Shandong Barite Rotary Kiln Production Project

1. Core Basic Parameters

Core Equipment: Φ2.5×50m special rotary kiln for barite

Production Process: Raw ore crushing → batching and balling → drying and preheating → high-temperature roasting → cooling and screening → finished product packaging

Roasting Temperature: Controllable range of 800-1250℃; constant temperature roasting zone maintained at 1050-1200℃

Design Capacity: Annual processing capacity of 150,000 tons of barite raw ore; annual output of 120,000 tons of high-purity finished products

Operation Mode: 7×24-hour fully automatic continuous production with unattended operation

Environmental Protection Standard: Compliant with Shandong provincial industrial ultra-low emission standards with full compliance and resource utilization of three wastes (waste gas, waste water and solid waste)

Core Advantages: High automation level, low energy consumption, stable finished product quality and convenient operation and maintenance. Since its commissioning, the project has maintained stable operation with a significant increase in product qualification rate and high-end finished product proportion. The comprehensive energy consumption is reduced by more than 18% compared with traditional kilns. It solves the bottlenecks of traditional barite processing including limited production capacity, uneven product quality and excessive environmental emissions, serving as a benchmark project for regional barite deep processing.

2. Main Equipment Configuration

Centered on the Φ2.5×50m special rotary kiln, the project is equipped with a complete set of customized supporting equipment adapted to the high-temperature desulfurization and roasting working conditions of barite. Featuring wear resistance, high temperature resistance, stable operation and long service life, the full equipment configuration is specified as follows:

1) Core Roasting Host: The Φ2.5×50m special rotary kiln for barite adopts a cylinder made of high-quality heat-resistant steel plate with stress relief treatment, delivering excellent high-temperature deformation resistance and wear resistance. Equipped with heavy-duty support rollers and thrust rollers for continuous heavy-load operation, the kiln features frequency-convertible rotating speed, which adapts to ores of different particle sizes and impurity contents. It ensures uniform heating and sufficient roasting of materials, steadily improving the purity and whiteness of finished products.

2) Raw Material Pretreatment Equipment: Consisting of crushers, pulverizers, automatic batching machines and mixing & balling machines, this system grinds raw ore to a standard particle size of 80-100 mesh, realizes precise batching, uniform mixing and ball forming, ensures stable and uniform raw materials fed into the kiln, and avoids roasting defects.

3) Drying and Preheating Equipment: It utilizes waste heat from the kiln tail to pre-dry and preheat ore balls, removing material moisture, reducing internal kiln energy consumption and shortening the roasting cycle. It effectively eliminates kiln temperature fluctuation and crusting & blockage caused by wet material feeding.

4) Cooling and Screening Equipment: Matching vertical coolers and multi-stage vibrating screens are adopted to rapidly cool high-temperature finished products and stabilize material performance. Qualified products and residual materials are accurately screened, and residual materials can be recycled for reprocessing to achieve zero raw material waste.

5) Environmental Protection Treatment Equipment: Equipped with pulse dust removal, SCR denitrification, double-alkali desulfurization, waste heat recovery and workshop dust suppression systems, the equipment performs multi-stage treatment on kiln flue gas to efficiently remove dust, sulfides and nitrogen oxides. The whole production process adopts closed negative-pressure operation, with recycled waste water and fully recycled solid waste, realizing ultra-low emission and green production.

6) Intelligent Control System: Adopting PLC central control and segmented intelligent temperature control system, it real-timely monitors core parameters such as kiln body temperature, rotating speed and feeding capacity, and automatically adjusts production parameters according to raw ore working conditions. It supports remote monitoring and fault early warning, realizing fully automatic unattended production and greatly reducing operation and maintenance costs.

3. Integrated Solutions

Targeting the pain points of barite processing in Shandong including uneven raw ore quality, backward production processes, stringent environmental protection requirements and large-scale production difficulties, the project develops an integrated solution featuring intelligent roasting, energy saving and consumption reduction, ultra-low environmental protection and quality & efficiency improvement.

1) Precise Roasting for Quality Upgrade: Leveraging the large length-diameter ratio of the rotary kiln, the system stably maintains a constant temperature roasting range of 1050-1200℃ to fully desulfurize and purify materials. It dynamically adapts to raw ores of different grades, solving the problems of low purity and unstable quality of finished products, and the finished products meet the material standards for high-end drilling and fine chemical industries.

2) Waste Heat Circulation for Energy Saving and Cost Reduction: The waste heat from the kiln tail is recycled for raw material drying and factory heating. Combined with variable frequency speed regulation and zoned thermal insulation structure, thermal energy loss is reduced significantly. The modular equipment design allows independent maintenance of single units without full-line production shutdown loss, achieving a substantial reduction in comprehensive energy consumption.

3) Ultra-Low Emission for Compliant Production: A multi-stage flue gas treatment, workshop dust suppression and three-waste resource utilization system is established, with all emission indicators superior to local ultra-low emission standards. It completely avoids environmental protection risks and meets the requirements of regular environmental supervision and inspection.

4) Intelligent Automatic Control for High-Efficiency Mass Production: Full-process automatic control enables 24-hour continuous production without manual intervention. Intelligent fault early warning ensures stable equipment operation, and the modular layout facilitates convenient operation and maintenance, fully adapting to large-scale mass production demands.

5) Closed-Loop Production for High-Efficiency Resource Utilization: A closed-loop system covering raw material processing, roasting processing, finished product screening, waste material recovery and waste heat circulation is constructed. All residual materials and dust are secondary utilized to maximize resource utilization efficiency.