We design high-efficiency calcination and drying systems for the removal of moisture from industrial minerals and chemical materials, or for the alteration of their chemical structure. At IPS Makina, we offer rotary kiln and dryer solutions specialised to the thermal behaviour of different materials, with a focus on energy saving.
Calcination & Firing Unit: This is the main reactor centre of the plant, where crushed gypsum rock of 0–10 mm particle size, containing 18–20% crystal water, is converted into high-quality base plaster by reducing its bound water content to 4–6% through controlled heat transfer.
Application Areas & Materials Processed
• Gypsum Rock & Phosphogypsum: Production of building plaster through calcination.
• Industrial Sand & Minerals: Drying of silica sand, calcite, clay and bentonite.
• Coal & Ores: Pre-process drying of high-moisture ores.
• Chemical Products: Moisture control of granular products such as fertilisers and salts.
Drying & Calcination Process Stages
• Feeding & Dosing: Conveying the material to the kiln or dryer at a regular, controlled flow rate.
• Combustion & Heat Generation: Production of the required thermal energy through natural gas, LNG, diesel or solid-fuel burner systems.
• Heat Transfer (Drying/Calcination): The material loses moisture or undergoes chemical reaction (calcination) through direct or indirect contact with hot gases.
• Dust & Gas Treatment: Safe atmospheric release of hot gases and airborne particles generated during the process through filtration.
• Cooling Section: Reduction of the high-temperature material exiting the thermal process to a suitable temperature for subsequent stages.
Our Technical Advantages
• Maximum Thermal Efficiency: Maximum heat transfer surface with minimum fuel through specialist internal lifter designs.
• Precise Temperature Management: Advanced PID-controlled automation system operating within ±2°C tolerance.
• Long Mechanical Service Life: Special alloy steel shell resistant to thermal expansion and high-quality bearing units.
• Heat Recovery: Up to 25% saving in operating costs through pre-heating systems utilising waste heat.
Unit Descriptions
• Rotary Kiln Shell: The main cylindrical unit that maintains its strength at high temperatures, enabling the material to advance by rotation and ensuring homogeneous firing.
• Combustion Chamber & Burner System: High-technology combustion system with optimised emission values, where energy is generated in a controlled manner.
• Drive & Bearing System: Heavy-duty gear and roller mechanism ensuring smooth, speed-controlled rotation of the kiln shell.
• Jet-Pulse Dust Collection System: Filter unit with heat-resistant bags that cleans the high-temperature dust-laden gases arising during calcination.