A Rotary Hearth Furnace (RHF) is a crucial technology in industries like steelmaking, ironmaking, metallurgy, and chemical engineering. The furnace operates by rotating the hearth, which ensures even heat distribution across the materials being processed. RHFs are essential for tasks such as sintering, reduction, and hardening of metals and alloys. However, operating an RHF presents several challenges, especially in areas like energy efficiency, material handling, and product quality.

This article will explore the importance of RHFs in processing dezincification, delve into the critical role of binders for RHF dezincification, and explain how customized binder solutions—particularly organic binders—can help optimize RHF operations.

What is RHF Dezincification?

RHF Dezincification refers to the process of removing zinc (Zn) from dedusting ash. In steelmaking, handling solid waste containing zinc has long been a challenge. High zinc content in waste can negatively impact production efficiency. For example, if the zinc content in dust exceeds 5%, it can erode the blast furnace lining, which harms the furnace's operation and shortens its equipment lifespan. Using an RHF for dezincification effectively removes zinc from materials and offers significant cost savings.

The Role of Binders in RHF Applications

Binders are essential in RHF applications because they hold together raw materials before they are introduced into the furnace. The primary function of a binder in an RHF system is to ensure that the raw materials maintain their shape and integrity during processing. This is particularly important when dealing with fine powders or aggregates. Without an effective binder, materials could break apart due to the high temperatures and mechanical stresses inside the furnace.

Key Benefits of Using Binders in RHF:

Enhanced Bonding Strength: Jianjie binders provide a strong bond between particles, minimizing material breakdown during the furnace process. This is especially important for briquettes and pellets that need to maintain their structure at high temperatures.

Thermal Stability: Jianjie binders are specifically designed to withstand the high temperatures of an RHF, which can exceed 1000°C. This ensures the binder doesn't degrade during the heating cycle.

Environmental Benefits: Jianjie binders have lower emissions, making them a more sustainable choice for industries aiming to reduce their environmental footprint.

Reduced Dezincification: Binders help mitigate dezincification by maintaining stable structures that resist breakdown at high temperatures, which reduces zinc loss in zinc-containing materials.

How Jianjie Helps Customize RHF Solutions

Jianjie is a leading provider of custom binder solutions designed to optimize Rotary Hearth Furnace (RHF) operations. Our experts understand the unique challenges faced by industries using RHFs and work closely with clients to develop tailored solutions. Jianjie binder can help RHF dezincification in varioius ways:

Custom Binder Solutions: Jianjie binders are specially formulated to provide excellent bonding strength, thermal stability, and flexibility for various RHF applications, including high-temperature processing and dezincification.

Great Performance: Jianjie binders can help reduce the Reduction Disintegration Index (RDI) by 10%.

High Qualification Rate: Jianjie RHF dezincification binder contains calcium-oxidizing components that help prevent pellet disintegration.

Expert Consultation: We offer in-depth consultation services to help clients choose the best binder options based on specific material, temperature, and emission requirements.

Sustainability Focus: Jianjie binders are made from eco-friendly polymer materials, designed to minimize emissions and offer sustainable formulations. Moreover, Jianjie binders for RHF dezincification doesn't contain harmful materials like sulfur dioxide, potassium (K), lead (Pb), etc.

Quality Assurance: All our binders undergo rigorous testing in real-world RHF applications to ensure they meet industry standards and contribute to optimal furnace performance.

Customer Success Story：Optimizing Dezincification in RHF

Customer Information:

1. Raw Materials: 28% dedusting ash, 68% slaked dedusting ash, 12% coke fines.

2. pH: 14, 1% active calcium oxide.

What are Their Challenges:

Customer's goal was to produce metallized briquettes through the RHF dezincification process. The briquettes would be roasted at high temperatures (1250°C) for 25-30 minutes, with an RDI (Reduction Disintegrity Index) under 20%. The customer needed a cost-effective solution for this high-temperature process.

Jianjie Solution:

Based on the raw material conditions and roasting requirements, Jianjie developed a customized binder that provided both calcium resistance and pulverization reduction. After production testing, the briquettes remained intact without disintegrating, and the RDI was reduced by 10%, which helped the customer save costs and optimize their RHF process.

Summary

The Rotary Hearth Furnace (RHF) is vital in industries like steelmaking, ironmaking, and chemical engineering. By using customized binder solutions, manufacturers can address key challenges—such as energy efficiency, product quality, and dezincification—improving furnace performance and sustainability.

Jianjie offers expert solutions for optimizing RHF operations with custom binder formulations tailored to your specific needs. As RHF technology evolves, innovative binder solutions will be crucial for maintaining high performance and staying competitive in the industry.