Refractory Design for Pellet Rotary Kiln
2026-04-13
球团回转窑耐材设计
Refractory Design for Pellet Rotary Kiln
一、工况特点（Working Conditions，生产实操重点）
球团回转窑：Pellet Rotary Kiln，又称链篦机-回转窑，是冶金行业氧化球团生产的核心热工设备，与链篦机、环冷机配套使用，核心功能是将链篦机预热后的850℃左右球团矿进行高温焙烧、固结，生产合格球团矿，现场主流为连续式生产，重点保障焙烧均匀性和设备连续运行效率。 Pellet Rotary Kiln: Also known as Grate-Kiln, it is the core thermal equipment for oxidized pellet production in the metallurgical industry, used in conjunction with grate and circular cooler. Its core function is to perform high-temperature roasting and consolidation of pellet ore (about 850℃) preheated by the grate to produce qualified pellet ore. The on-site mainstream is continuous production, focusing on ensuring roasting uniformity and continuous equipment operation efficiency.
工作温度：按生产流程分三段（现场实操重点控制）：进料段（窑尾）1050～1080℃、焙烧段（核心区）1250～1320℃（高温区域长度15～20m）、出料段（窑头）1150～1180℃，焙烧时间25～35min，温度波动≤±30℃（保证球团强度和品质）。 Working Temperature: Divided into three sections according to production process (key on-site control): feed section (kiln tail) 1050～1080℃, roasting section (core area) 1250～1320℃ (high-temperature area length 15～20m), discharge section (kiln head) 1150～1180℃, roasting time 25～35min, temperature fluctuation ≤±30℃ (ensure pellet strength and quality).
介质环境：现场接触铁精矿球团、高温烟气（含CO₂、SO₂）及焙烧产物，窑内为氧化气氛；核心问题：球团翻滚摩擦磨损、高温烟气冲刷、温度梯度导致热应力，窑体回转产生的机械振动，直接影响耐材附着性和使用寿命。 Medium Environment: On-site contact with iron concentrate pellets, high-temperature flue gas (containing CO₂, SO₂) and roasting products, and the kiln is in an oxidizing atmosphere; core problems: pellet rolling friction and wear, high-temperature flue gas scouring, thermal stress caused by temperature gradient, and mechanical vibration generated by kiln rotation, which directly affect refractory adhesion and service life.
主要损毁形式（生产现场重点关注）：球团摩擦磨损、高温热震剥落、气氛侵蚀、窑体回转导致的衬体松动、局部高温烧损及结圈附着冲刷；衬体脱落易造成窑壳过热，影响生产安全。 Main Damage Forms (key focus on production site): Pellet friction and wear, high-temperature thermal shock spalling, atmosphere corrosion, lining loosening caused by kiln rotation, local high-temperature burning and ring formation adhesion scouring; lining shedding is likely to cause overheating of the kiln shell and affect production safety.
核心要求（贴合生产实操）：耐高温、抗热震、抗磨损、抗氧化侵蚀，结构稳定且附着性强；适配窑体4.25%左右倾斜度，满足回转工况需求，正常工况下耐材使用寿命需达1～2年（窑口部位12～18个月），降低检修频次和停机损失。 Core Requirements (fit for production practice): High temperature resistance, thermal shock resistance, wear resistance, oxidation corrosion resistance, stable structure and strong adhesion; adapt to the kiln body inclination of about 4.25% to meet the rotation working condition requirements. Under normal working conditions, the refractory service life shall reach 1～2 years (12～18 months for the kiln mouth), reducing maintenance frequency and shutdown losses.
二、整体耐材结构设计（Production-Oriented Overall Refractory Structure Design）
现场采用“工作层+保温层+截热层”复合砌筑结构，结合梯度截热技术，适配回转窑连续运转和三段式温度梯度特点，兼顾耐材牢固性、保温节能和生产便利性，减少现场检修工作量，降低窑体散热损失。 On-site adoption of "working layer + insulation layer + heat insulation layer" composite masonry structure, combined with gradient heat insulation technology, adapting to the continuous operation of the rotary kiln and the characteristics of the three-section temperature gradient, balancing refractory firmness, heat insulation and energy saving, and production convenience, reducing on-site maintenance workload and kiln shell heat loss.
1. 工作层（Working Layer，生产核心层）
材质选型（现场直接选用）：焙烧段（核心区）用钢纤维增强刚玉莫来石复合浇注料、高铝莫来石预制砖，采用预制砖与浇注料间隔混合砌筑；进料段/出料段用高铝砖、高铝莫来石砖；窑口、结圈易发生区域用抗结圈、抗剥落浇注料；链篦机预热段用低水泥浇注料、轻质莫来石浇注料。 Material Selection (direct on-site selection): Steel fiber reinforced corundum mullite composite castable and high-alumina mullite precast bricks are used in the roasting section (core area), with precast bricks and castables alternately mixed and masonry; high-alumina bricks and high-alumina mullite bricks are used in the feed section/discharge section; anti-ring formation and anti-spalling castables are used in the kiln mouth and areas prone to ring formation; low-cement castables and lightweight mullite castables are used in the grate preheating section.
厚度要求（现场施工标准）：焙烧段150～200mm（抗高温、抗磨损、抗结圈），进料段/出料段120～150mm，窑口加厚至180～220mm（重点防护）；链篦机侧墙工作层厚度80～100mm。 Thickness Requirement (on-site construction standard): 150～200mm for the roasting section (high temperature resistance, wear resistance, anti-ring formation), 120～150mm for the feed section/discharge section, 180～220mm for the kiln mouth (key protection); 80～100mm for the working layer of the grate side wall.
施工要求（现场实操规范）：砖缝≤1.5mm，浇注料振捣密实、无气孔，预制砖与窑体通过锚固钉连接牢固；焙烧段采用高铝胶泥砌筑，进料段/出料段用粘土胶泥；砌筑平整贴合窑体，无松动、错缝，防止球团卡阻和烟气渗透，避免衬体早期脱落。 Construction Requirements (on-site operation specification): Brick joint ≤1.5mm, castable is compactly vibrated without pores, and precast bricks are firmly connected to the kiln body through anchor nails; high-alumina mortar is used for masonry in the roasting section, and fireclay mortar is used for the feed section/discharge section; masonry is flat and closely attached to the kiln body, no looseness or wrong joints, preventing pellet jamming and flue gas penetration, and avoiding early lining shedding.
2. 保温层（Insulation Layer，节能+护壳）
材质选型（现场常用）：纳米保温板、硅酸铝纤维板、轻质高铝砖，隔热效果优良，可有效降低窑体外表温度，减轻窑体负荷，适配现场节能降耗需求。 Material Selection (commonly used on site): Nano insulation board, aluminum silicate fiber board, lightweight high-alumina brick, with excellent heat insulation effect, which can effectively reduce the surface temperature of the kiln body, reduce the kiln body load, and adapt to on-site energy saving and consumption reduction needs.
厚度要求（现场控制）：链篦机、环冷机保温层厚度60～80mm，确保回转窑焙烧区外表温度≤200℃，环冷机Ⅱ冷却段外表温度≤80℃。 ensuring that the surface temperature of the rotary kiln roasting area is ≤200℃, and the surface temperature of the Ⅱ cooling section of the circular cooler is ≤80℃.
施工要求：紧贴工作层或截热层砌筑，无空隙、无破损，外侧用保温砂浆找平，预制砖底部保温层需做好密封，防止保温层脱落和热桥产生，减少热量损失。 Construction Requirements: Masonry closely attached to the working layer or heat insulation layer, no gaps or damage, outer side leveled with insulation mortar, and the insulation layer at the bottom of precast bricks must be well sealed to prevent insulation layer falling off and heat bridge generation, reducing heat loss.
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2026-10-13
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