Rotary Furnace

Lead Smelting Rotary Furnace Lead smelting rotary furnace is widely used for the Lead paste smelting of Battery recycling plants all over the world. SM Industry have rich experience in providing complete system according to customer requirements, which includes: rotary furnace and filters. The rotary furnace is consist of furnace body, driving system, burner hole, off-gas holefilters. Equipment name:� Lead smelting rotary furnace Capacity:� 1~20Tons/batch Application:� Lead acid battery recyclers, Lead ore smelter, Secondary Lead smelters Raw material:� Lead paste from used battery, Lead ore, Lead dross, Lead slag, crude Lead, and other Lead containing materials Product: 98% purity crude lead Fuel: natural gas, heavy oil, petroleum coke Brick: Mg-Cr brick Burner: pyronics burner Motor and reducer: China famous brand motors and reducers Related equipment: battery crushing and separation system, Lead kettles, ingot casting machine, Lead ladles Advantages 1.Good adaptability. It can be used for the roasting and smelting for many type of materials, its capacity can tolerate 50-100% of changes. Comparing with reverberatory furnace, it has higher production energy rate and lower fuel consumption. 2.Small length-diameter ratio, small temperature difference, quick heat transferring, and uniform smelting temperature in the furnace. 3.High heat efficiency and good seal performance. 4.Furnace can rotate, which make the firebricks has a longer life service. 5.Good operation environment with high mechanization level and low labor intensity. 6.The rotating speed can be adjusted according to process requirements. 7.Fuel can be diesel, natural gas, gas, powdered coal, heavy oil, and so on. The gas after heat exchanger will enter surface cooler and then dust bag collector. We can provide customized service for you, you are warmly welcome to visit us!

Rotary furnace is mainly used for metal salt calcination and metal oxide reduction process, such as APT calcination, blue tungsten reduction, etc.

This kind of cast spiral rotary furnace retorts is produced by your drwaings or we can design by your need. Wooden package or by your required

UNIVERSAL TILTING ROTARY FURNACE (UTRF) for Lead recycling the above mentioned photograph under production capacity 10 ton/batch. Universal Tilting Rotary Furnace is designed like a rotary closed well furnace. It has advantages of rotary furnace, rebvetory furnace and dry hearth furnace in a single equipment. Main advantage of UTRF is that it can be rotated as well as tilted. Firstly lead scrap is loaded in furnace with smelting flux and furnace locked. The material is heated with the help of oil/gas burner which is mounted on the door, until it reaches melting point. Heating is immensely faster because of horse shoe flame design. Due to the quick heating, consumption of oil and melt loss is very less as compared to the conventional tube furnace. Merits of Universal Tilting Rotary Furnace: 1. Less amount of flux is required for melting. 2. Efficient working condition. 3. All non-ferrous scrap can be recycled in a single unit. 4. Homogenous charge resulting in high quality of material. 5. Self-cleaning of lining. 6. Recurring cost is approximately 30% less as compared to horizontal rotary furnace. 7. Ensures faster melting rate. 8. Better yield. Comparison between UTRF and Horizontal fixed axis Rotary Furnace: The traditional furnace (fixed axis rotary furnace) is primarily a rotating tube with burner on one end and flue at the other. The furnace functions under negative pressure and gets cold air from outside making it virtually impossible to control the atmosphere in the furnace, which is nearly always oxidizing (air rich). It view of it, large amount of flux is required to protect the charge. Consumption of oil is also high because travel length of flue gas is less. On the other hand, UTRF furnace is designed with a single entrance and exist point. The door carries burner and flue. The furnace operates under positive pressure and during firing of the burner there is complete absence of cold air from outside resulting in reduced amount of flux required during operation. In addition the furnace operates at an angle, the charge is mixed with similar action that of a concrete mixing machine. This improves homogeneity heat transfer resulting in high thermal efficiency. Salient Features of Universal Tilting Rotary Furnace: 1. Tap to tap cycle time 4- 5 Hrs. 2. Energy consumption 600 Kw/MT 3. Robust steel structure with proven drum 4. Life of refractory lining is long 5. Oversize driving system and bearings. 6. Tilting, door opening and closing is hydraulically operated. 7. Sturdy interlocks for safety of the equipment. 8. Less manpower required. Only two persons per shift can operate the furnace.

Rotary Hearth Furnace Based Pig Iron This is the Latest Technology to Produce the Pig Iron or MS Iron out of the Iron Ore Fines and Non-coking Coal. In this Technology, the Coal Consumption is the minimal as compared to the Tunnel Kiln Process or Rotary Kiln Process. Through RHF, either Pig Iron (Fe=96-97% C=3.0-4.0%) or MS Steel (Fe=99% C=0.2% Mn=0.3% etc) or HBI (Hot Briquetted Iron) (Fe=92% C=0.25%) can be made, depending upon the requirement. The entire time for the Reduction, Melting and Product Out will be around 45 min, so the larger capacity of the Plants can be made. This process is also Lowest Space Consuming Plant. The Best Part of this Technology is that we can Product the Ferro Alloys too, like Ferro Nickel (Fe-Ni), Ferro Chrome (Fe-Cr) or Ferro Vanadium (Fe-V) etc from the same Plant, by implementing different Parameters of Operations. We can Control the Low Carbon Ferro Chrome, MS Steel and many more.

Rotary tilting refining furnace The rotary tilting refining furnace is mainly used for the pyrometallurgical refining of recycled metals (mostly used for impure copper). In order to improve the technical and economic comprehensive indicators of the tilting refining furnace, it is best to have a copper grade higher than 90% when entering the furnace. For raw materials with lower copper grades, it is best to first undergo pre-treatment in the blast furnace and blowing furnace before entering the tilting furnace. The furnace body of the rotary furnace is installed on a rotating frame, which, under the action of a hydraulic cylinder, can tilt the furnace body within a certain angle range to achieve process actions such as feeding, melting, and dumping slag. At the same time, the furnace body can rotate around its axis under the action of the transmission mechanism; The rotary motion improves the heating efficiency of the furnace and is of great significance for the overheating of the molten metal. When melting metal in this furnace, a certain amount of slag forming agent needs to be added. The molten slag forming agent and slag liquid have a protective effect on solid and liquid metals, which can prevent metal oxidation The burning loss rate of elements such as silicon and manganese in a rotary cupola is equivalent to that of a coke burning cupola. The content of carbon elements in the rotary furnace is decreasing, so it is necessary to add a certain amount of carburizing agent ( graphite) to the furnace material.

About Rotary Furnace The Rotary Melting Furnace is a very flexible and universal equipment used for recycling many non-ferrous metals. It is the major lead production technology used in India and many other countries for Secondary Lead Production. A lead production system based on this technology has certain distinct characteristics such as: •Equipment scalable for installing higher capacities •Recovers all lead in one production cycle •Plates & powder from scrap battery as well as slag from Mini Blast Furnace can be used as raw material •Requires addition of certain consumables •Can be fired with various fuels •Generates high Pollution both as Flue Gases & Fugitive Emissions Description of Rotary Furnace It is a Rotary kiln in the form of a metallic cylinder with conical sides on both ends. Mild steel plate is used for construction of this shell and its thickness varies depending upon the capacity of the equipment. This shell is rotated on its own axis at 1-2 rpm. For this purposes tyres (also called riding rings) are fitted on the shell. These are fabricated from MS squares or flats, machined for a smooth finish. These tyres ride on steel rollers which are again machined finely. These rollers are fitted on a robust MS structural frame and driven by a gear & motor arrangement. The shell is lined inside with insulation and fire bricks of suitable Alumina content. Conical ends of the furnace are open on both sides. The furnace is charged with Raw material along with additives from the front end. This side is provided with a movable door on which a burner is mounted. The burner can be a conventional one or a fully automatic one depending upon the fuel used. At the other end, an exhaust block lined with refractory bricks is provided. A tapping hole is provided in the center of the shell from where molten metal & slag are discharged. Flue gases generated are sucked from the exhaust block side of the furnace. A typical 3.0 TpB Rotary Furnace has the following standard sizes & specifications : •Outside dimensions of the Rotary •Shell dia : 2075mm •Shell length : 2500mm •Total length : 4500mm •Charging dia : 450mm •Exhaust side dia : 450mm •Refractory thickness : 200mm •Fuel : Furnace Oil •Burner : Model 4 A Make: Wesman with complete assembly •FD Fan capacity : 550 cmh at 44mm of WG •Gear Box in drive : 8”, 1:40 Ratio •Motor in drive : 15.0 HP x 960 RPM •Structure used for base : ISMC 250 x 80 Advantages •Recovers 100% lead in the first operation. •Slag produced is lead free. •Equipment can be scaled up for higher production capacities. Disadvantages •Many chemicals are required for operation. •High power consumption. •Difficult to produce low Antimony lead suitable for soft lead purposes. •Fugitive Emissions need to be captured in addition to flue gases. •Need skilled operators and careful maintenance.

About Rotary Furnace The Rotary Melting Furnace is a very flexible and universal equipment used for recycling many non-ferrous metals. It is the major lead production technology used in India and many other countries for Secondary Lead Production. A lead production system based on this technology has certain distinct characteristics such as: Equipment scalable for installing higher capacities Recovers all lead in one production cycle Plates & powder from scrap battery as well as slag from Mini Blast Furnace can be used as raw material Requires addition of certain consumables Can be fired with various fuels Generates high Pollution both as Flue Gases & Fugitive Emissions Description of Rotary Furnace It is a Rotary kiln in the form of a metallic cylinder with conical sides on both ends. Mild steel plate is used for construction of this shell and its thickness varies depending upon the capacity of the equipment. This shell is rotated on its own axis at 1-2 rpm. For this purposes tyres (also called riding rings) are fitted on the shell. These are fabricated from MS squares or flats, machined for a smooth finish. These tyres ride on steel rollers which are again machined finely. These rollers are fitted on a robust MS structural frame and driven by a gear & motor arrangement. The shell is lined inside with insulation and fire bricks of suitable Alumina content. Conical ends of the furnace are open on both sides. The furnace is charged with Raw material along with additives from the front end. This side is provided with a movable door on which a burner is mounted. The burner can be a conventional one or a fully automatic one depending upon the fuel used. At the other end, an exhaust block lined with refractory bricks is provided. A tapping hole is provided in the center of the shell from where molten metal & slag are discharged. Flue gases generated are sucked from the exhaust block side of the furnace. A typical 3.0 TpB Rotary Furnace has the following standard sizes & specifications : Outside dimensions of the Rotary Shell dia : 2075mm Shell length : 2500mm Total length : 4500mm Charging dia : 450mm Exhaust side dia : 450mm Refractory thickness : 200mm Fuel : Furnace Oil Burner : Model 4 A FD Fan capacity : 1250 cmh at 1000mm of WG Gear Box in drive : 8, 1:40 Ratio Motor in drive : 15.0 HP x 960 RPM Structure used for base : ISMC 250 x 80 Manufacturing Process Lead to be manufactured from Rotary Furnace can be obtained directly from scrapped batteries or as slag from Mini Blast Furnace. In case of former, batteries are cut open or broken to segregate lead scrap, plastic and other materials from them; lead scrap in the form of lead powder/ plates etc. is charged in the furnace along with a proportionate charge of additives. In the case of latter, slag produced from Mini Blast Furnaces is charged into the Rotary Furnace, again with proportionate additives. This process is a batch type process. After filling the required quantity of raw material (either manually or mechanically), the lid of the furnace at the front is closed. The burner attached to the moving door is then fired. Complete mass of lead raw. Material along with additive chemicals is heated at high temperature inside the furnace. After some time, molten lead is collected at the bottom of the furnace by puncturing the central opening of the Rotary Furnace. Lead is collected either directly into Jumbo Ingot Moulds or in receiving channels from which they are poured into Jumbo Ingot Moulds. After draining the Furnace of the first batch, production of next batch is undertaken and the Furnace is again charged with raw material. After three such batches, one batch of slag collected in Rotary Furnace is executed. This process leads to generation of flue gases which are toxic in nature and need appropriate and adequate Air Pollution Control System for their treatment. The steps of Charging and Tapping of Rotary Furnace also lead to generation of Fugitive Emissions which need to be captured at source and treated to maintain ambient air standards at workplace. Process Details of a typical 3.0 TpB Rotary Furnace Raw Material Charged3000 kgs/ Batch Total additive chemicals charged:400-500 kgs/ Batch Rotational speed1-2 RPM Fuel usedFurnace Oil Calorific value of fuel used8600 kCal/ kg. Fuel consumed30-40 lt/ hr. Air provided for process1250 cmh Lead produced9000-10000 kg/day (for Raw Material feed of 12-15 T raw material being lead powder and plates) Flue gas generation15000 cmh Section View of Rotary Furnace Advantages and Disadvantages of Rotary Furnace Advantages Recovers 100% lead in the first operation. Slag produced is lead free. Equipment can be scaled up for higher production capacities. Disadvantages Many chemicals are required for operation. High power consumption. Difficult to produce low Antimony lead suitable for soft lead purposes. Fugitive Emissions need to be captured in addition to flue gases. Need skilled operators and careful maintenance. Air Pollution Control Device for Rotary Furnace Apart from plates and paste of lead oxide from scrap batteries, slag from Mini Blast Furnace is charged in the Rotary Furnace. In addition to these, certain compounds of sulphur are also present in the batteries. When this material is heated in the presence of carbon, lead oxide is converted to lead. This conversion along with burning of fuel generates flue gases and fumes containing dust, dirt, oxides of lead, lead particles and such other impurities etc. Hence, to meet various goals of maintaining employees' health and factory environments as well as regulatory requirements, it becomes imperative to get high end Air Pollution Control Systems to be installed with the Rotary Furnaces. Characteristics of Air Pollution generated in Rotary Furnace Selection of Technology for Air Pollution Control System Based on the parameters and the standards mentioned, the following technology is adopted for Air Pollution Control System in Rotary Furnace: Rotary Chamber Gravity Chamber Involute Cyclone Pulse Jet based Bag House Filtration System Details of Equipments allow with Functions Rotary Chamber Rotary Chamber receives very hot gases from Rotary Furnace while cold gases from atmosphere are induced into chamber via specially designed profile. Thus chamber works as an equalizing chamber to reduce the temperature of gases and also where sedimentation of dust particulate matter takes place. Duct & Bends Ducts and Bends are required to convey flue gases from point of suction to final top of the chimney and connect various equipments like gravity chamber, cyclone, bag house, ID Fan and chimney. All bends and reducers are aerodynamically designed and have provision of manhole cleaning mechanism. Gravity Chamber It is a low pressure drop device which: Allows large size particles to settle down Cools down temperature of flue gases Used as spark arrestor to entrap live or red hot particles. Involute Cyclone Cyclone is used to remove medium size particles from flue gases stream. The treated flue gases are discharged from top and dust is collected at bottom. Bag Filtration System It is used for final filtration of flue gases to remove fine dust particulate matter using Pulse Jet Technology. Treated gases from all the bags are collected at top of bag house and passed through ID Fan to exhaust the same through chimney. The dust is collected at bottom of hopper and is discharged through Rotary Air Lock Valve. ID Fan ID Fan provides necessary driving force to convey flue gases from top of furnace to top of the chimney. The volume sucked overcome the total resistance offered by equipment and duct with the help of fluid horse power provided by ID Fan driven by suitable motor. Stack (Chimney) The generated gases are passed into atmosphere after treatment through chimney of suitable height and diameter. At the time of Delivery