How to Achieve Energy Saving and Heat Preservation in Rotary Kiln

Recommendations for high-strength thermal insulation materials: ultra-high-strength ultra-microporous thermal insulation modules. This product combines the compressive strength of heavy bricks with a body density of 2.3g/cm³ or above, and the light weight of a body density of 0.8g/cm³. Thermal conductivity of quality bricks.

The cold surface temperature of large-scale rotary kilns in the cement industry is generally 280-320°C. Because there are no materials with high strength and low thermal conductivity, effective insulation cannot be achieved, resulting in a huge waste of energy.

According to calculations, the use of 40-50mm thick ultra-high-strength ultra-microporous thermal insulation modules in conjunction with conventional cement kiln working layer materials can reduce the cold surface temperature of the kiln body by 100°C-130°C. A medium-sized clinker line with a daily output of 5,000 tons can save about 5,500 tons of standard coal annually. The rotary kiln in the cement industry alone can save companies 20 billion in fuel costs every year. Various types of rotary kilns are used in more than a dozen industries and can save companies hundreds of billions every year.

The ultra-high-strength ultra-microporous thermal insulation module not only takes into account the compressive strength of heavy bricks with a body density of 2.3g/cm³ or above but also has the thermal conductivity of lightweight bricks with a body density of 0.8g/cm³. It is an ideal choice for insulation materials in dynamic kilns such as cement rotary kilns, hazardous waste rotary kilns, alumina calcining rotary kilns, and pellet rotary kilns with high requirements for material compressive strength.

Various measures can be taken to achieve energy saving and insulation in rotary kilns, including high-strength insulation materials. Here are some ways to improve the insulation of your rotary kiln:

High-strength thermal insulation materials: The use of high-strength, high-temperature-resistant thermal insulation materials, such as refractory bricks, ceramic fibers, high-temperature concrete, etc., can effectively reduce heat energy loss and improve the thermal insulation performance of the kiln. These materials remain stable in high-temperature environments and reduce heat conduction, thereby reducing energy consumption.

Thermal insulation coating: Some special thermal insulation coatings can be applied to the surface of the rotary kiln to form a thermal insulation layer and reduce heat loss.

Optimize kiln structure: Properly designed kiln structure, including appropriate insulation, internal shape, and material distribution, to reduce heat energy transmission and thermal radiation.

Heat recovery technology: Use a heat recovery system to recycle and reuse the heat energy in the high-temperature exhaust gas to improve energy efficiency.

Temperature control and automation: Through temperature control and automation systems, the operation of the kiln can be managed more effectively and excessive waste of energy can be avoided.

Thermal insulation coating: Install thermal insulation coating on the outside of the kiln, such as refractory bricks, ceramic fiber blankets, etc., to reduce heat energy transfer and improve the insulation effect.

Energy management and monitoring: Establish effective energy management and monitoring to detect and solve energy waste problems promptly.

It is necessary to select suitable energy-saving insulation measures based on the specific kiln type, process flow and temperature requirements, and comprehensive consideration of various factors. It is recommended to consult with a kiln engineer or energy manager to develop an energy-saving program suitable for your situation.