Commissioning of the 110m long horizontal kiln had a number of challenges, including adjustment of the Burner Management System (BMS) Air/Fuel ratio to produce a perfect flame pattern and efficient heat transfer to the product. The wet magnetite (Vanadium/Iron/Titanium) concentrate travels towards the flame, propelled by the rotation of the kiln. The product is cooled as it exits the kiln via heat recovery chambers to improve the energy efficiency. The final product is then cooled, dried and reduced in a DC Arc Furnace to produce Ferro-Vanadium ingots.
This photo shows the horizontal kiln, which is seated on rollers which are designed to allow for expansion of the steel frame. Multiple temperature sensors built into the structure measure the product as it flows towards the hot end of the kiln. The exhaust gas is filtered to remove dust, and a small negative pressure is maintained at the product feed chute at all times to prevent flameout.
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