Henan Hongke Heavy Machinery Co., Ltd. is pleased to report on the ongoing installation of a brand-new Φ1.6×36m aluminum dross rotary kiln at a customer site in Chongqing, China. This is a completely new production line—not a refurbishment, not an upgrade of old equipment—designed from the ground up for aluminum dross recycling and resource recovery.
Project Background: Turning Aluminum Waste into Value
Aluminum dross is a byproduct of aluminum smelting and recycling operations. It contains metallic aluminum, aluminum oxides, salts, and other compounds . Traditionally, much of this dross was sent to landfill, but increasing environmental regulations have driven the industry toward recycling and resource recovery .
Our customer in Chongqing operates in the secondary aluminum sector. They generate significant volumes of aluminum dross and were looking for a sustainable solution to process this material rather than pay rising disposal costs. They wanted to:
Recover valuable aluminum from the dross
Produce a stable, saleable byproduct (such as alumina-rich material for refractories)
Meet strict environmental standards for emissions and waste treatment
Reduce long-term operating costs compared to landfilling
The customer made it clear: they wanted a brand-new, purpose-built rotary kiln system specifically designed for aluminum dross calcination—not a repurposed cement or lime kiln.
The Challenge: Processing Complex, Variable Dross
Aluminum dross is a challenging material to process. It varies in composition depending on the source (primary vs. secondary smelting), contains both metallic and oxidized aluminum, and often includes salt fluxes used in the recycling process . Dross can have a chain-like oxide microstructure that traps metallic aluminum, making recovery difficult .
Key challenges for aluminum dross calcination include:
| Challenge | Impact |
|---|---|
| Variable feed composition | Requires flexible process control |
| High temperature requirements | Temperatures up to 1200–1500°C for complete oxidation and phase transformation |
| Salt flux handling | Salt components can cause corrosion and emissions issues |
| Ring formation | Dross can stick to kiln walls and form buildup |
| Emission control | Must capture salts, dust, and potential hazardous compounds |
Our customer needed a kiln system that could handle these challenges reliably and efficiently.
Our Solution: Φ1.6×36m Rotary Kiln System
Henan Hongke Heavy Machinery engineered and manufactured a complete brand-new calcination line centered around a Φ1.6×36m rotary kiln—a configuration well-suited for aluminum dross processing at moderate capacity.
Key Equipment Specifications
| Parameter | Value |
|---|---|
| Kiln diameter | 1.6 meters |
| Kiln length | 36 meters |
| Processing capacity | Custom-engineered to customer requirements |
| Operating temperature | Up to 1,200–1,500°C |
| Kiln inclination | 3–4% |
| Rotation speed | Variable frequency drive |
| Drive system | Heavy-duty gear drive with auxiliary motor |
| Sealing system | Labyrinth seals with air purge at both ends |
Complete System Configuration
1. Feed System
The system includes a variable-speed feeder designed to handle aluminum dross consistently—critical for maintaining stable calcination conditions.
2. Φ1.6×36m Rotary Kiln
The core calcination unit features a high-quality carbon steel shell with a specialized refractory lining designed to resist the corrosive effects of salt fluxes and high-temperature aluminum oxide compounds. Research has shown that high-alumina refractories with spinel additions offer good erosion resistance for aluminum dross processing applications . The 36-meter length provides sufficient residence time for complete thermal treatment at high temperatures. The rotating design ensures uniform heat distribution across the material.
3. Burner System
The multi-fuel burner can operate on natural gas or other fuels, maintaining stable temperature control up to 1500°C—necessary for complete oxidation and phase transformation of aluminum compounds .
4. Dust Collection and Off-Gas Treatment
A multi-stage dust collection system captures fine particles, salts, and potentially hazardous compounds to ensure emissions meet environmental standards.
5. Automation & Control
PLC-based centralized control monitors temperature profiles, feed rates, kiln rotation speed, and emissions in real time. Full data logging supports process optimization and quality documentation.
Key Advantages: Brand-New, Purpose-Built
| Feature | Benefit |
|---|---|
| New design | Built to modern standards—no hidden wear, full service life ahead |
| Specialized refractory | High-alumina with spinel option—resists salt corrosion and abrasion |
| High-temperature capability | Up to 1500°C—complete dross oxidation and phase transformation |
| Advanced seals | Minimizes heat loss and prevents cold air ingress |
| Automated controls | Consistent operation, reduced labor requirements |
| Integrated dust collection | Meets environmental compliance standards |
What the Customer Gets
Once fully operational, this calcination system will deliver:
Recovered aluminum value – metallic aluminum recovered from dross
Saleable byproduct – alumina-rich calcined material suitable for refractory or construction applications
Reduced disposal costs – less material going to landfill
Environmental compliance – emissions and waste managed according to regulations
Brand-new reliability – modern equipment with full warranty and support
About Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd. (Henan Hongke Machinery) has been manufacturing industrial processing equipment since 2006. Our product portfolio includes:
Rotary Kilns – for aluminum dross, lime, dolomite, metallurgy, and mineral calcination
Rotary Dryers – for sludge, biomass, and industrial materials
Ball Mills – for ore, slag, cement, and chemical grinding
Crushers – for primary and secondary size reduction
We provide custom engineering, full manufacturing, installation guidance, and after-sales support for customers worldwide.
Summary
The Φ1.6×36m aluminum dross rotary kiln installation in Chongqing demonstrates Henan Hongke Machinery's ability to deliver brand-new, purpose-built calcination solutions for the aluminum recycling industry. By integrating high-temperature capability, specialized refractory, and automated controls, the system will transform challenging aluminum dross into valuable recovered materials while meeting environmental standards.
For aluminum dross processing, mineral calcination, or other thermal treatment applications, contact Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd.
Rotary Kilns | Rotary Dryers | Ball Mills | Crushers – Built New, Built Right