highly energy-intensive process, and the rotary kiln is the most important part of the process. Having a comprehensive model of the kiln in order to reduce manufacturing costs, better performance can be created. In this paper, the influence processes in a simulated cement rotary kiln and operating parameters on the output of the study were to develop and validate the systems using the same batch. The followings were examined: solid phase, gas and coating temperature change in a rotary kiln.

Enhanced recovery of zinc and lead by slag composition optimization in rotary kiln

High-efficiency recovery of Zn and Pb from silicon-rich zinc leaching residues is realized in a rotary kiln.Characterizations by means of XRD,SEM,EDS and ICP reveal that the leaching residue contains 12.4 wt.%SiO_(2),16.1 wt.%Zn,and 7.4 wt.%Pb.Thermodynamic analysis shows that metallic vapor of Zn and Pb can be easily generated from the zinc leaching residue at 1150-1250°C inside the rotary kiln.Viscosities and melting points of 13 slag compositions were analyzed and three slag compositions(47wt.%SiO_(2)-23wt.%CaO-30wt.%FeO,40wt.%SiO_(2)-28wt.%CaO-32wt.%FeO,and 40wt.%SiO_(2)-30wt.%CaO-30wt.%FeO)possessed the desirable physical properties,with the melting point and viscosity in the range of 1150-1280°C and 0.2-0.5 Pa·s,respectively.The industrial tests show that adopting the optimized slag composition can contribute to very high recovery rates of Zn and Pb(97.3%for Zn and 94.5%for Pb),corresponding to slags with very low average contents of Zn and Pb(0.51 wt.%Zn and 0.45 wt.%Pb).The National-Standard leaching tests of the water-quenched slags result in 1.82 mg/L Zn,~0.01 mg/L Cu,0.0004 mg/L As,~0.01 mg/L Cd,0.08 mg/L Pb,and~0.02 mg/L Hg in the leachate,verifying the detoxification of the zinc leaching residue at the same time.

Study on reactions of gaseous P_2O_5 with Ca_3(PO_4)_2 and SiO_2 during a rotary kiln process for phosphoric acid production

In a rotary kiln process for phosphoric acid production,the reaction between gaseous phosphorus pentoxide（P2O5）and phosphate ore and silica contained in feed balls（the so-called P2O5＂absorption＂）not only reduces phosphorous recovery but also generates a large amount of low melting-point side products.The products may give rise to formation of kiln ring,which interferes with kiln operation performance.In this study,the reactions of gaseous P2O5with solid calcium phosphate（Ca3（PO4）2）,silica（SiO2）and their mixture,respectively,were investigated via combined chemical analysis and various characterizations comprised of X-ray diffraction（XRD）,Fourier-transform infrared（FT-IR）spectroscopy,thermogravimetric analysis and differential scanning calorimeter（TG＆DSC）,and scanning electron microscopy and energy dispersive spectrometer（SEM＆EDS）.Attentions were focused on apparent morphology,phase transformation and thermal stability of the products of the P2O5＂absorption＂at different temperatures.The results show that the temperature significantly affected the＂absorption＂.The reaction between pure Ca3（PO4）2 and P2O5 occurred at 500℃.Calcium metaphosphate（Ca（PO3）2）was the primary product at the temperatures≤900℃ with its melting point≤900℃ while calcium pyrophosphate（Ca2P2O7）was obtained over 1000℃,which has a melting point≤1200℃.The＂absorption＂by pure SiO2 started at 800℃ and the most significant reaction occurred at 1000℃ with formation of silicon pyrophosphate（SiP2O7）product of melting point≤1000℃.Using mixed Ca3（PO4）2and SiO2as raw material,the＂absorption＂by Ca3（PO4）2 was enhanced due to existence of silica.At 600–700℃,silica was inert to P2O5and thus formed a porous structure in the raw material,which accelerated diffusion of gaseous P2O5inside the mixture.At higher temperatures,the combined＂absorption＂by calcium phosphate and reaction between silicon dioxide and the＂absorption＂product calcium pyrophosphate,reinforced the＂absorption＂by the mixture.Besides,it was found that both Ca（PO3）2and SiP2O7were unstable at high temperatures and would decompose to Ca2P2O7and SiO2,respectively,at over 1000℃ and 1100℃ with the release of gaseous P2O5at the same time.