Henan Hongke Heavy Machinery Co., Ltd. is pleased to share an update on a Φ 1.8×35m rotary kiln for sludge treatment at a customer site in Fushun, Liaoning Province, China. The system has been running stably since commissioning and has received positive feedback from the customer. This is a brand-new installation—not a refurbishment, not an upgrade of old equipment.
Project Background: Sludge Treatment in Fushun
Fushun is a traditional industrial city in Liaoning Province with a long history in coal, oil shale, and chemical production. Industrial operations in the region generate significant volumes of sludge that require safe, effective treatment.
Our customer operates a sludge treatment facility serving local industrial and municipal sources. The sludge they handle is wet, variable in composition, and challenging to process. Their existing treatment methods were struggling to keep up—and disposal costs were rising.
They needed a reliable thermal treatment system that could:
Handle wet, sticky sludge consistently
Reduce sludge volume significantly
Meet environmental emission standards
Operate continuously with minimal downtime
Be brand-new—not a used or refurbished unit
Why This Customer Chose Henan Hongke Machinery
After evaluating several suppliers, the customer selected Henan Hongke Heavy Machinery for several reasons:
1. Experience with Sludge Processing
Sludge is not an easy material. It's wet, it sticks to equipment, and it varies from batch to batch. We demonstrated our understanding of these challenges and our ability to design a kiln that handles them.
2. Custom-Engineered for Their Sludge
We don't sell generic kilns. Our engineering team designed this Φ 1.8×35m kiln around the customer's specific sludge characteristics—moisture content, organic fraction, and target throughput.
3. Complete, Brand-New System
The customer wanted a purpose-built system, not a refurbished unit or a repurposed cement kiln. We delivered a complete production line, built from the ground up.
4. One-Stop Solution
We supplied the full scope—feed system, kiln, burner, dust collection, discharge, and controls. The customer didn't have to coordinate multiple suppliers.
5. Long-Term Support
The customer wanted a partner who would be there after commissioning. We provide spare parts, technical advice, and ongoing service.
What We Supplied
A complete sludge treatment line built around a Φ 1.8×35m rotary kiln.
| Key Specification | Value |
|---|---|
| Kiln diameter | 1.8 meters |
| Kiln length | 35 meters |
| Application | Sludge treatment / calcination |
| Operating temperature | Up to 1,200°C (adjustable by zone) |
| Drive system | Heavy-duty gear drive with auxiliary motor |
| Sealing system | Labyrinth seals with air purge |
| Control | PLC-based with temperature monitoring |
The system includes:
Controlled feed system for consistent material entry
Φ 1.8×35m rotary kiln with refractory lining
Multi-fuel burner (gas or pulverized coal)
Dust collection system (cyclone + bag filter)
Discharge and cooling system
PLC-based controls with full data logging
How the Sludge Treatment Process Works
| Stage | What Happens |
|---|---|
| Feed | Wet sludge enters through a controlled feed system |
| Drying | Material is heated; moisture evaporates |
| Calcination | Organic content is destroyed at high temperature |
| Discharge | Treated material exits the kiln |
| Gas treatment | Exhaust gases pass through dust collection before release |
The rotary kiln operates on a simple principle: the drum rotates slowly, and internal lifting flights shower the material through the hot gas stream. This ensures uniform contact between the sludge and the heat source—consistent treatment without hot spots or incomplete processing.
Actual Results: Stable Operation Confirmed
The system has been running stably since commissioning. Key results:
| Performance Metric | Result |
|---|---|
| Operational stability | Continuous operation with minimal interruptions |
| Sludge volume reduction | Significant volume reduction achieved |
| Emission compliance | Dust and gas emissions within regulatory limits |
| Product quality | Treated material meets disposal and reuse requirements |
| Customer feedback | Positive—system performs as expected |
The customer has expressed satisfaction with the system's performance and reliability.
Customer Feedback
"The kiln has been running smoothly since we started it up. It handles our sludge without the sticking and clogging issues we had before. The emissions are under control, and we're finally meeting our treatment targets." — Operations Manager, Fushun sludge treatment facility
What This Means for Our Customer
| Benefit | Value |
|---|---|
| Reliable operation | Continuous processing with minimal downtime |
| Consistent treatment quality | Uniform results, batch after batch |
| Environmental compliance | Emissions controlled to meet regulations |
| Reduced disposal costs | Volume reduction lowers transport and landfill fees |
| Full support | Commissioning, spare parts, technical assistance |
| Brand-new reliability | No hidden wear, full service life ahead |
Building Long-Term Partnerships
At Henan Hongke Heavy Machinery, we view a successful commissioning as the start of a long-term relationship. Our commitment to the Fushun customer includes:
Technical support – process optimization and troubleshooting
Spare parts availability – critical components stocked for quick delivery
Maintenance guidance – support for preventive maintenance planning
Future cooperation – ready to assist with capacity expansion or process changes
We're not just a supplier. We're a partner.
About Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd. (Henan Hongke Machinery) has been designing and manufacturing industrial processing equipment since 2006. Our product portfolio includes:
Rotary Kilns – for sludge treatment, 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 focus on one-stop solutions for mining and materials processing—complete systems, not just individual machines. From engineering to installation and after-sales service, we stay with our customers every step of the way.
Let's Talk About Your Sludge Treatment Project
Whether you need a rotary kiln for sludge treatment, other waste processing, or any thermal application, we're here to help.
Contact Henan Hongke Heavy Machinery Co., Ltd. – we'll listen to your needs and deliver equipment that works.
Henan Hongke Heavy Machinery Co., Ltd.
Rotary Kilns | Rotary Dryers | Ball Mills | Crushers – Built for Reliability, Backed by Service