lab scale rotary kiln

Scope of application

Used for laboratory research on sample sintering, drying, pyrolysis, and other processes, such as ceramic sintering, alumina roasting, and activated carbon activation.

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lab scale rotary kiln

lab scale rotary kiln is a specialized high-temperature thermal treatment equipment designed for laboratory research, pilot-scale tests, and small-scale production trials. Compared with large industrial rotary kilns, the laboratory rotary kiln features a compact size, flexible operation, precise temperature control, and lower energy consumption. It is capable of simulating industrial processes in a limited space, making it an essential research tool for universities, R&D institutions, new materials enterprises, and environmental research centers.

The kiln body is made of high-temperature resistant materials and equipped with an automatic temperature control system. It enables continuous feeding and discharging of materials, which allows for uninterrupted experiments. The lab rotary kiln is widely applied in new material synthesis, catalyst preparation, metal oxides experiments, biomass pyrolysis, activated carbon production, and waste treatment studies.

2. Structure of Laboratory Rotary Kiln

Although smaller in scale, the lab scale rotary kiln shares the same fundamental structure as industrial kilns. The main components include:

(1) Kiln Body

The kiln body is the core of the system, generally made of welded steel plates lined with refractory materials or ceramic fiber insulation. This ensures stable operation under high temperatures. Typical diameters range from 50 mm to 500 mm, with lengths from 0.5 m to 3 m, meeting diverse laboratory requirements.

(2) Transmission System

Consisting of a motor, reducer, and gear mechanism, the transmission system drives the kiln body to rotate slowly. The rotational speed is adjustable, typically between 0.2–10 rpm. The rotation ensures that the material is evenly exposed to heat during processing.

(3) Heating System

The lab kiln can adopt electric heating, gas heating, or infrared heating methods. Electric heating rotary kilns are most common, equipped with precision temperature controllers that maintain stability from room temperature up to 1200°C or even 1600°C.

(4) Feeding and Discharging System

For continuous operation, the rotary kiln is equipped with a feeding hopper and a cooling discharge device. This minimizes manual handling and increases experimental efficiency.

(5) Control System

Modern laboratory rotary kilns come with intelligent controllers, PLC systems, and data acquisition devices. These allow real-time monitoring of temperature, rotation speed, and atmosphere, with additional safety features such as over-temperature alarms and power-off protection.

3. Working Principle of Lab Scale Rotary Kiln

The working principle is similar to that of industrial rotary kilns. The process includes:

1. Feeding: Materials are loaded into the kiln through the feeding device.
2. Rotation & Heating: The kiln rotates slowly while materials tumble inside, ensuring even exposure to high temperatures.
3. Thermal Processing: Depending on experimental requirements, the material undergoes drying, preheating, calcination, reduction, or pyrolysis.
4. Cooling & Discharge: After heat treatment, materials are cooled and discharged for collection and analysis.

4. Applications of Laboratory Rotary Kiln

The lab rotary kiln is widely used in multiple fields:

(1) New Material Research

• Ceramic material sintering
• Metal oxide synthesis
• Catalyst carrier treatment

(2) Energy & Environmental Protection

• Biomass pyrolysis for biochar production
• Solid waste incineration and treatment
• Sludge drying and pyrolysis

(3) Metallurgical Experiments

• Small-scale ore roasting
• Optimization of metallurgical processes
• Oxidation and reduction of rare metals

(4) Chemical & Pharmaceutical Industry

• Calcination of chemical intermediates
• Catalyst preparation
• Heat treatment of pharmaceutical raw materials

5. Advantages of Lab Scale Rotary Kiln

1. Compact and flexible design – Easy to install and operate in laboratories.
2. Precise temperature control – PID controllers maintain accuracy up to ±1°C.
3. Energy-efficient and eco-friendly – Excellent insulation reduces power consumption.
4. Simulation of industrial processes – Small-scale trials provide reliable data for scale-up.
5. High automation – Equipped with PLC and remote monitoring options.
6. Versatility – Supports experiments under air, nitrogen, hydrogen, and inert gas atmospheres.

6. Operation and Maintenance of Laboratory Rotary Kiln

Operation Process

• Pre-check: Inspect power supply, transmission, and temperature control before operation.
• Material preparation: Load material into the feeding hopper according to requirements.
• Start-up: Set parameters such as speed, heating rate, and target temperature.
• Processing: Monitor temperature curves and material conditions during the experiment.
• Cooling and discharge: Stop heating, cool down, and then collect processed materials.

Maintenance

• Regularly check the kiln lining for wear and tear.
• Monitor motor and reducer for abnormal noise.
• Clean the discharge port to avoid blockages.
• Calibrate temperature controllers periodically to ensure accuracy.

7. Selection and Procurement Guide

When purchasing a lab scale rotary kiln, consider the following factors:

1. Temperature range – Choose kilns rated for 1200°C, 1400°C, or 1600°C depending on requirements.
2. Kiln size – Select diameter and length according to material volume and experiment scale.
3. Heating method – Electric heating is most common; gas heating is suitable for special studies.
4. Atmosphere control – Ensure compatibility with inert, reducing, or oxidizing gases if needed.
5. Automation – Decide whether PLC, remote control, and data logging are required.
6. After-sales support – Reliable manufacturers provide installation guidance and technical services.