Detailed design of Rotary Kiln The design considerations of a

rotary kiln are:

Specifications
Kiln details
Stages in clinker manufacture 1. Kiln slope
Operation LP cyclone preheaters inline calciners 2. Kiln length
Kiln pics 3. Kiln diameter
Important operational parameters 4. Heat load
Heat balance 5. Residence time

Expected operational parametes 6. Volume loading

Kiln barring 7. Material of construction

8. Refractory lining material.
Kiln performance and efficiency
Mechanical drawing
P and id
Specification sheet

Capacity= 4045 tpd 170tp/hr

Feed=6288 tpd
Co2 removed =2243 tpd
Sizing of kilns has been largely empirical.
Kiln capacity: 4045 tpd
Kiln : 4.5m, 66m
Kiln length: (z

1.77×√Q×L×F
Retention time (in minutes) = S×D×n

Where, Q = Angle of repose (usually 350)

L = Length of the kiln (m)
F = Multiplying factor (1)
1.77×√35×L×1
T= 2.29×D×n

Using retention time 27 minutes

2.29×4.5×2.5
L= 1.77×√35×1

L= 66.43m

Using the formula

t = p×d×N
where, t – Residence time (mins) L- Length of kiln (m) p- Slope of kiln
(degrees) d- Diameter (m)
 N-revolutions per minute
Θ-angle of repose (degrees)
Therefore length is given by

L =
Taking t = 35, p=9, d=3.2, n= 0.6
L = 35 x 9 x 3.2x0.6
1.77 x 6
L= 56.01 m

Kiln diameter:
The following rotary kiln slopes were found in cement plant operation handbook.
5% slope for kilns with diameters up to 2.8m
4% slope for kilns with diameter from 3-3.4m
3%slope for kilns with diameter above 3.4m
Therefore kiln slope of 4% the diameter of the kiln is taken to be:
Kiln diameter = 3.2m.
Kiln diameter = 4.5m

Kiln slope (z,hb)

It is generally 2° or 3.5 %. For calciner kiln up to 4% at a reduced speed. To promote longitudinal
travel of the solid the rotary kiln is mounted on a slope of 4%.
Slope = tan (Kiln slope)
Kiln slope = arc tan (slope)
Kiln slope = arc tan (0.04)
Kiln slope = 2.3 degrees
Retention time (hb
For kilns with calciners, retention time could be as short as 27-30 minutes

1.77×√Q×L×F
Retention time (in minutes) = S×D×n

Where, Q = Angle of repose (usually 350)

L = Length of the kiln (m)
F = Multiplying factor (1)
S = Slope of kiln (degrees)
D = Diameter (m)
N = Speed (rpm)
1.77×√35×66×1
T= 2.29×4.5×2.5

=27.01 minutes
Percent filling (hb)
To keep the difference between temperature at surfaces of material and its core, to a minimum it
is desirable to keep degree of filling between 4-6 %.
1.667×𝑇×𝑄×𝑎
Percentage filling (%) = 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑘𝑖𝑙𝑛×𝑏
T = retention time in minutes
Q = Capacity of clinker in tph
a = Ratio of raw meal feed/ product
=1.5545
b= for clinker 1.2 t/m3
1.667×𝑇×𝑄×𝑎
Percentage filling (%) = 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑘𝑖𝑙𝑛×1.2

1.667×27×168×1.5
= 1049.7×1.2
= 9.6%

Peripheral speed (hb, z

To keep same or about same degree of filling, retention time is reduced by increasing kiln speed. A kiln that
was earlier rotating at 1.67 rpm with a peripheral speed of 35 cm Isec will now be rotating at
4.2 rpm or a perpheral speed of 87.5 cm/sec.
3 Kiln speed
Using the equation of filing level

% of filling level =
Assuming 16% filing level,

Kiln speed =
Kiln speed = 0.6 rpm
Kiln speed = 2.5 rpm
=
Heat loads (z
Heat required in raising the feed to 14000C
Q = m Cp ∆T
Q = 11.64kg/s x 0.88 kJ/kgoC x (1400-25)0C Q = 14084 KJ

Heat loss per unit area in the furnace

N.B furnace is made up of 0.20m of firebrick and 0.10 m insulating brick.
Q = T1 – T 2
Σ x1 / k1A
Where; Q = heat loss
T1and T2 = inside and outside temperatures

Q =
Q = 72.58 W/m2

Kiln power
1. Friction power (PI) and
2. Load power (P2)

Friction power(KW), P1 = 0.595 × (W × 𝐷𝑟

Dt × Db × 𝑛×𝐻)

Where, W = Total weight of rotating parts including weight of refractory and charge
in kiln in tons
Dt, Db and Dr are diameters of tyre, bearing and roller respectively (m)
n = Speed (rpm)
H = friction factor (usually 0.018 for kilns)

0.595 × (W × Dt × Db × 𝑛×0.018)
P1 = 𝐷𝑟

load power (kw), P2 = 86.43 × (D Sin h)3 ×L × K × n

Where,
D sinh,
D is diameter of kiln inside lining,
h is half angle at center, formed by the charge.
L is length of kiln (m)
K is a constant, (usually 0.00076 for kilns)
n is speed (rpm)

P2 = 86.43 × (D Sin h)3 ×L × K × n

Rotary kiln

It is a cylinder shaped vessel slanted somewhat to the level which is pivoted gradually about its
axis. The material to be processed is bolstered into the upper end and may experience a specific
measure of blending. Hot gases go along the oven inverse way to the procedure material (counter
current). Hot gases are created by a flame inside the furnace.
Kiln shell material
This is made from rolled mild steel plate welded to form a cylinder .Mild steel is used because of
its good thermal conductivity, resistant corrosion and can withstand high stresses.

Refractory lining material (hb,z

Study Parameter Deviation Causes Consequence Existing Recommended
node safeguards actions

Heating Temperature High MFC Burn Temperature A digital

chamber malfunction controller thermocouple
can be used
continuously
Low Improper Condensation Temperature A digital
insulation of toluene controller thermocouple
Controller can be used
malfunction continuously
Line Flow High MFC Over pressure No safe Flow meter after
connecting malfunction and impinger guards impinger outlet
impinger outburst
outlet and
Tee Low Leakage, Toluene Manual Short distant
condensation inhalation leakage connection
of toluene checking
and blockage
Line Flow High MFC Over pressure No Flow meter after
connecting malfunction and impinger safeguards impinger outlet
MFC and outburst
impinger
Low Leakage in Toluene Manual Actual flow
valve and inhalation leakage measurement
connection checking after MFC

Line Flow High MFC Error in Manual Monitoring of

connecting malfunction results flow flow before GC
3-Way checking inlet
valve and
GC Low Leakage, Blockage and Manual Short distant
Condensation overpressure flow connection to
in line checking GC
No Leakage in Toluene Manual Short distant
valve and inhalation leakage connection,
connection checking Monitoring of
flow.
Kiln is a cylinder. Refractory lining is 150, 200 and 250 mm thick according diameter of the kiln.
Quantity of bricks can be roughly estimated

D = diameter inside shell

d = diameter inside refractory
L = length of kiln
Volume of bricks = 0.785 (D2 - d2 ) L m3
If bulk density is 1.9 t / m3,
Weight of bricks = ::::: 1.5( D2 - d2) L tons.

This is also true of all round vessels like caiciners, ducts like t.a. ducts.
Ready reckoner tables or graphs can be built up to estimate weight of refractory for kilns of
different diameter

Refractory bricks called andalusite based fire bricks are used in lining to insulate the steel shell
from the high temperatures inside the rotary kiln, and to protect it from the corrosive properties
of the process material. The refractory selected depends upon the temperature inside the kiln and
the chemical nature of the material being processed. The thickness of the lining is 200 mm.

Thickness of the kiln shell

Operating pressure = 1 atm
Operating temperature = 350 degrees
Diameter of the kiln = 3.2 meters
Design pressure at 5% above operating temperature

Design pressure = N/m2

Design pressure = 1.064 105 N/m2
Therefore the design stress for mild steel at is 841 MPa

Minimum thickness =

Thickness =
Thickness = 200mm

Thermal expansion of the kiln shell

A = ά ×∆𝑇×l
Where;
A-Thermal expansion of the kiln shell ά –linear expansion index for steel (0.000012mm/m) l-
Length (m)
T- Change in temperature
A = 0.000012 (1000-25)× 3.2 × 1000mm
A = 37.44 mm

Stress Analysis
The stresses that act on the rotary kiln are axial and compressive stresses Axial stress =
where;
p- Density of mild steel Di – inner diameter t- Thickness
C- Corrosion allowance
Assuming a corrosion allowance of 3mm,

Axial stress =
Axial stress = 518.2 N/m2
Longitudinal stress due to pressure

Where,
P- Design pressure
Di – inner diameter
t- Thickness

Longitudinal stress due to pressure = 3.72 × 𝟏𝟎𝟓 Pa

Table 4: Design parameters of rotary kiln

Kiln length 56.01m

Kiln diameter 3.02m

Kiln slope 4%

Kiln speed 0.6 rpm

Design pressure 1.064 105 N/m2

Operating pressure 1 atm

Operating temperature 1000 -1400 degrees

Shell thickness 200mm

Heat load 14 084 KJ

 Clinker production output 264tons/day

Kiln feed 1006 tons/day

Fuel requirements 39 tons/day

Material of lining Refractory brick lining

Material of construction Mild steel

Kiln Feed = 95.037 kg/day and composition as follows