Ferroalloy and Nonferrous Smelting Rotary Kiln

Ferochrome reduction,ferronickel pre-reduction,direct reduction,ferromanganese decomposition,ferrovanadium reduction

The refractory materials and their configurations used in rotary kilns for smelting ferrochrome reduction, ferronickel pre-reduction, direct reduction, ferromanganese decomposition, ferrovanadium reduction, ferroalloys and non-ferrous smelting are basically borrowed from the refractory materials and configurations used in cement rotary kilns. Since the smelting process of cement materials is very different from that of ferrochrome reduction, ferronickel pre-reduction, direct reduction, ferromanganese decomposition, ferrovanadium reduction, ferroalloys and non-ferrous smelting, there are significant differences in their material state, smelting temperature, and material corrosion ability. This results in a shorter service life of the refractory materials for the ferronickel rotary kiln that uses the refractory materials used in cement kilns, which seriously affects the operation and production cost of ferronickel smelting. During the production of rotary kilns for ferrochrome reduction, ferronickel pre-reduction, direct reduction, ferromanganese decomposition, ferrovanadium reduction, ferroalloy and non-ferrous smelting, the materials at the kiln mouth are already in a molten state, and the molten materials have a considerable erosion on the kiln mouth castables. Since the temperature here fluctuates frequently and is in the medium-temperature stage of castable sintering, the castables currently used have relatively poor performance in terms of corrosion resistance, thermal shock resistance and medium-temperature strength, resulting in a very short service life. The service life of kiln mouth castables provided by some manufacturers is even only one month, which greatly increases the smelting cost of ferrochrome reduction, ferronickel pre-reduction, direct reduction, ferromanganese decomposition, ferrovanadium reduction, ferroalloy and non-ferrous smelting.

The rotary kiln for ferrochrome reduction, ferronickel pre-reduction, direct reduction, ferromanganese decomposition, ferrovanadium reduction, ferroalloy and nonferrous smelting consists of a feed port, a preheating zone, a transition zone, a firing zone (high temperature zone) and a firing zone discharge port. The temperature of the transition zone of the kiln body is basically around 600-700℃. In this zone, the material has undergone partial internal combustion through the previous drying and preheating, and is prone to semi-melting and agglomeration, and the slag is more obvious, so the wear is greater, and when it is close to the high temperature zone, the material is basically in a semi-molten state, and has already produced a certain degree of corrosiveness. The temperature of the firing zone is around 1000-1200℃. During the production process, the high-temperature slag erodes and violently scours the lining refractory of the rotary kiln, the impact of the material during the rotation of the rotary kiln, and the structural stress generated by the oxidation-reduction reaction will all erode the rotary kiln. Once eroded, the refractory will peel off and the service life cannot be guaranteed. Ferrochrome reduction, ferronickel pre-reduction, direct reduction, ferromanganese decomposition, ferrovanadium reduction, ferroalloy and non-ferrous smelting rotary kiln lining refractory materials need to withstand severe thermal, mechanical and chemical damage, so the lining refractory materials should have good corrosion resistance, high wear resistance and high strength.

Special castables for ferrochrome reduction, ferronickel pre-reduction, direct reduction, ferromanganese decomposition, ferrovanadium reduction, ferroalloy and non-ferrous smelting rotary kiln, introducing special bauxite and corundum aggregate, fused mullite and corundum fine powder, andalusite, alumina powder, silica powder, pure calcium aluminate cement, calcium zirconate or zircon according to scientific particle grading compound preparation.

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