Henan Hongke Heavy Machinery Co., Ltd. has delivered a Φ2.5×60m rotary kiln for quartz sand whitening to a customer in India. The line is designed for 150 tons per day and uses high-temperature calcination to expose iron impurities for downstream removal.
This article covers the full project: customer background, the original problem, equipment configuration, delivery timeline, commissioning results, and customer feedback.
1. Customer Background
Location: India
Industry: Quartz sand processing / high-purity silica
Quartz sand (SiO₂) is a key raw material for glass, ceramics, foundry, and semiconductor applications. Natural quartz sand often contains iron impurities that reduce whiteness and optical clarity. Iron occurs in three forms: within the quartz crystal lattice, as independent mineral inclusions, and within gas-liquid inclusions—making removal technically challenging .
Our customer is a quartz sand processor in India, supplying high-grade silica to glass and ceramics producers. Their existing process could not consistently reduce iron content to meet premium product specifications. The target for this project was 150 tons per day of whitened quartz sand.
2. The Original Problem
Before approaching Henan Hongke Machinery, the customer faced several practical constraints:
| Problem | Impact |
|---|---|
| Inconsistent whiteness | Product failed to meet premium glass/ceramic specifications |
| Iron locked in inclusions | Conventional washing could not expose trapped impurities |
| Variable feed quality | Iron content and mineralogy varied between batches |
| Throughput limitations | Could not meet growing demand from downstream buyers |
| Dust and emissions | Environmental compliance pressure |
| Process control | Temperature profile was not stable enough for consistent phase transformation |
The customer needed a purpose-built calcination kiln—not a modified dryer—to trigger the crystal phase transformation that exposes iron for subsequent acid leaching.
3. Why the Customer Chose Henan Hongke Machinery
After evaluating several suppliers, the customer selected us for specific, practical reasons:
a) Understanding of quartz whitening chemistry
Quartz whitening via calcination relies on the α-quartz to β-quartz phase transformation at approximately 573°C, with further structural changes at higher temperatures. Rapid quenching creates micro-cracks on particle surfaces, exposing iron impurities for acid leaching . We discussed these parameters during technical exchange—not just dimensions and price.
b) Design matched to their quartz
Quartz from different deposits behaves differently during calcination. We reviewed the customer’s feed characteristics before finalizing the kiln configuration and temperature profile.
c) Complete line responsibility
We supplied the full scope: feed system, Φ2.5×60m rotary kiln, burner system, cooling system, dust collection, and PLC controls. The customer did not have to coordinate multiple suppliers.
d) Proven configuration for 150 TPD
Φ2.5×60m is a well-established model for medium-scale mineral processing, matching the customer’s target capacity .
e) Long-term support commitment
The customer wanted a supplier available for process optimization and spare parts after handover.
4. Equipment Configuration
The delivered line is built around a Φ2.5×60m rotary kiln.
| Parameter | Specification |
|---|---|
| Kiln diameter | 2.5 m |
| Kiln length | 60 m |
| Application | Quartz sand whitening via calcination |
| Design capacity | 150 TPD |
| Operating temperature | Up to 1,200°C (adjustable) |
| Kiln inclination | 3.5–4% |
| Rotation speed | Variable frequency control |
| Sealing | Labyrinth seals with air purge |
Scope of supply:
| System | Function |
|---|---|
| Feed system | Screw or belt feeder for consistent material entry |
| Φ2.5×60m rotary kiln | Calcination and phase transformation |
| Burner system | Multi-fuel (gas or pulverized coal) |
| Cooling system | Controlled cooling after calcination |
| Dust collection | Cyclone + bag filter for emission compliance |
| Control system | PLC-based with temperature monitoring across zones |
5. Delivery Timeline
| Stage | Status |
|---|---|
| Technical exchange and process design | Completed |
| Quartz testing and parameter definition | Completed |
| Manufacturing at Henan Hongke facility | Completed |
| Factory assembly and no-load testing | Completed |
| Shipment to India | Completed |
| On-site installation | Completed |
| Commissioning and hot testing | Completed |
| Handover to customer | Completed |
6. Commissioning Results
| Performance Metric | Result |
|---|---|
| Calcination temperature control | Stable across heating zones |
| Phase transformation | Consistent β-quartz formation for iron exposure |
| Throughput | Meets agreed design capacity of 150 TPD |
| Whitened product quality | Iron content reduced to meet downstream specifications |
| Dust emissions | Within regulatory limits |
| Operational stability | Continuous operation achieved |
7. Customer Feedback
“The kiln has been running steadily since commissioning. Temperature control is stable, and the whitened quartz meets our customers’ specifications. The engineering team was responsive during installation and commissioning. We’re satisfied with the equipment and the support.” — Production Manager, Indian quartz sand processor
8. What This Means for the Customer
| Benefit | Practical Value |
|---|---|
| Consistent whitened product | Meets premium glass and ceramic specifications |
| Higher market value | Whitened quartz commands premium pricing |
| Reliable 150 TPD capacity | Meets downstream contract volumes |
| Environmental compliance | Dust collection meets regulatory standards |
| Full-scope supplier | Single point of responsibility |
| New equipment | Full service life ahead |
9. Building Long-Term Partnerships
Our commitment to the Indian customer does not end at handover. We continue to provide:
Technical support on temperature profile optimization
Spare parts availability for critical components
Maintenance guidance and preventive maintenance planning
Support for future capacity expansion or process adjustment
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 quartz sand whitening, lime, dolomite, metallurgy, and mineral calcination
Rotary Dryers – for sludge, sand, gypsum, 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.
Let’s Talk About Your Quartz Whitening Project
If you are processing quartz sand and need to reduce iron content for high-grade applications, we can discuss kiln sizing, temperature profile, and downstream leaching integration based on your material data.
Contact Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd.
Rotary Kilns | Rotary Dryers | Ball Mills | Crushers – Built for Reliability, Backed by Service