Vertical Kilns
Vertical kilns are cylindrical, brick-lined structures that are heated by fires at their base. They have been used for centuries for a variety of purposes, from lime burning and glass-making to agricultural drying and cement manufacture.
Vertical kilns are typically powered by fuels such as coal, wood or natural gas. The combustible fuel is burned in a distinct chamber at the base of the kiln, and the hot flue gases travel up the kiln chamber to provide the necessary heat. The intense heat provided by the flames can reach temperatures of up to 1300 °C, while the chamber remains relatively cool at one end and gradually gets hotter as it moves up towards the chimney.
Vertical kilns are typically relatively tall. They can range in size from small manual kilns used in farmers’ home farms to towering industrial-scale kilns capable of processing vast amounts of material. Industrial vertical kilns are usually quite deep, sometimes over 30 meters in length, and the height of the chamber can exceed 15 meters.
Vertical kilns are an efficient and reliable way to process materials such as limestone, dolomite and fireclay.
Due to their design, the temperature within the kiln is evenly distributed, ensuring that the material is uniformly heated throughout. This is essential for making high-quality construction materials such as cement.
The speed and efficiency of the vertical kiln process make it ideal for large-scale production. For example, a single vertical kiln can process up to 40 tonnes of limestone in around 8 hours.
Moreover, due to their tall, cylindrical design, vertical kilns are well suited for use in energy- and space-limited locations. Additionally, they can easily be retrofitted with modern equipment such as pre-heaters and waste-heat recovery systems, allowing them to remain competitive in the modern age.
In the past, the cost of constructing and operating vertical kilns has been a major deterrent to wider adoption. However, due to advances in technology, the costs of constructing and operating modern vertical kilns have become more competitive. Furthermore, advances in materials and insulation have also helped to reduce the overall cost of running vertical kilns, making them a more viable option for large-scale production.
Indeed, in recent years, vertical kilns have seen renewed interest as a practical and efficient solution for processing a range of minerals and materials. They are becoming increasingly popular in industries such as cement manufacture, where their efficient and reliable heating properties make them ideal for large-scale production.
Overall, vertical kilns are an effective and efficient way to process a diverse range of materials. Their uniform heating, speed and cost-effectiveness make them an attractive option for industries that require large-scale production.
