Henan Hongke Heavy Machinery Co., Ltd. has successfully completed the shipment of a Φ1.8×35m rotary kiln system for sludge calcination to a customer in Russia. This project demonstrates our capability to deliver heavy-duty thermal processing equipment engineered for demanding environmental applications.
The Challenge: Industrial Sludge Disposal
Our Russian customer operates an industrial processing facility generating significant volumes of high-moisture sludge — a byproduct with high organic content, fine particle size, and challenging handling characteristics. Disposal options were costly, and environmental regulations were tightening. The customer needed a thermal treatment solution that could:
Reduce sludge volume by over 70% through calcination
Destabilize organic contaminants for safe disposal or potential reuse
Operate continuously with minimal downtime
Meet strict emission standards for industrial waste processing
The key challenge: sludge feed with high moisture content and sticky consistency that tends to agglomerate inside conventional thermal equipment.
Our Solution: Designed for Sludge Characteristics
We don't sell generic kilns. Every system is engineered for the specific material, throughput target, and site conditions.
For this 30 TPH Russian project, our technical team conducted a full assessment of the sludge characteristics (moisture content, organic fraction, ash composition, and flow properties). Based on this analysis, we designed a Φ1.8×35m rotary calcination kiln with several custom features.
Key Equipment Specifications
| Specification | Value |
|---|---|
| Kiln diameter | 1.8 meters |
| Kiln length | 35 meters |
| Capacity | ~30 tons per hour |
| Operating temperature | 850–1200°C (adjustable) |
| Drive system | Heavy-duty gear drive with auxiliary motor |
| Sealing system | Labyrinth seals with air purge |
Custom Design Features
1. Anti-Sticking Internal Structure
Sludge has a notorious tendency to stick to kiln walls and form rings — a major operational headache. We equipped this kiln with specialized internal flights and lifters that continuously break up and tumble the feed material, preventing build-up and ensuring uniform exposure to heat.
2. Heavy-Duty Sealing System
The kiln uses advanced labyrinth seals with air purge to prevent leakage of process gases and dust — critical for environmental compliance and operator safety.
3. Efficient Heat Transfer Design
The long L/D ratio (35m length vs. 1.8m diameter) provides extended residence time, allowing complete thermal decomposition of organic matter. The system operates at temperatures of 850–1200°C, sufficient for full calcination of the sludge solids.
4. Complete System Integration
Beyond the kiln itself, we supplied:
Feed system with screw conveyor for consistent material entry
Afterburner chamber for complete combustion of volatile organics
Cyclone dust collector for particulate removal
Induced draft fan for controlled gas flow
Complete electrical control panel with temperature monitoring
Why Rotary Kiln for Sludge Calcination?
Rotary kilns are widely recognized as the most reliable solution for sludge thermal treatment due to their:
Material flexibility — handles wet, sticky, variable feed without clogging
High temperature capability — achieves full destruction of organics
Continuous operation — 24/7 processing with minimal intervention
Proven track record — extensively used in sludge incineration and calcination worldwide
Henan Hongke Machinery Difference
Henan Hongke Heavy Machinery Co., Ltd. brings over a decade of experience in designing and manufacturing industrial rotary equipment — kilns, dryers, and coolers — for metallurgical, chemical, environmental, and building materials applications.
Our commitment:
Custom engineering — matched to your material and throughput
Full support — from site evaluation to commissioning
After-sales service — spare parts, technical guidance, and remote support
The Result
The Φ1.8×35m sludge calcination kiln is now on its way to Russia, ready to transform an expensive disposal problem into a sustainable, compliant operation. The system will process approximately 30 tons of sludge per hour, producing a stable, reduced-volume ash product suitable for disposal or potential reuse as a construction material component.
Need a Similar Solution?
If you're dealing with sludge disposal challenges — industrial sludge, sewage sludge, oil sludge, or other organic waste streams — we can design and build a rotary calcination system that works for your specific material and production targets.
Contact Henan Hongke Heavy Machinery Co., Ltd. – we don't just sell equipment. We deliver solutions that work.
Henan Hongke Heavy Machinery Co., Ltd.
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