Project Overview
| Item | Details |
|---|---|
| Customer Background | A zinc smelting enterprise in Baiyin, Gansu, expanding into secondary zinc oxide production |
| Project Location | Baiyin, Gansu Province, China |
| Core Equipment | Φ3.0×60m zinc oxide rotary kiln + complete production line |
| Capacity | 10,000 tons per year (approx. 28–30 TPD) |
| Main Challenge | Processing low-grade zinc residues with variable zinc content; strict emission control |
| Solution | Rotary kiln volatilization process with multi-stage dust collection and desulfurization |
Customer Pain Points
The customer operates in Baiyin‘s historic zinc smelting region and needed to monetize zinc-bearing residues from existing operations. Their challenges were threefold: the raw material had inconsistent zinc content (20–35%), making stable kiln operation difficult; the site required strict dust and SO₂ emission control; and they needed a complete line—not just a kiln—with reliable commissioning support. Previous attempts with smaller kilns yielded low zinc recovery and frequent nodulation issues.
Our Solution
Henan Hongke Heavy Machinery supplied a complete 10,000 TPY zinc oxide production line built around a Φ3.0×60m rotary kiln. The process uses the rotary kiln volatilization method: zinc-bearing materials are mixed with coke powder and fed into the kiln, where a 1,000–1,200°C reaction zone reduces zinc compounds to metal vapor, which re-oxidizes and is captured as zinc oxide dust .
Key configurations:
Rotary Kiln: Φ3.0×60m, 3.5% slope, variable speed drive (0.3–2.0 r/min), 100 kW main motor
Feed System: Batching and pelletizing section with controlled coke-to-ore ratio
Dust Collection: Settling chamber → surface air cooler → pulse bag filter → desulfurization tower
Discharge: Water-cooled screw conveyor for safe slag handling
Control: PLC-based monitoring of kiln temperature, draft, and feed rate
The line layout was designed to fit the customer’s existing facility footprint, with material flow routed to minimize manual handling between stages.
Delivery and Commissioning
Manufacturing completed in 55 days. The complete line was assembled and tested at our Henan facility before shipment. Our engineers spent 18 days on site in Baiyin for installation supervision, commissioning, and operator training. The line reached stable 30 TPD output within two weeks of hot commissioning.
Results
| Metric | Target | Achieved |
|---|---|---|
| Annual output | 10,000 t | 10,200 t (first year) |
| Zinc recovery rate | 88% | 91% |
| Kiln availability | 85% | 92% |
| Emission compliance | SO₂ < 400 mg/m³ | 280 mg/m³ average |
Customer feedback: “The line runs steadily. Hongke’s engineers stayed until our operators were confident, not just until the kiln turned.”
Why Henan Hongke Heavy Machinery
We deliver one-stop solutions for mineral processing—rotary kilns, Rotary Dryers, ball mills, crushers, and the complete lines around them. This project was a turnkey delivery: from process design to commissioning. As a heavy machinery manufacturer with global service capability, we build equipment for your material, not for a catalog.
FAQ
Q: What zinc content in raw material is suitable for this process?
A: The rotary kiln volatilization method works economically with zinc content above 15–20%. Lower grades may still be viable depending on coke cost and zinc price. We assess this during process design.
Q: How do you prevent ringing/nodulation in the kiln?
A: We control the coke ratio, kiln temperature profile, and feed granulometry. The Φ3.0×60m configuration with variable speed allows operators to adjust residence time as material conditions change.
Q: What emission control equipment is included?
A: The standard line includes settling chamber, surface cooler, pulse bag filter, and desulfurization tower. Emission limits depend on local regulations; we size the system accordingly.
Q: Can the line handle different zinc-bearing feedstocks?
A: Yes, with batching adjustments. The line is designed for flexibility across zinc residues, dust, and low-grade ore, provided the zinc content stays within a workable range.
Ready to start your project? Contact our engineers for a free process assessment and quote.