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There are many types of sand kiln burners, also known as shaft kiln burners or cement kiln burners, used for cement and sand with different air and fuel combinations.
The specifications of the sand kiln burners vary according to the model and manufacturer's details. Industrial burners typically start with a 20 mm fuel inlet line that tapers or reduces according to the distance to the fuel tank. The fuel pump pressure is between 2.5-3.0 bar to allow atomization of the fuel, and the flow rate is between 30-80 liters an hour. The air fan, whose job is to mix the fuel with air, has a flow rate of 300-450 m3 per hour, and its motor is 0.75-1.5 kW. The atomization of the fuel is done through an air-atomizing nozzle. The parameter details may change according to whether it is a light or heavy fuel oil burner.
Sand rotary kiln burners that use natural gas or propane operate differently. Natural gas projects require a gas inlet line of at least 3/4 inches with a low-pressure requirement of 7” to 14” w.c. or a high-pressure requirement of 3 to 60 psig. Fuel propane lines are similar but use liquid propane gas from a tank. The gas flow rate is higher than oil and can range between 1000-2000 m3 per hour. The gas mixture uses an air mixture system called a vortex to ensure efficient combustion in the kiln. The parameter for sand rotary kiln burners with an air vortex may be 41.5 to 42.2 kcal/m3.
All machines have a fan that blows air used for combustion. It has a diverse pressure range from 0.5-3.0 bar. The atomization of the fuel from the oil tank is done through the air pressure and a nozzle. The exact details of the fan and pump vary for every design and model.
All burners require regular maintenance to ensure they do not develop problems and operate efficiently. According to the manufacturer, the first step is to familiarize oneself with the entire burner and what parts require lubrication and their oiling points. This is usually included in the manuals supplied with the burners. Parts that require frequent oiling are the driving motor bearing, chain hoists, running gear, side thrust rollers, cage bearing, thrust bearings, roller support blocks, gear boxes, vent bearings, and front and rear kiln bearings, among others.
Some parts may require grease instead of oil, such as the side gear bearings and the gear boxes. Users are advised to follow instructions carefully and know which part requires oil or grease. Apart from lubrication, the sand burner needs to be cleaned. To maintain efficiency and minimize pollution, many companies now install dust collection systems to suppress dust internally. A few companies use automated systems so that the machines do not require to be shut down for cleaning.
Generally, the dust is first collected and sent to the mixing area. A conveyor system usually helps the product to be sent to the processing area before it is finally used in the furnace. The cleaner the system, the more product ends up in the kiln and the less energy required to put into processing.
The efficiency of sand kiln burners affects the economy of many industrial and commercial sectors and their overall development. The following list shows some major usage scenarios of these burners:
Ceramic industry:
Sand kiln burners are commonly used in ceramic industries in various countries to fire ceramics such as porcelain, sanitary ware, and tableware. Control the combustion intensity of the burner to achieve the desired firing temperature and ensure the quality of ceramic products.
Cement production:
Semi-automated or fully automated sand kiln burners are essential equipment in the cement industry. They provide the thermal energy required for cement calcination in cement kilns by burning different types of fuels.
Glass manufacturing:
Sand kiln burners also play an important role in the glass manufacturing industry. They are responsible for providing the required high temperatures for glass melting and shaping in the glass production process.
Refractory materials:
Refractory materials need to withstand high temperatures and harsh environments, so their manufacturing processes require professional-grade burners to make the final product more reliable. Sand kiln burners ensure uniform firing and stable quality in the production of refractory materials by providing high-temperature combustion.
Metallurgical industry:
The metallurgical industry involves steelmaking, nonferrous metal smelting, and other processes. Some metallurgical industries use sand kiln burners to provide combustion heat for certain processes, such as metal refining and alloy smelting. These ensure that the metals are correctly processed and have the desired properties.
Mineral processing:
Some mineral processing industries use sand kiln burners for mineral drying, calcination, and other processes. They help improve the quality and yield of mineral products.
Food industry:
In the food industry, sand kiln burners are used for food drying, roasting, sterilization, and other processes. They provide the required heat sources to ensure food processing is sanitary and safe, while also meeting the relevant quality standards.
Textile industry:
Sand kiln burners can also be used in the textile industry. They provide the heat sources for textile drying, finishing, and other processes, thus, improving production efficiency and product quality.
Choosing the right sand kiln burner requires careful consideration of various factors to ensure its suitability for specific needs. Assess the type of fuel available and selection a sand kiln fuel burner that is compatible with the fuel. In addition, the size of the sand kiln plays a significant role in determining the design and capacity of the burner. Also, the efficiency of the burner impacts the overall operating costs of the kiln.
The environmental impact of the kiln burner should also be considered, including factors like emissions and compliance with regulations. The cost of the burner and its maintenance requirements over time is also important considerations. Finally, seek advice from experts and conduct thorough research before making a final decision.
Q1: What is a sand kiln burner made of?
A1: High standard sand kiln burners are made of robust materials such as metal alloys and ceramics that can withstand extreme temperatures.
Q2: How does a sand kiln burner work?
A2: A sand kiln burner operates by atomizing the fuel and injecting it into the combustion chamber. Then, a high voltage transformer generates electric arcs that ignite the injected fuel. When completely burned, the products of combustion move through the kiln, providing the necessary heat for the material.
Q3: What are the trends in sand kiln burners?
A3: Recently, the development of energy-saving technology and environmentally-friendly technologies for reducing carbon emissions has been focused on in sand kiln burners.
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